A tampon pledget is made by assembling one or more pads in a pad compression configuration, radially compressing the pad compression configuration in a traverse direction into a cylindrical form, and axially compressing the cylindrical form in a direction along a vertical axis to form the tampon pledget. In one embodiment, the axial compression is performed as a pressure is applied to at least one of a first and a second end of the cylindrical form. In one aspect of the present invention, the formed tampon pledget has an absorbent capacity as measured by the syngyna test of between about 6.0 grams to 9.0 grams and a density of about 0.4603 grams/cubic centimeter. In another aspect of the invention, the formed tampon pledget has an absorbent capacity as measured by the syngyna test of between about 9.0 grams to 12.0 grams and a density of about 0.4755 grams/cubic centimeter.

A process of forming a shaped, dimensionally stable tampon includes the steps of: radially compressing a tampon blank to form a dimensionally stable intermediate pledget having an intermediate pledget diameter and a longitudinal axis; placing the intermediate pledget into a hollow carrier and inserting the intermediate pledget and hollow carrier into a mold; urging the intermediate pledget into the mold via a ram bearing on an end of the intermediate pledget contained within the hollow carrier and withdrawing the hollow carrier from the mold to permit the exposed end of the intermediate pledget to substantially fill the mold and to form the shaped, dimensionally stable tampon; removing the shaped, dimensionally stable tampon from the mold; and enclosing the shaped, dimensionally stable tampon in a primary package that conforms to the shape thereof. The mold has an access opening through which the hollow carrier can be withdrawn.

A tampon absorbent for insertion into a vaginal cavity is provided. The tampon absorbent includes a longitudinal direction and has an insertion end and a withdrawal end. The tampon absorbent includes a first absorbent material portion at the insertion end for capturing body fluid and demonstrating a first expansion capacity, and a second absorbent material portion at the withdrawal end for storing body fluid and demonstrating a second expansion capacity. The second absorbent material portion is partially wrapped around the first absorbent material portion in a direction transverse (perpendicular) to the longitudinal direction, at a bonding region, whereby the first absorbent material portion is bonded to the second absorbent material portion at the bonding region.

A doming tool for manufacturing absorbent tampon includes a plurality of stations made of devices for shaping a tampon pledget tip, and a hollow mandrel engaging with the stations. The stations are supported by at least one mounting plate.

A press for shaping an absorbent tampon blank into a shaped tampon pledget includes a central cavity arranged and configured to accommodate an absorbent tampon blank having a front portion and a back portion. The main longitudinal axis of the press passes in the middle of the central cavity and a plurality of penetrating dies are arranged radially around the said main longitudinal axis. Each penetrating die has a pressing face on at least a fragment of its side facing the central cavity. The said press comprises at least one cam to actuate the plurality of penetrating dies. Furthermore, the plurality of penetrating dies comprises at least one penetrating die having a pressing face with a first shaped longitudinal profile, and least one penetrating die having a pressing face with a second shaped longitudinal profile.

Aspects of the present disclosure relate to methods for making tampons including primary absorbent members and secondary absorbent members. In some configurations, the tampons may be constructed with a primary absorbent member formed by a primary absorbent pad in a rolled configuration. In some configurations, the tampons may be constructed with a primary absorbent member formed by first and second primary absorbent pads positioned in a crossing configuration.

Tampons that provide a balance of adequate absorption with sufficient expansion properties during absorption and a relatively small initial diameter for comfortable insertion are provided.

A tubular shaped tampon can include an absorbent body defining a cylindrical shape having a hollow interior, a porous protective sleeve surrounding the absorbent body, and a string that holds the protective sleeve in place against the absorbent body and facilitates removal of the tampon after use. The absorbent body and protective sleeve can combine to define an overall tubular structure having an inner hollow region, providing increased surface area. Methods of manufacturing the tampon can include cutting a fluid absorbent material, rolling the cut material around elongated machine prongs to form an absorbent body, rolling a porous sheet around and extending beyond both distal ends of the absorbent body, pinching together distal ends of the porous sheet, pushing at least one distal end through the hollow interior of the absorbent body, stitching the distal ends of the porous sheet together, and punching a string through the protective sleeve and absorbent body.

A device and a corresponding method for shaping and/or smoothing at least one end of a tampon blank, in particular an axial end of a tampon blank, includes a guide unit driven by at least one shaft. The guide unit includes first and second conveyor planes. The device also includes shaping sleeves on the second conveyor plane for receiving at least one respective tampon blank, and rotatable shaping caps on the first conveyor plane, each designed to be operatively connected to at least one end of a tampon blank in a shaping sleeve. The first conveyor plane and the second conveyor plane are designed in order to guide a respective at least one of the shaping sleeves on the second conveyor plane coaxially relative to at least one of the rotatable shaping caps on the first conveyor plane on the conveyor plane. A computer program product controls the device.

A device and a corresponding method for shaping and/or smoothing at least one end of a tampon blank, in particular an axial end of a tampon blank, includes a guide unit driven by at least one shaft. The guide unit includes first and second conveyor planes. The device also includes shaping sleeves on the second conveyor plane for receiving at least one respective tampon blank, and rotatable shaping caps on the first conveyor plane, each designed to be operatively connected to at least one end of a tampon blank in a shaping sleeve. The first conveyor plane and the second conveyor plane are designed in order to guide a respective at least one of the shaping sleeves on the second conveyor plane coaxially relative to at least one of the rotatable shaping caps on the first conveyor plane on the conveyor plane. A computer program product controls the device.