MXPA97001358A - Plug applicator having a better folding tip - Google Patents

Abstract

The present invention relates to a plug applicator which has an improved tip to facilitate the insertion of a catamenial plug into the vagina of a woman. The plug applicator includes a first member capable of housing an absorbent plug. The first member has a central longitudinal axis and the first and second ends. An insertion tip is formed integrally on the first end of the first member and extends outwardly therefrom. The insertion tip includes a hemispherical shaped part and a semi-spherically formed frustoconical shaped part has an opening extending therethrough and the opening has a side wall which is aligned substantially parallel to the central longitudinal axis. The frusto-conical shaped part is located between the hemispherical shaped part and the end of the first member. The insertion tip contains a plurality of folds which are capable of expanding radially outwardly when the plug of the first member is ejected. The applicator further includes a second member mounted in the second end of the first member. The second is adapted to eject the plug through the insertion tip when pushed into the first member. The plug applicator is also described in combination with a catamenial stopper. Also disclosed is an apparatus and method for bending, folding and forming a tip on a tube hue

Description

PLUG APPLICATOR HAVING AN IMPROVED FOLDING TIP FIELD OF THE INVENTION This invention relates to a cap applicator having an improved folded tip to facilitate the insertion of a catamenial plug into a body cavity. More specifically, this invention relates to bending, folding and forming an insertion tip on one end of a paper stopper applicator.

BACKGROUND OF THE INVENTION Catamenial plugs and other types of absorbent media are routinely inserted into body cavities, such as a woman's vagina, to absorb menstrual fluid, blood and other kinds of body fluids.

A convenient way to place such absorbent plugs into a body cavity is through the use of an applicator. The comfortable and clean insertion of the absorbent caps are key to the repeated sale of such applicators. In addition, the applicator must be able to insert the absorbent plug into the body cavity using only a minimal amount of expulsion force.

Cork applicators are available in a variety of shapes and sizes being the most prevalent two-piece design telescopically assembled. In the two-piece applicator, the cap is housed in the outer tubing and is expelled into the vagina of a woman by an internal member which is mounted telescopically on the outer tubing and acts as a plunger. Some cap applicators use a hollow tube having an open insertion end through which the cap is always exposed while other applicators use a fully enclosed partially enclosed design. A thin film membrane can cover the insertion end of an applicator to completely enclose the leading end of a plug while the folds and creases can be used to partially enclose the leading end of a plug and protect it from contamination. Still other applicators, especially plastic applicators, have a plurality of flexible petals formed at the front end of the outer tube which can flex radially outwardly to allow the plug to be expelled. It will be appreciated that the diameter of the applicator, the material from which it is formed, the basic configuration of the applicator, the size and shape of the stopper placed on the applicator, as well as the ease of opening the front end of the applicator will all influence the required force to expel the cap from it. The ejection force must be kept reasonably low to allow proper operation of the applicator.

Although many have tried to design and manufacture plug applicators having these improved qualities, there is still a need for a plug applicator which is more comfortable to use. Those applicators having an open front end tend to expose the dry absorbent fibers of the plug to the inner walls of the female vagina and this can cause irritation during insertion. Commercially available plastic applicators, using a plurality of petal tips separated by cuts, can sometimes pinch or cut a woman's vaginal tissue during insertion and cause discomfort. Paper applicators having partially or completely closed tips tend to require an increased ejection force to eject the applicator cap and this may cause the applicator to deform or cause the cap to be inserted incorrectly. Such insertion may cause discomfort to the user.

A paper plug applicator having an improved folded tip has now been invented to facilitate the comfortable insertion of an absorbent plug into a woman's vagina while requiring a low expulsion force.

In addition, a method and apparatus for folding, folding and forming an insertion tip onto the paper plug applicator end providing a centered opening formed through the insertion tip have been invented. The central opening allows the folds to open with a minimum amount of ejection force and visual means are provided so that the consumer can verify that the applicator contains an absorbent cap.

SYNTHESIS OF THE INVENTION Briefly, this invention relates to a paper stopper applicator having an improved folded tip to facilitate the insertion of a catamenial stopper into a woman's vagina. The plug applicator includes a first member capable of housing an absorbent plug. The first member has a central longitudinal axis and the first second ends. An insertion tip is formed integrally on the first end of the first member and extends outwardly therefrom. The insertion tip includes a semi-spherical shaped part and a frusto-conical part. The hemispherical part d has a central opening formed through it and the opening has a side wall which is essentially aligned parallel to the central longitudinal axis of the first member. The frusto-conical part is located between the semi-spherical part and the first end of the first member. The insertion tip contains a plurality of folds capable of radially expanding outwardly when the plug is ejected from the first member. The plug applicator further includes a second member mounted telescopically at the second end of the first member. The second member is adapted to eject the plug through the insertion tip as it is pushed into the first member.

The plug applicator is also described in combination with a catamenial stopper having a shaped nose that approaches the inner surface of the first member.

The invention further relates to an apparatus and method for bending, folding and forming a tip on a hollow tub. The apparatus includes a first punch having a tubular section dimensioned to receive the tube and has a tip configured with a plurality of elongated slots formed therein. The first punch also contains a shoulder formed at an opposite end of the tubular section which acts as a stop for the tube. The first punch and the tube match a first matrix. The first die includes a base having a plurality of blades extending axially therefrom. Each blade is designed to engage with one of the grooves formed on the first punch and cause the tip of the tube to bend between them. After one end of the tube has been bent, it is transformed into a plurality of folds and conformed into an espherical configuration having a central opening formed therethrough. This is achieved by using a punch having a tubular section dimensioned to receive the tube. The second punch also has a semiespherically shaped tip with a pin extending outwardly from the apex thereof and a shoulder formed at the opposite end of the tubular section which acts as a stop for the tube. The second punch and the tube are castable with a second matrix. The second matrix includes a base having a hemispherical cavity formed therein with a central opening formed in the bottom of the cavity. The cavity is dimensioned to receive the second punch and the tube, and the opening is dimensioned to receive only the pin. The method for hooking the punches and dies to bend, fold and form one end of the tube are also described.

The general object of this invention is to provide a paper stopper applicator having an improved folded tip to facilitate the insertion of a catamenial stopper into a body cavity. A more specific object of this invention is to provide an apparatus and method for bending, folding and forming an insertion tip on one end of a paper stopper applicator.

Another object of this invention is to provide a plug applicator having a singularly formed tip that prevents premature contamination but which nevertheless virtually encloses the front end of an absorbent plug. Yet another object of this invention is to provide a plug applicator having a folded tip which essentially encloses the front end of the absorbent cap and which can be opened with a minimum amount of force.

A further object of this invention is to provide an apparatus for bending, folding and forming the insertion end of a paper stopper applicator in a hemispherical configuration having a central opening formed therethrough.

Still another object of this invention is to provide a plug applicator which is inexpensive to manufacture and easy to use.

Still another object of this invention is to provide an apparatus which is simple to build and easy to operate.

Still another object of this invention is to provide a method for bending, folding and forming the insertion end of a plug applicator at high speeds.

Still further an object of this invention is to provide a simple and inexpensive method for bending, folding and forming the insertion end of a plug applicator.

Still further, an object of this invention is to provide a paper stopper applicator which will minimize discomfort to a woman when she is inserted-an absorbent plug into her vagina.

Still further, an object of this invention is to provide a spirally wound plug applicator convolutely wound or sewn longitudinally with an improved tip to facilitate the insertion of an absorbent plug into a woman's vagina.

Other objects and advantages of the present invention will be more apparent to those skilled in the art in view of the following description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a perspective view of a two piece spirally wound paper stopper applicator.

Figure 2 is a cross-sectional view of a plug applicator shown in Figure 1.

Figure 3 is a view of the left end of the cap applicator shown in Figure 1 exhibiting oc folds.

Figure 4 is a cross-sectional view of the insertion tip taken along line 4-4 of Figure 3 showing an opening formed through the insertion tip and the opening having a side wall aligned substantially parallel to the axis longitudinal central d first member.

Figure 5 is a cross-sectional view an alternate embodiment of an insertion tip integrally formed on the first member and having an aperture formed therethrough where the aperture side wall is aligned at an angle to the central axis length of the first member.

Figure 6 is an alternate end view of a plug applicator exhibiting three folds.

Figure 7 is an additional alter end view of a plug applicator exhibiting ten and six pleats.

Figure 8 is a schematic view of a sheet taken along line 8-8 of Figure 3 showing shape and thickness of a fold.

Figure 9 is a cross-sectional view of the insertion tip taken along line 9-9 of Figure 3 showing one end of the folds extending into the shaped frusto-conical portion.

Figure 10 is a cross-sectional view of an alternate embodiment of the insertion tip exhibiting end of the folds ending at a point where the frusto-conical shaped pair is attached to the first end of the first member.

Figure 11 is a cross-sectional view of another embodiment of the insertion tip exhibiting one end of the folds ending at a point where the shaped hemispherical pair is attached to the formed frustoconical part.

Figure 12 is a perspective view of a cap applicator exhibiting the folds in an open arrangement. Figure 13 is a perspective view of a paper stopper applicator having an inner tube and an outer tubing.

Figure 14 is a transverse sectional view of the plug applicator shown in Figure 13.

Figure 15 is a left end view of plug applicator shown in Figure 13 exhibiting pleats.

Figure 16 is a schematic fold view taken along line 16--16 of Figure 1 showing the shape and thickness of a fold.

Figure 17 is a side elevational view of the outer tubing before the insertion tip is formed.

Figure 18 is a right end view of the outer tube shown in Figure 17.

Figure 19 is a perspective view of a first punch.

Figure 20 is a perspective view of a first punch having a plurality of grooves formed in the tip and showing the first punch being markable with the first die.

Figure 21 is a partial sectional view showing the first punch and the outer tube matching the first matrix.

Figure 22 is a side elevational view of the outer tubing exhibiting the insertion tip after suffering bent.

Figure 23 is a right end view of the outer tube shown in Figure 22.

Figure 24 is a perspective view of second punch and of the second matrix with the outer tube exhibited in phantom.

Figure 25 is a partial sectional view showing the second punch and the outer tube marrying the second matrix.

Figure 26 is a side elevational view of the outer tub showing the insertion tip after undergoing bending, bending and forming in a hemispherical configuration.

Figure 27 is a right end view of the outer tube shown in Figure 26.

Figure 28 is a perspective view of the cap applicator showing the folds in an open arrangement after the cap has been ejected from the inner tube.

DETAILED DESCRIPTION OF PREPARED MODALITIES Referring to Figures 1-3, the plug applicator 10 is shown which is designed to house the catamenial plug 12 and provide comfortable means for inserting the plug 12 into the vagina of the woman. The stopper is an absorbent member designed primarily for use by a woman during her menstrual period to absorb menstrual fluids, blood and other body fluids. The cap 12 may be made of natural or synthetic fibers including cellulose fibers such as cotton or fiber. rayon artificial fibers such as polyester, polypropylene, nylo or mixtures thereof. Other types of fibers can also be used, such as cellulose sponge or sponge formed from elastomeric materials. A mixture of rayon cotton fibers works well.

The cap 12 is normally compressed in the shape of a cylinder and may have a rounded or shaped, blunt front end. The plug 12 commonly has a withdrawal rope 14 fastened to one end thereof which serves as a means for removal of the plug soiled from the woman's vagina. The withdrawal rope 14 can be linked through opening 16, formed transversally through the plug 1. In addition, the withdrawal rope 14 can have a knot 18 formed at its free end to ensure that the rope 14 does not separate from the plug 12.

The plug applicator 10 includes a first member 20 and a second member 22. The first member 20 is preferably in the form of a hollow tube, spirally wound, coiled convolutely or longitudinally wound which is formed of paper, cardboard, paperboard or of a combination of them. The first member 20, also referred to as an outer tube, is quite stiff and has a relatively small diameter of about 10 millimeters to about 20 millimeters. The first member has a wall 24 with a predetermined thickness of about .2 millimeters to about .6 millimeters. Wall 24 can be constructed from a single layer of material or two or more layers can be formed which are joined together to form laminate. The use of two or more layers is preferred since it is allows the manufacture to use certain material in the vari layers that can improve the operation of the tap applicator 10. When two or more layers are used, all the layers can be wound spirally, coiled convolutely, sewn longitudinally to form an elongated cylinder. The wall 24 can be constructed using a thin, smooth layer of material on the outside or outside surface 26 which surrounds a possibly thicker and rougher layer. When the stop 24 contains at least three layers, the middle layer can be the thicker layer and the inner and outer layers can be smooth and / or slippery to facilitate the expulsion of the cap 1 and to facilitate the insertion of the first member 20 into the vagina of a woman respectively. By placing the sandwich shape a layer of rougher and thicker material between two smooth and thin layers, a cheap prime member 20 which is highly functional can be provided. The wall 24 must contain one to four layers, although more layers may be used if desired.

The layers forming the wall 24 can be held together with an adhesive, such as rubber, or by heat, ultrasonic pressure, etc. The adhesive can be either water soluble or insoluble in water. A water soluble adhesive is preferred for environmental reasons in which the wall 24 will break rapidly when immersed in water. Such immersion will occur in case the first member 20 is discarded by placing it in a toilet. Exposure of the first member 20 to a municipal waste treatment plant where water soaking will occur, chemical interaction and agitation will cause the wall 24 to break in a relatively short period of time.

The inner diameter of the first member 20 and usually less than about 19 millimeters preferably less than about 16 millimeters. Even when the outer diameter of the plugs varies, most d plugs used by a woman have an external diameter of less than about 19 millimeters. However, if one wishes to use this invention to administer drugs to an animal such as a field animal, larger size plugs 12 may be used.

It should be noted that the first member 20 can be spirally wound, coiled convolutely or sewn longitudinally into a cylindrical tubular shape. Any of these methods for forming a first tubular shaped member 20 is especially advantageous when the first member 20 is formed of a laminate. The reason for this is that when a laminate is wound circumferentially in a tube and an overlap or an end seam is formed; The end seam or overlap may interfere with the subsequent formation of the pleats on the front end thereof. A common problem with a rigid or stiff-walled tubular member having a relatively small diameter and an end seam is that the seam has a tendency to separate after forming if it is exposed to certain stresses and / or a high stress. humidity. The problem with a tubular member having an overlap is that a small part of the wall will be thicker than the remaining part and this will cause problems when one tries to fold one end of the tube. Accordingly, the first member 20 should be formed in a cylindrical configuration if the presence of an end seam or an overlap. Alternatively, the overlap near the end of the tube can be cut so that it has a uniform thickness.

The first member 20 is designed and configured to house the absorbent cap 12. As indicated above, the first member 20 must have a virtual outer surface 26 which facilitates the insertion of the first member 2 into the vagina of a woman. When the outer surface 26 is smooth and / or slippery, the first member 20 easily slides into the vagina of a woman without subjecting the internal tissues of the vagina to abrasion. The first member 20 can be coated to give a high slip characteristic. Wax, polyethylene, or a combination of wax and polyethylene, cellophane and clay are representative coatings that can be applied to the first member 20 to facilitate a comfortable insertion.

The first member 20 may be an elongated, straight cylindrical tube formed on a central longitudinal axis X-X. It is also possible to form the first member 20 in an arched form. The arched or curved shape can help provide comfort when the first member 20 is inserted into a woman's vagina. With a curved plug applicator, it is possible to use a curved plug which again may be more comfortable for some women to use since the shape of the plug can better fit the curvature of a woman's vagina.

The first member 20 has the ends separated and spaced first and second 28 and 30, respectively. The first member 20 can also be either a constant outer diameter or a stepped outer profile. Preferably, the first member 20 will have an essentially constant diameter over a main part of its length. Fully formed on the first member 28 of the first member 20 and extending outwardly therefrom to an insertion tip 32. The insertion tip 32 is designed to facilitate insertion of the first member 20 into the vagina of a woman in a manner comfortable. The insertion tip 32 includes a semi-spherical shaped part 34 and a frusto-conical shaped part 36. The frusto-conical shaped part 36 is located between the hemispherical shaped part 34 and the first member 20. The frusto-conical shaped part 36 tapers in toward the central axis longitudinal X-X as it approaches the shaped hemispherical part 34. The taper within is at an angle of between about 5 degrees at about 40 degrees relative to the outer surface 26 of the first member 20. Preferably, the angle is between about 5 degrees to about 25 degrees, and more preferably, the angle is between about 5 degrees to about 1 degrees. The frusto-conical shaped part 36 has an outer diameter at one end of which is approximately equal to outer diameter of the first member 20 and has an outer diameter at an opposite end which is approximately equal to the outer diameter of the shaped hemispherical part 34.

The length of the frusto-conical shaped part 3 can be as long as 25.4 millimeters. Preferably, the length of the frusto-conical shaped portion 36 is less than about 19 millimeters, and more preferably, about 3.1 millimeters to about 12.7 millimeters. The frustoconical shaped portion 36 provides a smooth and gradual transition from the hemispherical shaped part 34 to the first member 20 and thus facilitates the comfortable insertion of the plug applicator 10 into the vagina of a woman.

The semi-spherical shaped part 34 is placed on the front or insertion end of the cap applicator 10. The hemispherical shaped part 34 has a diameter which is only a fraction of the outer diameter of the first member 20. For example, the diameter of a part Semi-spherical conformation 34 may vary from about 50 per cent to about 90 percent of the outer diameter of prime member 20.

The insertion tip 32 has a wall 38 having a thickness which is approximately equal to the thickness of the wall 24 which forms the first member 20. However, it is possible to construct the wall 38 so that it has a thickness of which is less than or greater than the thickness of the wall 24, if desired.

Referring to Figure 4, the insertion tip 32 is shown in cross section with the frustoconical shaped portion 36 extending outwardly from the first end 28 of the first member 20. The frusto-conical shaped portion 3 terminates in a hemispherical shaped part 34. The section The cross section of the hemispherical shaped part 34 extends to an arc (A) of approximately 180 degrees. The hemispherical shaped part 34 is formed on a diameter which is sized to be equal to or slightly smaller than the smallest diameter of the frustoconical shaped part 36. For example, if the smallest outer diameter of the frustoconical shaped part 36 is of about .40 inches (about 10.0 millimeters), the hemispherical shaped part 34 can be formed about a diameter of about .40 inches (about 10.0 millimeters). This means that the smaller diameter of the shaped frusto-conical part 36 and the diameter of the hemispherical shaped part 34 will be equal and that the measurement will be equal to a fraction of the outer diameter of the first member 20.

A relatively small opening 40 is formed in the center of the hemispherical shaped part 34 and is coaxially aligned with the longitudinal axis X-X of the first member 20. The opening 40 can have a diameter of at least about 1.5 millimeters, preferably from about 1.5 to about 5.0 millimeters, and more preferably from about 3.0 to about 3.5 millimeters. Another way to design the diameter of the opening 40 is to make it less than about 30 percent of the diameter of the first member 20, preferably, between about 10 percent to about 30 percent of the diameter of the first member 20. , and more preferably, less than about 20 percent of the diameter of the first member 20. It should be noted that even though the opening 40 is described as a circle, it is possible to form the opening 40 in other shapes such as a polygon, a square, a pentagon, a hexagon, an octagon, etc. The small opening 40 should extend through the hemispherical shaped portion 34 of the insertion tip 32 and have a side wall 42 which is essentially aligned parallel to the longitudinal axis X-X.

In addition, the opening 40 may be rounded or contain a radi 44 on its outer surface to ensure that sharp edges are not present that could prick or cut the sensitive tissues of a woman's vagina. The purpose of the small opening 40 at the end of the insertion tip 32 is to facilitate the subsequent unfolding of the folds during use, as will be described below. The opening 40 also ensures that the folds will open symmetrically around the longitudinal X-X ej of the first member 20. An additional benefit of the opening 40 is that it provides visual means for the wearer to inspect the cap applicator 10 and to assure itself that the plug 12 is present in the first member 20.

The design of Figure 4 will be contrasted with the embodiment shown in Figure 5 where an enlarged opening 46 is shown having a side wall 48 which tapers downward and inward to form a sharp point 50 adjacent an interior surface 52 of the insertion tip 32. The sharp tip 50 is more likely to pinch or trap the vaginal tissue and thus may cause discomfort during insertion. In addition, the larger diameter of the opening 46 exposes a larger area of the absorbent cap 12 and this can cause abrasion with the vaginal tissues during insertion. For convenience, the modality shown in Figure 4 is more desirable.

Referring again to Figure 4, the configuration of the opening 40 is preferred because it is smaller in diameter and therefore exposes a smaller amount of the absorbent cap 12. Since a stopper is normally dry and consists of a plurality of absorbent fiber, this can cause abrasion against the walls of a woman's vagina when it is inserted. By reducing the amount of surface area of the plug 12 that is exposed to the vaginal tissue, the discomfort during the insertion process can not yet decrease. In addition, since the insertion tip 32 is essentially closed, this also lowers the frictional force between the outer surface 26 of the plug 10 and the walls of the vagina. In addition, the small diameter of the opening 40 also decreases the possibility of entrapment or pinching of vaginal tissue there.

Referring to Figures 3, 6 and 7, the insertion tip 32 is shown having a plurality of folds 5 which can be opened radially outwardly so that the insertion tip 32 has a diameter approximately equal to or greater than the diameter of the first member 20. If either an even or uneven number of folds 54 is present, said folds 54 may be spaced equally or this may not be uniformly arranged. Uniform folds spaced by an equal distance are preferred over a random array. For ease of manufacture it is preferred that the folds 54 are equally spaced one relative to each other. Each fold 54 is a fold formed by bending the material on itself and then pressing or adhering the material in place. Although eight equally spaced and spaced pleats 54 are shown in FIG. 3, it is possible to use several numbers of folds 54. Fold number 54 can vary from three to about thirty and six folds, preferably from about five folds. to about sixteen folds and more preferably from about six to about twelve folds.

In Figure 6, a modality e is shown where three equally spaced folds 54 are shown, while in Figure 7, sixteen folds 54 are displayed. The minimum number of folds 54 should not be less than three due to the force required to open the insertion tip 3 normally increases as the number of folds 54 decreases. If the force becomes too large, the plug applicator 10 must be bent, deformed during the insertion process and this may cause discomfort. When more than thirty-two folds 5 are used, the ejection force must be lowered but it becomes difficult to form as many folds on the insertion tip 32.

Referring to Figure 8, a schematic view of a fold 54 is shown. The fold 54 is obtained by folding the paper, cardboard, paperboard material over itself so that when the fold 54 is unfolded open it will occupy an area of much larger surface. The thickness of the material forming the insertion tip 32 may be equal to or slightly less than the thickness of the first member 20. For the first member 20, a thickness of about .1 millimeters to about .7 millimeters is satisfactory, with a preferred thickness being preferred. thickness of about .25 millimeters to about .5 millimeters. The insertion tip 32 can have a thickness of between about .1 millimeters to about .7 millimeters. In the bent condition, the fold 54 has a thickness, indicated by the letter "t" of less than about 0.7 millimeters, preferably of between about .25 millimeters to about .25 millimeters. Another way of saying this is by saying that the thickness of the fold 54, in the bent condition, will be more than twice the thickness of the material of which the insertion tip 32 is constructed. A particular apparatus and method for folding, folding and forming a tip on a hollow tube is taught in copending patent application of the United States of America number 08 / 300,987 filed on September 6, 1994 which is incorporated herein by reference and becomes a part thereof.

Referring to Figures 9-11, three different embodiments of a fold are displayed. In Figure 9, the fold 54 is shown as having a first end 56 which coincides with the side wall 42 of the opening 40. This means that the first end 56 of the fold 54 forms a part of the arc of the opening 40. fold 54 also has a second end 58 which coincides with a point located on the outer circumference of the frustoconically formed part 36. This point is spaced by a distance "a" from the location where the frusto-conical shaped part 36 is integrally joined to the first member 20. By forming the fold 54 with this particular length, one can control the amount of force necessary to open the insertion tip 32 and push the plug 12 through it. Usually, a lower force is required to open the folds when each fold 54 has a length which extends into the outer circumference of the frusto-conical shaped part 36.

In Figure 9, the hemispherical shaped part 34 extends to a radial arc, identified as the angle alpha (a), which extends from the first end 56 to the point where the hemispherical shaped part 34 is integrally joined to the frusto-conical shaped part 36. The angle alpha (a ) is between about 60 degrees to about 90 degrees, preferably between about 75 degrees to about 90 degrees, and more preferably to more than 80 degrees. The angle alpha (a) would be 90 degrees and the opening 40 would not be present. The size of the opening 40 will partially determine the exact angle of the semi-rigid shaped part 34. The angle alpha () should be as close to 90 degrees as possible without completely enclosing the front end of the plug 12.

In Figure 10, an alternate embodiment of an insertion tip 32 'is shown wherein a fold 54' is shown having a first end 56 which coincides with the side wall 42 of the opening 40. In other words, the first end 56 of the fold 54 'forms a part of the arc of the opening 40. The fold 54' also has a second end 60 which coincides with the point where the frusto-conical shaped part 36 is integrally attached to the first end 28 of the first member 20. By forming the fold 54 'with this particular length, one can control the amount of force needed to open the insertion tip 32' and push the plug 12 through it. Since the length of each fold 54 ', shown in Figure 10 is slightly longer than the length of each fold 54, shown in Figure 9, the force required to open the folds 54' may be slightly smaller.

In Figure 11, a third embodiment of an insertion tip 32"is shown wherein a fold 54" is shown having a first end 56 which coincides with the side wall 42 of the opening 40. In other words, the The first end 54 of the fold 54"forms a part of the arc of the opening 40. The fold 54" also has a second end 62 which coincides with the point where the hemispherical shaped part 36 is integrally attached to the frustoconical shaped part. 36. This point is spaced by a distance "b" from the place where the frusto-conical shaped part 36 is integrally joined to the first end 28 of the first member 20. By forming the fold 54"with this particular length, one can control the amount of force needed to open the insertion tip 32"and push the plug 12 through it. Even though the force required to open the folds 54"may be greater than the force required with the design shown in Figures 9 and 10, the force is still within acceptable limits.

It should be noted that both the length and the diameter of the commercially available plugs vary and therefore the plug applicators 10 must be manufactured in a variety of sizes. The plugs can vary in length from about 1 to about 3 inches (about 25.4 millimeters to about 76.2 millimeters) but preferably are about 2 inches (about 50.8 millimeters) in length. The diameter of the plug will vary from about .25 inches to about .75 inches (about 6.4 millimeters to about 19.0 millimeters). further, the material from which the cap 12 is constructed, the smoothness of the internal surface of the first member 20, the shape of the second member 22 etc., all contribute to establishing an expulsion force to open and eject the cap 12. This force must vary from ent to about 250 grams to about 1,500 grams preferably less than about 1,200 grams, and preferably less than about 1,000 grams. A lower force value is preferred since this ensures that plug applicator 10 will be less susceptible to being bent deformed upon ejection of plug 12. A bent applicator may cause the plug to be inserted incorrectly. A lower force rating also makes the plug applicator 10 s easier to use.

Referring again to Figures 1 and 2, first member 20 may have a gripping ring with finger 6 located near second end 30. The gripping ring with finger 64 may be formed integrally from the material of which the first constructed is constructed. member 20 or can be made as a separate member which is secured in place by some adhesive or some other type of fastening mechanism. The finger gripping ring 64 functions to provide one means for the user to grasp the first member 20 and hold between her middle and thumb fingers. The user may also place her index finger on the free end of the second member 22 and orient the first member 20 in relation to her vagin while she pushes the second member 22 within the prime member 20.

As stated above, the plug applicator 10 includes a second member 22 also commonly referred to as an inner tube. The second member 22, like the first member 20 may be a hollow tube spirally wound, coiled convolutely or longitudinally stitched constructed of paper, cardboard, paperboard, etc. The second member 22 can be constructed of the same material as the first member 20 or this can be made of a different material. In addition, the second member 22 can be constructed as a laminate having two or more layers which are spirally wound, coiled convolutely or sewn longitudinally into a cylindrical tube. It is preferred either a rolled tube or a longitudinally stitched tube because the finished tube will have a wall 66 with a constant thickness. However, some manufacturers may prefer to construct the second member 22 as a solid bar or some other unique shape. It is also possible to form a ring or flange for finger grip 68 on the outer end of the second member 22 to provide an enlarged surface on which the user can rest the index finger. The finger grip ring 68 therefore functions as a seat for the Index finger and facilitates movement of the second member 22 within the first member 20.

Referring to Figure 12, the second member 22 operates by being moved telescopically in relation to the first member 20. When the second member 22 is pushed into the first member 20, the plug 12 is forced forward against the folds 54. The contact by the plug 12 causes the folds 54 open radially outwardly to a diameter which is sufficient to allow the plug 12 to be ejected from the first member 20. The open arrangement of the folds 54 is shown in Figure 12 after the plug 12 has been ejected. With the plug 12 placed in the vagina of the woman, the plug applicator 10 is removed and disposed of properly.

The plug applicator 10 having the improved folded tip 32 works well in combination with a catamenial plug having a shaped nose. This is especially true when the nose formed on the plug 12 is configured to conform to the inner surface 52 of the insertion tip 32. For example, the plug 12 may be configured to have a generally rounded front end which conforms to the inner surface of the hemispherical shaped part 34 or alternatively, the plug 12 can be configured to have a frusto-conical shape with a rounded front end which conforms to the inner surface of the complete insertion tip 32.

Referring to Figures 13-15, a plug applicator 110 is shown which is designed to house an absorbent plug 112 and provide a comfortable means for inserting a plug 112 into a woman's vagina. The stopper is an absorbent member designed primarily for use by a woman during her menstrual period to absorb menstrual fluids, blood and other body fluids. The stopper 112 can be made of natural or synthetic fibers including cellulose fibers such as cotton or fiber. rayon, artificial fibers such as polyester, polypropylene, nylo or mixtures thereof. Other types of fibers may be used such as cellulose sponge or sponge formed from elastomeric materials. A mixture of cotton and rayon fibers works well.

The plug 112 is normally compressed in the shape of a cylinder and may have a shaped, blunt, rounded front end. The plug 112 commonly has a withdrawal cord 114 attached to one end thereof which serves as a means for removing the soiled plug from the woman's vagina. The withdrawal rope 114 is permanently fixed to plug 112, for example, by linking it through an opening 116 formed through the plug 112. In addition, the withdrawal rope 114 may have a knot 118 formed at the free end to ensure that the rope 114 will not separate from plug 112.

The plug applicator 110 includes an outer tube 120 and an inner tube 122. The outer tube 120 is preferably in the form of a hollow tube spirally wound, coiled convolutely or sewn longitudinally which is formed of paper, cardboard, paperboard or a combination thereof. The inner tube 122 can be formed of the same material as the outer tube 120, alternatively, it can be made of a different material. The inner tube 122 should have a constant external diameter com so that it slides easily into the inner diameter of the outer tube 120. It is also possible to construct the inner tube 122 as a solid bar or some other unique shape, which is directly clamped to plug 112.

Both the outer tube 120 and the inner tube 122 are quite rigid and commonly have a diameter of about 10 millimeters to about 20 millimeters, with the inner tube 122 being slightly smaller in diameter than the outer tube 120. The outer tube 120 it has a wall 124 with a predetermined thickness of about.2 millimeters to about .6 millimeters. The inner tube has a wall 126 which is slightly thinner. The walls 124 and 126 may be constructed of a single layer of material or may be formed of two or more layers which are joined together to form a laminate. The use of two or more layers or extracts is preferred since this allows the manufacturer to use certain material in the various layers which improves the performance of the plug applicator 110. When two or more layers are used, all the layers can be wound spirally. , coiled convolutely sew longitudinally to form an elongated cylinder. The exterior surface of the wall 124 can be constructed using a thin layer of material to facilitate insertion of the first member 120 into the vagina of a woman.

The layers forming the walls 124 and 126 can be held together with adhesive, such as rubber, or by heat, ultrasonic, etc. pressure. The adhesive can be either water soluble or water insoluble. A water-soluble adhesive is preferred for environmental reasons in the sense that tubes 120 and 122 will break rapidly when immersed in water. Such immersion will occur in case tubes 120 and 122 are discarded by depositing them in the toilet and draining them. Exposure of tubes 120 and 122 to the municipal waste treatment plant where water soaking will occur, interaction with chemicals and agitation will cause tubes 12 and 122 to separate and break in a relatively long period of time. short.

The outer tube 120 is dimensioned configured to house the absorbent cap 112 and the inner tube 122 is sized and configured to push the cap 112 out of the outer tube 120. The outer tube 120 may be an elongated, straight cylindrical tube formed on an axis longitudinal central X-X. It is also possible to form the outer tube 120 in an arcuate shape. The curved arched shape can help provide comfort when inserting the outer tube 120 into the vagina of a woman. The inner tub 122 should be configured to slide telescopically in the outer tube 120. With a curved plug applicator, it is possible to use a curved plug which can be more comfortable for some women to use since the shape of the plug is It will adjust better to the curvature of a woman's vagin.

The outer tube 120 has the ends separated and spaced first and second 128 and 130, respectively. The outer tube 120 can have either a constant outer diameter or a stepped outer profile. Preferably, the outer tube 120 will have an essentially constant diameter over a major part of its length. Integrally formed on the first end 128 of the outer tube 120 and extending outwardly thereof is an insertion tip 132. The insertion tip 132 is designed to facilitate insertion of the outer tube 120 into a woman's vagina in a comfortable manner . The insertion tip 132 contains a number of folds 134 and has a hemispherical configuration with a diameter which is approximately equal to the outer diameter of the outer tube 120. The folds 134 may be uniformly spaced apart and may be arranged at random. The insertion tip 132 can have the same thickness as the outer tube 120 or it can be made thinner or thicker, if desired.

An opening 136 is formed in the center of the semi-spherical shaped insertion tip 132 and is coaxially aligned with the longitudinal axis X-X. The opening 136 may have a diameter of at least about 1.5 millimeters, preferably between about 1.5 to about 5.0 millimeters, and more preferably, between about 3.0 to about 3.5 millimeters. Another way to measure the diameter of the opening 136 is to make it less than about 30 percent of the diameter of the outer tube 120, preferably, between about 10 percent to about 30 percent, and more preferably, of less than about 20 percent of the diameter of the outer tube 120. It should be noted that even though the opening 136 is described as a circle, it is possible to form the opening 136 in other shapes such as a polygon, a square, a pentagon, a hexagon, an octagon, etc. The opening 136 must extend completely through the insertion tip 132. The purpose of the opening 136 at the end of the insertion tip 132 is to facilitate the subsequent unfolding of the folds 134 during use. The opening 136 also ensures that the folds 134 will be systematically opened around the longitudinal axis X-x of the outer tube 120. An additional benefit of the opening 136 is that it provides a visual means for the user to inspect the plug applicator 110. and ensure itself, that plug 112 is present in outer tube 120.

With the opening 136 being small, it is less exposed from the absorbent plug 112 to the vaginal tissue when the plug applicator 110 is inserted into the vagina of a woman. Since a plug 112 is normally dry and consists of a plurality of absorbent fibers, this can cause an abrasion against the walls of a woman's vagina as it is inserted. By reducing the amount of surface area of the plug 112 which is exposed to the vaginal tissue, one can decrease the discomfort during the insertion process. In addition, since much of the insertion tip 132 is closed, the frictional force between the outer surface 126 and the outer tube 120 and the walls of the vagina is reduced. In addition, the small diameter of the opening 136 also decreases the possibility of trapping or pinching the vaginal tissue there.

Referring to Figures 15 and 16, the insertion tip 132 is shown having a plurality of folds 134 which can be opened radially such that the insertion tip 132 has a diameter which is approximately equal to or greater than the diameter of the outer tube 120. The term "crease" as used herein refers to the material which is folded on itself, for example, by bending the material on itself and then compressing it in place. A representative view of a fold 134 is shown in Figure 16. An even or uneven number of folds 34 may be present and said folds 34 may be equally spaced and separated or these may be uniformly or randomly arranged. For a manufacturing facility, it is preferred that the folds 34 are equally spaced apart in relation to one another. Each fold 34 is formed by bending the material on itself and then compressing it or adhering the material in place. Although eight equally spaced and spaced folds 34 are shown in Figure 15, it is possible to use several numbers of said folds 34. The number of the folds 34 may vary from three to about thirty-two folds, preferably from five to about sixteen folds, and more preferably, eight folds.

Referring again to Figures 13 and 14, the outer tube 120 may have a finger gripping ring 138 located near the second end 130. The finger gripping ring 138 may be integrally formed of the material of which the finger is constructed. outer tube 120 or this may be a separate member which is secured in place by an adhesive or some other type of fastening mechanism. The finger-engaging ring 138 functions to provide a means for the wearer to grasp the outer tube 120 and hold it between her thumb and middle fingers. The user can then place her Index finger on the free end of the inner tube 122 and orient the outer tube 120 in relation to her vagina while she pushes the inner tube 122 inside the other tube 120.

The inner tube 122 may have an inwardly directed flange 140 formed at its forward end which provides an enlarged surface for contacting the rear end of the plug 112. The inner tube 122 may also have a radially outwardly extending ring 142 formed to one side of the outer or free end of the inner tube 122 which provides an enlarged surface on which the user's finger can rest. The ring 142 therefore functions as a felt index finger and facilitates the movement of the inner tube 122 into the outer tube 120.

The inner tube 122 operates by moving telescopically in relation to the outer tube 120. As the inner tube 122 is pushed into the outer tube 120, the plug 112 is forced against the folds 134. The contact with the plug 112 causes the folds 134 open radially to a diameter which is sufficient to allow the plug 112 to be expelled from the outer tube 120. With the plug 112 properly positioned in the female's vagina, the plug applicator 110 is removed and disposed of properly.

A P A T O The outer tube 120 may have the insertion tip 132 formed in a desired hemispherical configuration with the central opening 136 by using the apparatus described below.

Referring to Figures 17 and 18, the outer tube 120 is shown before the insertion tip 132 is formed. In this phase, the outer tube 120 has an essentially constant inside diameter and the wall 124 has a constant thickness.

Referring to Figures 19 and 20, a first punch 144 is shown having a tubular section 146 which is sized and configured to receive the outer tube 120. In other words, the outer tube 120 must be able to slide into the section. tubular 146 with only a small amount of separation between them. The first punch 144 has a tip 148. The tip 148 can be smooth or be devoid of any slots as shown in Figure 19. Alternatively, the first punch 144 'can have a shaped tip 148 with a plurality of elongated slots 150 formed there, as shown in Figure 20. When the slots 150 are present, there must be at least four slots 150, preferably eight to twelve slots 150 with the eight slots 150 being more preferred. The purpose of the slots 150 will be explained later.

Tip 148 may be formed in a frusto-conical shape having a blunt end 152. Other shapes may also be used if desired. At least a portion of the outer surface of the tip 148 may be grooved 154 to provide a frictional surface between the tip 148 and the inner surface of the outer tube 120 as the insertion tip 132 is formed. An intermediate groove 154 will provide a surface frictional for the bending operation. The first punch 144 or 144 'also has a shoulder 156 formed at an opposite end of the tubular section 146 which acts as a stop for the outer tube 120. It should be noted that the length of the tubular section 146 is sized to conform closely to the length of outer tube 120. A typical outer tube 120 will have a length of between about 50.8 millimeters to about 101.6 millimeters, preferably from about 76.2 millimeters to about 88.9 millimeters, more preferably from at least about 79.2 millimeters. The tubular section 146 must have a length which is equal to or slightly greater than the initial length of the outer tube 120, as shown in Figure 17. The first end 128 of the tube 120 may be approximately evenly aligned with the tip 148 when the tube 120 is placed on tubular section 146. However, an extra length of about 1.5 millimeters on tubular section 146 of first punch 144 or 144 'is advgeous to allow first punch 144 or 144' to marry a first matrix 158 Referring to Figures 20 and 21, the first punch 144 'is shown with the outer tube 120 slid over the tubular section 146 so that the second end 130 of the outer tube 120 abuts the shoulder 156 and is castable with the first matrix 158. The axial contact of both the first punch 144 'and the outer tube 120 with the first die 158 allows the tip 132 of the outer tube 120 to bend. The term "bent" as used herein refers to pressing or pinching the material forming the insertion tip 132 in regular and small or blunt folds with troughs therethrough.

Referring to Figures 22 and 23, the bent tip 160 consists of a plurality of spine 162 and troughs 164 formed around the circumference of the first end 128 of the outer tube 120. The troughs 164 are the deepest on one side of the first end 128. and become less deep as the troughs move outward from the first end 128. The loins 162 are formed on a circle having a smaller diameter on one side of the first end 128 and expand outwardly as the loins 162 move outward from the first. extrem 128 Referring again to Figures 20 and 21, the bent tip 160 is formed by contacting the first punch 144 or 144 'with the first die 158. The first die 15 includes a base 166 having a plurality of blades 168 which extend axially out from it. There should be at least four blades 168, preferably, between eight to twelve blades, with eight blades being most preferred. For best results with hard cardboard papers, the slot 150 formed in the first punch 144 'should be aligned with a blade 168 formed in the first die 158. Either an even number or an uneven number of blades 168 can be used. A number even of blades 168 are easier to machine and the first die 158 will then have a symmetrical shape, which can also be advantageous. For example, matrices formed symmetrically can be measured through their tips to determine their size.

Blades 168 can vary from about 12.7 millimeters to about 50.8 millimeters in length. A length of approximately 25.4 millimeters is sufficient.

The blades 168 have an angled tapered inner surface 170 which then allows hunting with the flat tip 148 formed in the first punch 144 or to hunt with and axially enter a corresponding slot 158 formed in the first punch 144 '. The angle may vary depending on the taper on the flat tip 148 or depending on the angle at which each corresponding notch 150 is formed. The angle on each blade 168 may be the same as or different from the angle formed on the flat tip 148 and may be the same as or different from the slot at which each notch 150 is machined. When the notches 150 are present, each notch 150 must be sized to be greater than the corresponding blade 168 so that the thickness of the wall 124 of the outer tube 120 can be received within the notches 150. Each blade 168 is machined at an angle which is different from the angle at which the bottom of the notches 150 has to be machined. When the first punch 144 'is fully inserted into the first die 158, the angled surfaces 170 of each blade 168 are spaced from the bottom of each corresponding notch 150. This spacing allows the wall thickness of the outer tube 120 to get in shape sandwich between and providing the undulating surface which is the bend 160 shown in Figure 23. The angle at which each notch 150 and each blade 168 are formed can vary. The notches 150 and the blades 168 can be formed at identical angles in relation to a longitudinal central axis Y-Y of the first punch 144 'and the first matrix 158, or they can be formed at different angles in relation to one another. For the outer tubes 120 formed of hard cardboard, the good quality folds 134 can be formed using the first punch 144 with the flat tip 148 hunting with the first die 158. For a soft cardboard paper, it is advantageous to machine an angle of about 20 degrees to the Y-Y axis in the first die 158 and machining an angle of about 15 degrees to the Y-Y axis in the first punch 144 '.

Referring to Figure 21, one can see the position of the outer tube 120 on the first punch 144 'while the first end 128 is bent. The grooved surface 154 serves to prevent the outer tube 120 from moving towards the shoulder 156 when the first punch 144 'engages the first die 158. It has been found that the force exerted on the outer tube 120 decreases upon contacting the first punch 144 or 144 'deeper and deeper into the first die 158. When the grooved surface 154 is not present, this force can urge the outer tube 120 against the shoulder 156 and cause the second end 130 of the outer tube 120 it wrinkles and enlarges radially. Such a feature is not aesthetically pleasing and should be avoided.

After the inner tube 120 has a bent tip 160 formed on the first end 128 thereof, the first punch 144 or 144 'and the first die 158 are separated and the outer tube 120 is removed.

Referring to Figures 24 and 25, the outer tube 120 is then subjected to a second operation wherein the bent tip 160 is folded and compressed in a hemispherical configuration. This is achieved by using a second punch 172 having a tubular section 174 which is dimensioned to receive the outer tube 120. The second punch 172 has a hemispherically shaped tip 176 with a pin 178 extending outwardly from the apex of the tip 176 The pin 178 has a free or distal end 180. The second punch 172 also contains a shoulder 182 formed at an opposite end of the tubular section 174 which acts as a stop for the outer tube 120. It should be noted that the length of the The tubular section 174 is dimensioned to conform closely to the length of the outer tube 120. The second punch 172 is designed to have the outer tube 120 slid over the tubular section 174 until the second end 130 of the outer tube 120 is butted against the shoulder 182. In this position, the bent tip 160 formed on the first end 128 of the outer tube 120 should extend around 1.5 millimeters to about 3.0 millimeters beyond the apex of the semiespherically shaped tip. The free end 180 of the pin 178, however, will extend beyond the crimped end 160 to at least 1.5 millimeters, and preferably more.

At least a portion of the hemispherically shaped tip 176 may be scored 184 to provide a frictional surface between the tip 176 and the inner surface of the outer tube 120 as the insertion tip 132 is formed. A medium ridging 184 will provide a suitable friction surface for the bending and forming operation. The grooved surface 184 serves to prevent the outer tube 120 from moving towards the shoulder 182 of the second punch 172.

The pin 178 may have a length of at least 1.5 millimeters, but is preferably larger. Bolt 178 should have a diameter of at least 3.1 millimeters, and may be larger if desired. The cross section of the bolt 178 is preferably circular but must be of a different configuration if desired. A circular cross section is preferred since it forms an opening with a circular periphery. A circular opening is aesthetically pleasing to the eye and since one purpose of the opening 136 is to allow the consumer to see if the plug 112 is present in the plug applicator 110, the opening may be circular. Bolt 178 is shown having an essentially constant outside diameter. However, it is possible to form the pin 178 so that it tapers down to a diameter from a larger diameter located on one side of the point of attachment to the apex of the hemispherical tip 176 to a smaller diameter adjacent to the free end 180. .

The second punch 172 is sized or configured to make contact with a second matrix 186, to transform the bent tip 160 of the outer tube 120 into a plurality of folds 134 and to form the folds 134 in a hemispherically shaped nose 190, see Figures 26 and 27. The folds 134 may be spaced apart and evenly or randomly spaced apart and They may have a kite tail type appearance. The length of each fold 134 should be aligned approximately straight with or parallel to the longitudinal axis of the tube 120 against being undulated or curved. A straight fold usually requires a lesser amount of force to open. The folds 134 should terminate at a point 188 which is approximately tangent to the point where the hemispherically shaped tip 190 is attached to the outer surface of the outer tube 120. The semi-frusically shaped tip 190 will have a central aperture 192 formed therethrough. same due to the presence of the pin 178. The opening 192 allows the consumer to visually inspect the plug applicator 10 to see if the plug 112 is present. The opening 192 may vary with the diameter of the tube 120 but should not be so large as to allow a woman to feel it when inserting the plug 112 into her vagina. If the opening 192 is very large, this can cause discomfort when the woman inserts the plug 110 into her vagina.

Referring again to Figures 24 and 25, the second die 186 includes a base 194 having a first end 196 and a second end 198. A semi-spherically shaped cavity 200 formed in the base 194 on one side of the first end 196. The cavity is hemispherically Shaped 200 is dimensioned to receive the semiespherically shaped tip 176 formed on the outer tube 120 as well as the wall thickness of the outer tube 120. This difference in size will allow the insertion tip 132 to be formed on the first end 128 of the outer tube 120. The surface of the cavity 200 is preferably polished to improve the appearance of the finished semiespherically shaped tip 176 and to facilitate the removal of the finished tube 120 from the second die 186. The polished surface may have a "surface roughness value". average of between about 4 microinches to around 16 microinches.

The base 194 also has a central duct 202 formed therein which is essentially aligned along a longitudinal central axis Z-Z. The conduit 202 extends from the bottom of the cavity 200 to the second end 198. If desired, the conduit 202 may be a closed conduit which terminates very close to the second end 198. The conduit 202 is sized and configured to receive only the bolt 178. The outside diameter of the bolt 178 should be slightly smaller than the inside diameter of the conduit 202. The relationship between the second matching stud 172, the outer tube 120 and the second matrix 186 is clearly shown in Figure 25.

It should be noted that both the length and the diameter of the commercially available plugs vary and therefore the plug applicator 110 must be manufactured in a variety of sizes. The plugs can vary in length from about 25.4 millimeters to about 76.2 millimeters but preferably they are around 50.8 millimeters in length. The diameter of the stopper will vary from about 6.4 millimeters to about 19.0 millimeters. In addition, the material from which the plug 112 is constructed, the smoothness of the inner surface of the outer tube 120, the shape of the inner tube 122 etc. all contribute to establishing an ejection force necessary to open and eject plug 112. This force should vary from about 250 grams to about 1,500 grams, preferably less than about 1,200 grams, and more preferably, less than about of 1,000 grams. A lower force value is preferred since this ensures that the plug applicator 110 will be less susceptible to being bent or deformed upon the ejection of the plug 112. A bent applicator may cause the plug to be inserted incorrectly. A lower force value also makes the plug applicator 110 easier to use. The size of the opening 192 will also affect the amount of force necessary to open the folds 134. Typically, the larger the diameter of the opening 192, the lower the force required to open the folds 134.

M E T O D O The method of folding, folding and forming a semiespherically shaped tip 190 on a hollow tube 120 is as follows, using the above-identified punches 144, 144 'and 172, and matrices 158 and 186. The above-identified punches 144, 144' and 172 and matrices 158 and 186 can be manually and automatically hooked and uncoupled to form insertion tip 132 on outer tube 120. It is contemplated that punches 144, 144 'and 172, and matrices 158 and 186 will be driven to sufficient speeds for bending, folding and forming in excess of 100, preferably in excess of 300, and more preferably more than 500 outer tubes per minute.

The method involves sliding the hollow tube 120 over the first punch 144 or 144 'until one end 130 of the tube 120 makes contact with the shoulder 156. The first punch 144 or 144' and the tube 120 are moved to make contact with the first die 158 and a plurality of bends are formed on the opposite end 128 of the tube 120. The plurality of bends form the folded end 160. The first punch 144 or 144 'is then disengaged from the first one. Matrix 158 and tube 120 having bent end 160 removed from first punch 144 or 144 '. The tube 120 is then slid over the second punch 172 until the unfolded end 130 of the tube 120 makes contact with the shoulder 182. The second punch 172 and the tube 120 come into contact with the second die 186 thus allowing the pin 178 that extends axially as it enters conduit 202. Marriage of second punch 172 with second die 186 transforms folded end 160 of tube 120 into a plurality of folds 134 and forms folds 134 in a hemispherically shaped tip 190 having a central opening 192 formed therethrough. Once the tip 190 is formed, the second punch 172 is disengaged from the second die 186 and the outer tube 120 is removed from the second punch 172.

Although the invention has been described in conjunction with several specific embodiments, it should be understood that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Therefore, this invention is intended to cover all alternatives, modifications and variations that fall within the spirit and scope of the appended claims.

Claims (44)

R E I V I N D I C A C I O N S

1. A plug applicator comprising: a) A first member capable of housing an absorbent cap, said first member having a central longitudinal axis and first and second ends; b) An insertion tip integrally formed on said first end of said first member and extending outwardly therefrom, said insertion tip including a shaped hemispherical part and a shaped frustoconical portion, said frustoconical portion shaped having an aperture formed through the same and said opening having a side wall which is aligned essentially parallel to said central longitudinal axis and said frusto-conical shaped part is located between said shaped hemispherical part and said first end of said first member, said insertion tip includes a plurality of folds able to expand outwards when the plug of the first member is ejected; Y c) a second member mounted telescopically at said second end of said first member, said second member being adapted to eject said plug through the insertion tip when pushed through said first member.

2. The plug applicator as claimed in clause 1 characterized in that said frusto-conical shaped portion extends outwardly from the first end of said first member and tapers inward at an angle of between about 5 degrees to about 40 degrees .

3. The plug applicator as claimed in clause 2 characterized in that said frusto-conical shaped part tapers inwardly at an angle of between about 5 degrees to about 25 degrees.

4. The plug applicator as claimed in clause 2 characterized in that said frusto-conical shaped part has a length of less than one inch.

5. The plug applicator as claimed in clause 4 characterized in that said formed frusto-conical part reduces in diameter from the point of attachment to said first end of said first member to the point of attachment to said hemispherical shaped part.

6. The plug applicator as claimed in clause 1 characterized in that said insertion tip contains an even number of folds.

7. The plug applicator as claimed in clause 1 characterized in that said insertion tip contains an uneven number of folds.

8. The plug applicator as claimed in clause 1 characterized in that said insertion tip contains between three to thirty-two folds.

9. The plug applicator as claimed in clause 1 characterized in that said insertion tip contains from six to twelve folds.

10. A plug applicator comprising: a) a first hollow member capable of housing an absorbent plug, said first member having a virtually smooth outer surface, a central longitudinal axis, and the first and second ends; b) an insertion tip integrally formed on said first end of said first member and extending outwardly therefrom, said insertion tip includes a hemispherical shaped part and a frustoconical shaped part, said hemispherical shaped part having an aperture formed therethrough the same and said opening has a side wall which is aligned essentially parallel to said central longitudinal axis, and said frustoconical shaped part located between said hemispherical shaped part and said first end of said first member, said insertion tip includes at least three folds capable of expanding radially outwardly upon expelling said plug from said first member; Y c) a second member mounted telescopically at said second end of said first member, said second member being adapted to eject the plug through the insertion tip as it is pushed into the first member.

11. The plug applicator as claimed in clause 10 characterized in that each of said folds has a first end which coincides with said opening and a second end which coincides with a point on an outer surface of said frustoconical shaped part.

12. The plug applicator as claimed in clause 10 characterized in that each of said folds has a first end which coincides with said opening and a second end which coincides in a place where said frustoconical shaped part is attached to said first member.

13. The plug applicator as claimed in clause 10 characterized in that each of said folds has a first end which coincides with said opening and a second end which coincides in a place where said hemispherical shaped part is attached to said frustoconical shaped part.

14. The plug applicator as claimed in clause 10 characterized in that said frusto-conical shaped part has an outer diameter at one end which is approximately equal to the outer diameter of said first member.

15. The stopper applicator as claimed in clause 14 characterized in that said frustoconical shaped part has an outer diameter at an opposite end which is approximately equal to the outer diameter of said hemispherical shaped part.

16. A plug applicator comprising: a) a first spirally wound and hollow member capable of housing an absorbent plug, said first member having a virtually smooth outer surface, a central longitudinal axis, and the first and second ends; b) an insertion tip integrally formed on said first end of said first member and extending outwardly therefrom, said insertion tip includes a hemispherical shaped part and a frustoconical shaped part, said hemispherical shaped part having an aperture formed therethrough the same and said opening has a side wall which is aligned substantially parallel to said central longitudinal axis, and said frustoconical shaped part located between said spherical shaped part and said first end of said first member, said insertion tip includes eight approximately spaced-apart folds. by an equal distance of separation which are capable of expanding radially outwardly when said plug is expelled from the first member; Y c) a second member mounted telescopically at said second end of said first member, said second member being adapted to eject said plug through said insertion tip when pushed into said first member.

17. The plug applicator as claimed in clause 16 characterized in that said frusto-conical shaped part has an outer diameter at one end which is approximately equal to the outer diameter of said first member.

18. The plug applicator as claimed in clause 16 characterized in that said opening has a diameter of at least about 1.5 millimeters.

19. The plug applicator as claimed in clause 18 characterized in that said opening has a diameter of between about 1.5 millimeters to about 5.0 millimeters.

20. The plug applicator as claimed in clause 16 characterized in that said first member has an outer diameter and said hemispherical shaped part has a diameter which varies from about 50 percent to about 90 percent of said outer diameter of said first member.

21. The plug applicator as claimed in clause 16 characterized in that said side wall of said apparatus contains a radius formed on one side of an outer surface of the insertion tip.

22. The plug applicator as claimed in clause 16 characterized in that said bends have a thickness of less than 0.5 millimeters.

23. In combination, a plug applicator and a catameneal stopper having a shaped nose, said combination comprises: a) a first member capable of housing said catameneal plug, said first member having a central longitudinal axis and the first and second ends; b) an insertion tip integrally formed on said first end of said first member and extending outwardly therefrom, said insertion tip includes a hemispherical shaped part and a frustoconical shaped part, said hemispherical shaped part having an aperture formed therethrough the same and said opening has a side wall which is aligned essentially parallel to said central longitudinal axis, and said frustoconical shaped part located between said hemispherical shaped part and said first end of said first member, said insertion tip includes a plurality of folds which are capable of expanding radially outwardly when said plug of said first member is ejected; and c) a second member telescopically mounted on said second end of said first member, said second member being adapted to eject said plug through the insertion tip when pushed into the first member.

24. The combination as claimed in clause 23 characterized in that said nose formed on said cap is configured to conform to the inner surface of said insertion tip.

25. An apparatus for bending, folding and forming a point on a hollow tube, said apparatus comprises: a) A first punch having a tubular section dimensioned to receive said tube and a shoulder formed at an opposite end of said tubular section which acts as a stop for said tube; b) a first matrix salable with said first punch and the tube for bending one end of said tube, said first matrix includes a base having a plurality of blades extending axially outwardly therefrom, each of said blades is capable of hooking said tube and bending the tip of said tube placed between them; c) a second punch having a tubular section dimensioned to receive said tube and having a semi-spherical shaped tip with a pin extending outward from the apex of said tip, said second punch further having a shoulder formed at an opposite end of said tubular section that acts as a stop for said tube; Y d) a second matrix salable with said second punch to transform said bent end of said tube into a plurality of folds and form said folds in a semi-spherical shaped tip having a central opening formed therethrough, said second matrix includes a base having a semi-spherical cavity formed there with a central duct formed in the bottom of said cavity, said cavity being dimensioned to receive both said second punch and said tube and said duct being dimensioned to receive only the bolt.

26. The apparatus as claimed in clause 25 characterized in that said bolt has a diameter of at least 0.125 inches.

27. The apparatus as claimed in clause 25 characterized in that said bolt has a circular cross-sectional configuration.

28. An apparatus for bending, folding and forming a point on a hollow tube, said apparatus comprises: a) a first punch having a tubular section sized to receive said tube and having a tip configured with a plurality of elongated slots formed therein, and a shoulder formed at an opposite end of said tubular section that acts as a stop for said tube; b) a first matrix salable with said first punch and the tube for bending one end of said tube, said first matrix includes a base having a plurality of blades extending axially outwardly therefrom, each of said blades is capable of engaging with one of these slots formed on said first punch and bending the tip of said tube placed therebetween; c) a second punch having a tubular section dimensioned to receive said tube and having a semiespherically shaped tip with a pin extending outward from the apex of said tip, said second punch further having a shoulder formed at an opposite end of the tubular section that acts as a stop for said tube; Y d) a second matrix salable with said second punch to transform said bent end of said tube into a plurality of folds and form said folds in a semiespherically shaped tip having a central opening formed therethrough, said second matrix includes a base having a hemispherical cavity formed therein with a central conduit formed in the bottom of said cavity, said cavity being dimensioned to receive both the second punch and said tube and said conduit being dimensioned to receive only said bolt.

29. The apparatus as claimed in clause 28 characterized in that said tip configured and formed on said first punch contains a grooved area which facilitates the bending of the tube when said first punch is brought into contact with the first die.

30. The apparatus as claimed in clause 28 characterized in that said semiespherically shaped tip on said second punch contains a grooved area which facilitates folding and forming said tube when said second punch is brought into contact with said second die.

31. The apparatus as claimed in clause 28 characterized in that said first matrix contains at least four blades.

32. The apparatus as claimed in clause 28 characterized in that said first matrix contains at least eight blades.

33. The apparatus as claimed in clause 28 characterized in that said first punch contains at least four elongated notches.

34. An apparatus for bending, folding and forming a point on a hollow tube, said apparatus comprises: a) a first punch having a tubular section dimensioned to receive said tube and having a tip configured with eight elongated slots formed therein, and a shoulder formed at an opposite end of said tubular section which acts as a stop for said tube; b) a first matrix salable with said first punch and the tube for bending one end of said tube, said first matrix includes a base having eight blades extending axially outwardly therefrom, each of said blades is capable of engaging with one of said slots formed on the first punch and bending the tip of said tube placed therebetween; c) a second punch having a tubular section dimensioned to receive said tube and having a semiespherically shaped tip with a pin extending outwardly from the apex of said tip, said second punch further having a shoulder formed at an opposite end of said tubular section; which acts as a stop for said tube; Y d) a second matrix salable with said second punch to transform said bent end of said tube into eight folds and form said eight folds in a semiespherically shaped tip having a central opening formed therethrough, said second matrix includes a base having a semi-performally formed cavity there with a central duct formed in the bottom of said cavity, said cavity is dimensioned to receive both said second punch and said tube and said duct being dimensioned to receive only said bolt.

35. The apparatus as claimed in clause 34 characterized in that said bolt has a diameter of at least 0.062 inches.

36. The apparatus as claimed in clause 34 characterized in that said bolt has an essentially constant diameter.

37. The apparatus as claimed in clause 34 characterized in that said bolt has a free end and said bolt tapers in diameter downward from a larger diameter located on one side of its fastening point to said tip to a smaller diameter in its free end.

38. The apparatus as claimed in clause 34 characterized in that said bolt has a length of at least 0.06 inches.

39. A method for folding, folding and forming a point on a hollow tube using a first punch having a tubular section dimensioned to receive said tube and having a tip configured with a plurality of elongated slots formed therein, and a shoulder formed at an opposite end of the tube. said tubular section which acts as a stop for said tube, a first matrix salable with said first punch and the tube for bending one end of said tube, said first matrix includes a base having a plurality of blades extending axially outward from the same, each of said blades is able to hook with one of said slots formed on said first punch and bend the tip of said tube placed between them, a second punch having a tubular section sized to receive said tube and having a tip semiespherically shaped with a pin extending outward from the apex of said tip, said second point In addition, it has a shoulder formed at an opposite end of said tubular section acting as a stop for said tube, and a second matrix salable with said second punch to transform said bent end of said tube into a plurality of folds and form said folds in a semiespherically shaped tip having a central opening formed therethrough, said second matrix includes a base having a hemispherical cavity formed therein with a central duct formed at the bottom of said cavity, said cavity being dimensioned to receive both the second punch and said tube and said conduit being dimensioned to receive only said bolt, said method comprises the steps of: a) sliding said hollow tube over the first punch until one end of said tube makes contact with said shoulder; b) moving said first punch and the tube to contact said first die to form a plurality of folds on an opposite end of said tube; c) sliding said tube over the second punch until the non-bent end of said tube makes contact with said shoulder; and d) moving said second punch and the tube to contact said second matrix and engaging said pin in said duct to transform said bent end of said tube into a plurality of folds and forming said folds in a semiespherically shaped tip having a central opening formed through it.

40. The method as claimed in clause 39 characterized in that when one end of said tube makes contact with the shoulder, the opposite end of said tube is approximately even with said tip configured and formed on said first punch.

41. The method as claimed in clause 39 characterized in that said first punch and said first die are engaged to form at least four folds at one end of said fold.

42. The method as claimed in clause 39 characterized in that said second punch and said second matrix are engaged to form an opening having a circular periphery.

43. The method as claimed in clause 39 characterized in that said first punch and said first die are axially engaged so that each tube of said blades formed on said first die is axially aligned with one of the corresponding grooves formed on said first punch .

44. A method for folding, folding and forming a point on a hollow tube using a first punch having a tubular section dimensioned to receive said tube and having a tip configured with a plurality of elongated slots formed therein, and a shoulder formed at an opposite end of the tube. said tubular section which acts as a stop for said tube, a first matrix salable with said first punch and the tube for bending one end of said tube, said first matrix includes a base having a plurality of blades extending axially outwardly therefrom, each of said blades is capable of engaging one of said slots formed on said first punch and bending the tip of said tube placed between the same, a second punch having a tubular section sized to receive said tube and having a semiespherically shaped tip with a pin extending outwardly from the apex of said tip, said second punch further having a shoulder formed at an opposite end of said tubular section which acts as a stop for said tube, and a second matrix salable with said second punch to transform said bent end of said tube into a plurality of folds and form said folds in a semiespherically shaped tip having a central opening formed through the same, said second matrix includes a base having a semi-dry cavity rich formed there with a central duct formed in the bottom of said cavity, being dimensioned to receive both the second punch and the tube and said duct being dimensioned to receive only the bolt, said method comprises the steps of: a) sliding the hollow tube over the first punch until one end of the tube makes contact with the shoulder; b) moving said first punch and said tube to contact said first matrix to form a plurality of folds on an opposite end of said tube; c) unhooking the first punch from said first die and removing said folded tube from said first punch; d) sliding the bent tube over the second punch until the unfolded end of the tube makes contact with the shoulder; e) moving said second punch and said tube to make contact with the second matrix and engaging the pin in said duct to transform said bent end of said tube into a plurality of folds and forming said folds in a hemispherically shaped tip having a central opening formed through it; Y f) disengaging said second punch from the second die and removing said bent and formed tube from said second punch. SUMMARY A tampon applicator is described which has an improved folded tip to facilitate the insertion of a catamenial plug into the vagina of a woman. The plug applicator includes a first member capable of housing an absorbent plug. The first member has a central longitudinal axis and the first and second ends. An insertion tip is formed integrally on the first end of the first member and extends outwardly therefrom. The insertion tip includes a hemispherical shaped part and a frustoconical shaped part. The hemispherical shaped part has an opening extending therethrough and the opening has a side wall which is aligned essentially parallel to the central longitudinal axis. The frustoconical shaped part is located between the hemispherical shaped part and the first end of the first member. The insertion tip contains a plurality of folds which are capable of expanding radially outwardly when the plug of the first member is ejected. The applicator further includes a second member telescopically mounted at the second end of the first member. The second member is adapted to eject the plug through the insertion tip when pushed into the first member. The plug applicator is also described in combination with a catamenial stopper. Also disclosed is an apparatus and method for bending, folding and forming a point on a hollow tube.