Apparatus for shaping the introductory end of a tampon and method using such apparatus

1 . Apparatus ( 100 ) for shaping the introductory end ( 172 ) of a tampon ( 162 ), comprising:

a carrying pipe ( 106 ) for holding the tampon ( 162 );

a support wheel ( 104 ) that carries a plurality of carrying pipes ( 106 ), the support wheel ( 104 ) comprising conveying means to transport each carrying pipe ( 106 ); and

a head-shaping station ( 108 ) for shaping the introductory end ( 172 ) of the tampon ( 162 );

characterized in that the head-shaping station ( 108 ) comprises an ultrasonic device ( 110 ).

2 . Apparatus ( 100 ) according to the claim 1 , characterized in that the ultrasonic device ( 110 ) comprises at least one head-shaping sonotrode ( 116 ) emitting ultrasonic vibrations at a frequency between 10 kHz and 70 kHz.

3 . Apparatus ( 100 ) according to the claim 2 , characterized in that the ultrasonic device ( 110 ) comprises a first and a second head-shaping sonotrode ( 116 a , 116 b ) emitting ultrasonic vibrations at a frequency between 10 kHz and 70 kHz.

4 . Apparatus ( 100 ) according to the claim 3 , characterized in that the first and second head-shaping sonotrodes ( 116 a , 116 b ) are aligned on an arcuate axis.

5 . Apparatus according to claim 1 , characterized in that the head-shaping station ( 108 ) comprises an actuation mechanism ( 146 ) enabling the movement of the ultrasonic device ( 110 ) closer or remoter to the support wheel ( 104 ) and the tampon ( 162 ).

6 . Apparatus according to claim 5 , wherein the apparatus ( 100 ) comprises a pushing mechanism ( 112 ) comprising a plate ( 120 ) with at least one protruding peg ( 118 ) to press against a trailing-end ( 168 ) of the tampon ( 162 ) that is opposite to the introductory end ( 172 ).

7 . Apparatus according to claim 3 , wherein the first and second head-shaping sonotrodes ( 116 a , 116 b ) have different cross sectional profiles.

8 . Apparatus according to claim 2 , wherein the head-shaping sonotrode ( 116 ) has a cavity ( 136 ) that is ogive shaped.

9 . Method for shaping the introductory end of a tampon using the apparatus ( 100 ) according to claim 1 , comprising the steps of:

a. placing a tampon ( 162 ) inside a carrying pipe ( 106 );

b. conveying said carrying pipe ( 106 ) and tampon ( 162 ) to a head-shaping station ( 108 );

c. shaping the introductory end ( 172 ) of the tampon ( 162 );

d. conveying said tampon ( 162 ) away from the head-shaping station ( 108 );

characterized in that the shaping of the introductory end ( 172 ) of the tampon ( 162 ) is done with an ultrasonic device ( 110 ).

10 . Method according to claim 9 , characterized in that the ultrasonic device ( 110 ) comprises at least one head-shaping sonotrode ( 116 ) emitting ultrasonic vibrations at a frequency between 10 kHz and 70 kHz during a lapse of time which is comprised between 0.1 and 1 s.

11 . Method according to claim 10 , characterized in that the ultrasonic device ( 110 ) comprises a first and a second head-shaping sonotrode ( 116 a , 116 b ) emitting ultrasonic vibrations at a frequency between 10 kHz and 70 kHz during a lapse of time which is comprised between 0.1 and 1 s, the tampon ( 162 ) being shaped by the first head-shaping sonotrode ( 116 a ) then subsequently by the second head-shaping sonotrode ( 116 b ).

12 . Method according to claim 10 , characterized in that the shaping of the introductory end ( 172 ) of the tampon ( 162 ), step (c), further comprises the sub-steps:

a. the head-shaping sonotrode ( 116 ) and a peg ( 118 ) slide forth towards the tampon ( 162 ), the head-shaping sonotrode ( 116 ) slides to abut against the tampon's head ( 172 ) and the first peg ( 118 ) slides to abut against a trailing end ( 168 ) of the tampon;

b. the head-shaping sonotrode ( 116 ) emits ultrasonic vibrations at a frequency between 10 kHz and 70 kHz, during a lapse of time which is comprised between 0.1 and 1 s;

c. the head-shaping sonotrode ( 116 ) and the peg ( 118 ) slide back away for the head-shaped tampon ( 162 ).

13 . Method according to claim 10 , characterized in that the shaping of the introductory end ( 172 ) of the tampon ( 162 ), step (c), further comprises the sub-steps:

a. a peg ( 118 ) slides forth within the carrying pipe ( 106 ) and abuts against the compressed tampon ( 162 ) and pushes said tampon ( 162 ) up against the head-shaping sonotrode ( 116 ) which is in a stationary position;

b. the head-shaping sonotrode ( 116 ) applies ultrasonic vibrations to the tampon introductory end ( 172 ) at a frequency between 10 kHz and 70 kHz during a lapse of time which is comprised between 0.1 and 1 s;

c. the peg ( 118 ) slides back and the head-shaping sonotrode ( 116 ) slides forth so that the head-shaping sonotrode ( 116 ) pushes the tampon ( 162 ) back to its initial position in the carrying pipe ( 106 );

d. the head-shaping sonotrode ( 116 ) slides backwards to its stationary position.

14 . Method according to claim 11 , where:

a. the introductory end ( 172 ) of the tampon ( 162 ) is shaped by the first head-shaping sonotrode ( 116 a ) using the following sub-steps:

i. the head-shaping sonotrode ( 116 a ) and a peg ( 118 a ) slide forth towards the tampon ( 162 ), the head-shaping sonotrode ( 116 a ) slides to abut against the tampon's head ( 172 ) and the first peg ( 118 a ) slides to abut against the a trailing end ( 168 ) of the tampon;

ii. the head-shaping sonotrode ( 116 a ) emits ultrasonic vibrations at a frequency between 10 kHz and 70 kHz during a lapse of time which is comprised between 0.1 and 1 s;

iii. the head-shaping sonotrode ( 116 a ) and the peg ( 118 a ) slide back away for the head-shaped tampon ( 162 );

b. the carrying pipe ( 106 ) and tampon ( 162 ) are conveyed to the second head-shaping sonotrode ( 116 b ) position;

c. the introductory end ( 172 ) of the tampon ( 162 ) is shaped by the second head-shaping sonotrode ( 116 b ) using the following sub-steps:

i. a peg ( 118 b ) slides forth within the carrying pipe ( 106 ) and abuts against the compressed tampon ( 162 ) and pushes said tampon ( 162 ) up against the head-shaping sonotrode ( 116 b ) which is in a stationary position;

ii. the head-shaping sonotrode ( 116 b ) applies ultrasonic vibrations to the tampon introductory end ( 172 ) at a frequency between 10 kHz and 70 kHz during a lapse of time which is comprised between 0.1 and 1 s;

iii. the peg ( 118 b ) slides back and the head-shaping sonotrode ( 116 b ) slides forth so that the head-shaping sonotrode ( 116 b ) pushes the tampon ( 162 ) back to its initial position in the carrying pipe ( 106 );

iv. the head-shaping sonotrode ( 116 b ) slides backwards to its stationary position.

15 . Apparatus ( 100 ) according to the claim 1 , characterized in that the ultrasonic device ( 110 ) comprises at least one head-shaping sonotrode ( 116 ) emitting ultrasonic vibrations at a frequency between 20 kHz and 50 kHz.

16 . Apparatus ( 100 ) according to the claim 2 , characterized in that the ultrasonic device ( 110 ) comprises a first and a second head-shaping sonotrode ( 116 a , 116 b ) emitting ultrasonic vibrations at a frequency between 20 kHz and 50 kHz.

17 . Method according to claim 9 , characterized in that the ultrasonic device ( 110 ) comprises at least one head-shaping sonotrode ( 116 ) emitting ultrasonic vibrations at a frequency between 20 kHz and 50 kHz.

18 . Method according to claim 9 , characterized in that the ultrasonic device ( 110 ) comprises at least one head-shaping sonotrode ( 116 ) emitting ultrasonic vibrations during a lapse of time which is comprised between 0.2 and 0.5 s.

19 . Method according to claim 10 , characterized in that the ultrasonic device ( 110 ) comprises a first and a second head-shaping sonotrode ( 116 a , 116 b ) emitting ultrasonic vibrations at a frequency between 20 kHz and 50 kHz.

20 . Method according to claim 10 , characterized in that the ultrasonic device ( 110 ) comprises a first and a second head-shaping sonotrode ( 116 a , 116 b ) emitting ultrasonic vibrations during a lapse of time which is comprised between 0.2 and 0.5 s.

21 . Method according to claim 11 , characterized in that the shaping of the introductory end ( 172 ) of the tampon ( 162 ), step (c), further comprises the sub-steps:

a. the head-shaping sonotrode ( 116 a , 116 b ) and a peg ( 118 a , 118 b ) slide forth towards the tampon ( 162 ), the head-shaping sonotrode ( 116 a , 116 b ) slides to abut against the tampon's head ( 172 ) and the first peg ( 118 a , 118 b ) slides to abut against a trailing end ( 168 ) of the tampon;

b. the head-shaping sonotrode ( 116 a , 116 b ) emits ultrasonic vibrations at a frequency between 10 kHz and 70 kHz during a lapse of time which is comprised between 0.1 and 1 s;

c. the head-shaping sonotrode ( 116 a , 116 b ) and the peg ( 118 a , 118 b ) slide back away for the head-shaped tampon ( 162 ).

22 . Method according to claim 11 , characterized in that the shaping of the introductory end ( 172 ) of the tampon ( 162 ), step (c), further comprises the sub-steps:

a. a peg ( 118 a , 118 b ) slides forth within the carrying pipe ( 106 ) and abuts against the compressed tampon ( 162 ) and pushes said tampon ( 162 ) up against the head-shaping sonotrode ( 116 a , 116 b ) which is in a stationary position;

b. the head-shaping sonotrode ( 116 a , 116 b ) applies ultrasonic vibrations to the tampon introductory end ( 172 ) at a frequency between 10 kHz and 70 kHz during a lapse of time which is comprised between 0.1 and 1 s;

c. the peg ( 118 a , 118 b ) slides back and the head-shaping sonotrode ( 116 a , 116 b ) slides forth so that the head-shaping sonotrode ( 116 a , 116 b ) pushes the tampon ( 162 ) back to its initial position in the carrying pipe ( 106 );

d. the head-shaping sonotrode ( 116 a , 116 b ) slides backwards to its stationary position.

23 . Method according to claim 11 , where:

a. the introductory end ( 172 ) of the tampon ( 162 ) is shaped by the first head-shaping sonotrode ( 116 a ) using the following sub-steps:

i. a peg ( 118 a ) slides forth within the carrying pipe ( 106 ) and abuts against the compressed tampon ( 162 ) and pushes said tampon ( 162 ) up against the head-shaping sonotrode ( 116 a ) which is in a stationary position;

ii. the head-shaping sonotrode ( 116 a ) applies ultrasonic vibrations to the tampon introductory end ( 172 ) at a frequency between 10 kHz and 70 kHz during a lapse of time which is comprised between 0.1 and 1 s;

iii. the peg ( 118 a ) slides back and the head-shaping sonotrode ( 116 a ) slides forth so that the head-shaping sonotrode ( 116 a ) pushes the tampon ( 162 ) back to its initial position in the carrying pipe ( 106 );

iv. the head-shaping sonotrode ( 116 a ) slides backwards to its stationary position;

b. the carrying pipe ( 106 ) and tampon ( 162 ) are conveyed to the second head-shaping sonotrode ( 116 b ) position;

c. the introductory end ( 172 ) of the tampon ( 162 ) is shaped by the second head-shaping sonotrode ( 116 b ) using the following sub-steps:

i. the head-shaping sonotrode ( 116 b ) and a peg ( 118 b ) slide forth towards the tampon ( 162 ), the head-shaping sonotrode ( 116 b ) slides to abut against the tampon's head ( 172 ) and the first peg ( 118 b ) slides to abut against the a trailing end ( 168 ) of the tampon;

ii. the head-shaping sonotrode ( 116 b ) emits ultrasonic vibrations at a frequency between 10 kHz and 70 kHz during a lapse of time which is comprised between 0.1 and 1 s;

iii. the head-shaping sonotrode ( 116 b ) and the peg ( 118 b ) slide back away for the head-shaped tampon ( 162 ).