Tampon pledget with improved by-pass leakage protection

Abstract

A tampon has two pledgets or one pledget with an absorbent layer and a leak shield located therebetween. The pledgets or pledget with the absorbent layer and the leak shield are folded such that the leak shield covers a portion of the surface of at least one of the pledgets. Both pledgets or the one pledget with the absorbent layer have absorbencies that are each greater than an absorbency of the leak shield. In another embodiment of the tampon, the leak shield comprises a fluid impervious or fluid repellent material(s). In another embodiment of the tampon, the leak shield comprises of an absorbent or hydrophilic material. Yet in another embodiment, the leak shield comprises of multiple layers of materials that are hydrophilic, hydrophobic, or a combination thereof. A method of fabricating a tampon includes forming a pledget, combining a fluid-impervious polymer material with an absorbent material to define a polymer laminate, ramming the pledget and the laminate into an oven tube, and stitching the laminate to the pledget.

1 . A tampon, comprising:
 a first pledget;   one of a second pledget and an absorbent layer; and   a leak shield located between said first pledget and one of said second pledget and said absorbent layer and covering a portion of the surface area of said first pledget;   wherein said first pledget and one of said second pledget and said absorbent layer have absorbencies that are greater than an absorbency of said leak shield.   
   
   
       2 . The tampon of  claim 1 , further comprising a string attached to one or more of said first pledget, one of said second pledget and said absorbent layer, and said leak shield. 
   
   
       3 . The tampon of  claim 1 , wherein said first pledget comprises an inner layer and an outer layer arranged together. 
   
   
       4 . The tampon of  claim 1 , wherein said tampon is capable of expanding in thickness upon contact with body fluids to at least about twice the thickness of said tampon in a dry state. 
   
   
       5 . The tampon of  claim 1 , wherein said second pledget is fabricated from a hydro-entangled composite material comprising about 50% rayon and about 50% PET fibers. 
   
   
       6 . The tampon of  claim 1 , wherein said leak shield is fabricated from an absorbent non-woven material comprising about 30% cotton and about 70% polypropylene fibers. 
   
   
       7 . The tampon of  claim 1 , wherein said leak shield is fabricated mostly of a hydrophobic non-woven material. 
   
   
       8 . The tampon of  claim 1 , wherein said leak shield is fabricated mostly of a hydrophilic non-woven material. 
   
   
       9 . The tampon of  claim 7 , wherein said hydrophobic non-woven material comprises of 100% polyester fibers and is applied to at least one of said first pledget and said second pledget during a pre-forming process. 
   
   
       10 . The tampon of  claim 7 , wherein said hydrophobic non-woven material comprises of SMS and is applied to at least one of said first pledget and said second pledget during a post-forming process. 
   
   
       11 . The tampon of  claim 8 , wherein said hydrophilic non-woven material comprises of SBPP containing a surfactant finish. 
   
   
       12 . The tampon of  claim 1 , wherein said leak shield is fabricated mostly of a fluid impervious or fluid repellent material. 
   
   
       13 . The tampon of  claim 12 , wherein said fluid impervious material is a polymer film or poly laminate composite. 
   
   
       14 . The tampon of  claim 12 , wherein said fluid repellent material is an apertured polymer film. 
   
   
       15 . The tampon of  claim 13 , wherein the polymer film is a breathable micro-porous film. 
   
   
       16 . The tampon of  claim 1 , wherein said leak shield comprises two or more layers of non-woven material. 
   
   
       17 . A tampon, comprising:
 a pledget having a first absorbency; and   a leak shield covering at least a portion of said pledget and having a second absorbency, said second absorbency being less than said first absorbency, said leak shield comprising a polymer film that is impervious to fluid or material that is fluid repellent.   
   
   
       18 . The tampon of  claim 17 , wherein said polymer film of said leak shield is a breathable micro-porous film. 
   
   
       19 . The tampon of  claim 17 , wherein said leak shield comprises of a poly laminate composite containing a poly film on the inside layer in contact with said pledget and a non-woven layer on the outside layer. 
   
   
       20 . The tampon of  claim 17 , wherein said material of said leak shield is a hydrophobic non-woven. 
   
   
       21 . The tampon of  claim 20 , wherein said hydrophobic material is an apertured polymer. 
   
   
       22 . The tampon of  claim 20 , wherein said hydrophobic material is non-woven material comprising a meltblown layer located between two spunbond layers. 
   
   
       23 . The tampon of  claim 20 , wherein said hydrophobic material is a non-woven material having uniformly distributed nanofibers. 
   
   
       24 . The tampon of  claim 17 , further comprising a string attached to one or more of said leak shield and said pledget. 
   
   
       25 . A tampon, comprising:
 a pledget having a first absorbency;   a leak shield positioned adjacent said pledget and covering at least a portion thereof, said leak shield being less than said first absorbency, said leak shield comprising an absorbent or hydrophilic material.   
   
   
       26 . The tampon of  claim 25 , further comprising a string attached to one or more of said first pledget and said leak shield. 
   
   
       27 . The tampon of  claim 25 , wherein said leak shield comprises of an absorbent layer is fabricated from a material that is one or more layers of non-woven, airlaid, spunlaced, hydro-entangled, tissue, and/or flocked fibers. 
   
   
       28 . The tampon of  claim 27 , wherein said absorbent layer is fabricated from a hydro-entangled composite material comprising about 50% rayon and about 50% PET fibers. 
   
   
       29 . The tampon of  claim 25 , wherein said absorbent layer is a carded, thermal bonded, non-woven material. 
   
   
       30 . The tampon of  claim 29 , wherein said non-woven material comprises about 30% cotton and 70% polypropylene fibers. 
   
   
       31 . The tampon of  claim 25 , wherein said first pledget comprises an outer layer and an inner layer, and wherein said leak shield is positioned adjacent said outer layer. 
   
   
       32 . A tampon, comprising:
 a pledget having a first absorbency;   a leak shield having three or more layers positioned adjacent to said pledget and covering at least a portion thereof, said leak shield having an absorbency that is less than said first absorbency.   
   
   
       33 . The tampon of  claim 32 , wherein said leak shield is fabricated of a hydrophobic non-woven layer adjacent to said pledget, a first absorbent layer adjacent to said hydrophobic non-woven layer, and a second absorbent layer adjacent to said first absorbent layer, wherein said second absorbent layer has a greater absorbency than said first absorbent layer. 
   
   
       34 . The tampon of  claim 32 , wherein said leak shield is fabricated of a fluid impervious layer adjacent to said pledget, a first absorbent layer adjacent to said fluid impervious layer, and said absorbent layer adjacent to said first absorbent layer, wherein said second absorbent layer has a greater absorbency than said first absorbent layer. 
   
   
       35 . The tampon of  claim 32 , wherein said leak shield is fabricated of a hydrophobic layer adjacent to said pledget, an absorbent layer adjacent to said hydrophobic layer, and a hydrophilic layer adjacent to said absorbent layer. 
   
   
       36 . The tampon of  claim 32 , wherein said leak shield is fabricated of a hydrophilic layer adjacent to said pledge, a first absorbent layer adjacent to said hydrophilic layer, and a second absorbent layer adjacent to said first absorbent layer, wherein said second absorbent layer has a greater absorbency than said first absorbent layer. 
   
   
       37 . A method of fabricating a tampon, comprising the steps of:
 forming a first pledget;   combining a fluid-impervious polymer material with an absorbent material to define a polymer laminate;   registering said polymer laminate on an opening of an oven tube such that said absorbent material is in contact with said opening of said oven tube;   ramming said first pledget and said polymer laminate into said oven tube; and   stitching said polymer laminate to said first pledget using a string.   
   
   
       38 . The method of  claim 37 , further comprising inserting said fabricated tampon into an applicator barrel.