Textured Condom Manufacturing via Pre-Coated Mandrel
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Solution Overview
Problem
Current methods for manufacturing condoms with textured features, such as ribs or projections, are limited in height and structural integrity, failing to provide sufficient stimulation and often result in weak spots, with existing techniques unable to produce features greater than 0.1 mm in height effectively.
Innovation Solution
A method involving direct application of latex or a compatible vehicle to the condom mandrel to create raised patterns, followed by drying and over-dipping to form condoms with projections that are permanently attached, allowing for heights and widths greater than previously achievable, up to 0.9 mm and 3 mm respectively, and enabling the creation of multicolor designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If deeper etching of the condom mandrel is used to create higher textured features, then the height of raised patterns increases, but the structural integrity of the condom deteriorates due to formation of weak spots
Solution Approach 1:
The mandrel is pre-coated with a release agent before dipping into the latex bath. This preliminary action prevents latex from adhering to the etched portions of the mandrel, allowing deep etching to create high raised patterns without forming weak spots, as the release agent protects the mandrel surface during the dipping process
Solution Approach 2:
A release agent is introduced as an intermediary substance between the mandrel surface and the latex coating. This release agent enables the creation of high raised patterns by preventing latex adhesion to the etched mandrel surface, thereby maintaining structural integrity while achieving greater pattern heights
2Shape
If broader etching is used to create wider raised patterns, then the width of patterns increases, but the pattern definition deteriorates as latex forms uniform coating instead of filling voids
Solution Approach 1:
The mandrel is pre-coated with a release agent before dipping. This preliminary coating ensures that when broader etching is used, the latex will not fill the etched voids but will instead form a uniform coating over them, preserving pattern definition while allowing wider raised patterns to be created
Solution Approach 2:
The release agent acts as an intermediary that prevents latex from adhering to broadly etched sections of the mandrel. This maintains the voids in the etched areas, allowing the latex to form a uniform coating that preserves the pattern definition while enabling broader raised patterns
3Ease of manufacture
If traditional dip molding with etched mandrels is used, then production process is simple, but the height of textured features is limited to about 0.1 mm or less
Solution Approach 1:
The mandrel is pre-coated with a release agent before the standard dipping process. This simple preliminary step enables the creation of much higher raised patterns (up to 0.9 mm or more) while maintaining the simplicity of the overall dip molding process, eliminating the need for complex multi-step manufacturing
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
This method enables the production of condoms with more pronounced and stable raised patterns that provide enhanced tactile and visual stimulation, improving user experience while maintaining the structural integrity of the condom.
Implementation Method 1
applying latex (as is or thickened with some agent) or another latex compatible vehicle directly to the surface of the condom mandrel to produce a raised pattern... drying the applied pattern
Implementation Method 2
dipping the patterned mandrel in latex one or more times (over dip) to form a condom containing the raised pattern
Data Source
AI summary
A method of manufacturing a condom having an open end and a closed end, wherein the method is comprised of the steps of coating a bare mandrel with a pattern of coating material to form visual stimulation means, and subsequently uniformly applying additional material over these patterns to complete the formation of the condom, and thereby create projections between the ends of the condom for stimulation.