Composite Polyurethane Condom Lamination Without Delamination
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Solution Overview
Problem
Natural rubber latex condoms are limited by thickness and protein allergies, while waterborne polyurethane condoms lack flexibility, and laminating these materials results in delamination due to low adhesion.
Innovation Solution
A composite polyurethane condom is created with a special adhesive layer containing aliphatic sulfonated waterborne polyurethane, which has amino and sulfonic groups, allowing firm attachment of materials with different polarities without delamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If physical lamination method is used to combine natural rubber latex and waterborne polyurethane, then the condom can integrate characteristics of both materials, but the adhesion between the two materials is low causing delamination
Solution Approach 1:
The patent introduces a waterborne polyurethane adhesive layer as an intermediary between natural rubber latex and waterborne polyurethane layers. This adhesive layer contains specific functional groups that enhance chemical bonding with both materials, serving as a mediator that resolves the adhesion problem while maintaining the integrated structure of the composite condom.
Solution Approach 2:
The patent creates a multi-layer composite structure combining natural rubber latex, waterborne polyurethane adhesive, and waterborne polyurethane layers. By using composite materials with different properties in each layer, the invention achieves both the versatility of integrated material characteristics and the reliability of strong inter-layer adhesion through the specialized adhesive layer.
2Ease of manufacture
If natural rubber latex is used for condom production, then the condom can be manufactured, but the thickness is difficult to be less than 0.04 mm
Solution Approach 1:
The patent divides the condom structure into multiple thin layers: natural rubber latex layer, waterborne polyurethane adhesive layer, and waterborne polyurethane layer. By segmenting the single-thickness constraint into multiple thinner sub-layers, the invention achieves an overall thickness less than 0.04 mm while maintaining manufacturability through the dip-molding process for each layer.
3Length of moving object
If waterborne polyurethane is used for condom production, then thinness can be achieved, but the flexibility has a certain gap compared with natural rubber
Solution Approach 1:
The patent merges the advantages of different materials by combining natural rubber latex (providing flexibility and elasticity) with waterborne polyurethane (providing thinness and strength). The composite structure integrates the flexible natural rubber layer with the thin waterborne polyurethane layer, achieving both thinness and flexibility that neither material could achieve alone.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composite condom maintains flexibility and thinness, withstanding hot alkaline or hot water without delamination, and exhibits high adhesion and resilience.
Implementation Method 1
the adhesive layer includes an aliphatic sulfonated waterborne polyurethane, the aliphatic sulfonated waterborne polyurethane contains amino groups, sulfonic groups and carboxyl groups in its molecular chain
Data Source
AI summary
A composite polyurethane condom and a preparation method thereof. The composite polyurethane condom includes a first substrate layer, an adhesive layer formed on the first substrate layer, and a second substrate layer formed on the adhesive layer. A special adhesive layer is added between the two layers of materials, so that, for example, two materials with different polarities can be firmly attached together without delamination.