Method and system for manufacturing elastomeric articles

Abstract

A method of manufacturing a device having a first elastomeric portion and a second elastomeric portion, the second elastomeric portion being formed into a nonplanar shape, i.e., a vaginal discharge collection device that is formed of an elastomeric rim and a flexible film reservoir, including the steps of loading a rim into a carrier plate, laying film over the rim, heat sealing the film to the rim, preheating the rim and film, drawing the film into a chamber by creating a vacuum to form the collector, and removing the collector from the carrier plate.

What is claimed is:  
     
         1 . A method of manufacturing a device having a first elastomeric portion and a second elastomeric portion, said second elastomeric portion being formed into a nonplanar shape, said method comprising the steps of: 
 loading said first elastomeric portion into a carrier plate;    laying said second elastomeric portion over said first elastomeric portion;    heat sealing said second elastomeric portion to said first elastomeric portion;    preheating said first and second elastomeric portions;    drawing said second elastomeric portion into a chamber by creating a vacuum to form a nonplanar shape; and    removing the device from said carrier plate.    
     
     
         2 . A method of manufacturing a vaginal discharge collector having a rim and a reservoir, said method comprising the steps of: 
 loading a rim into a carrier plate;    laying film over said rim;    heat sealing said film to said rim;    preheating said rim and film to approximately 290 degrees F. for approximately 8 seconds;    conveying said carrier plate into a vacuum chamber while maintaining said rim and film at an approximate temperature of 250 degrees F.;    elevating a second lower platen containing at least one mandrel heated to approximately 220 degrees F. which comes into contact with a center portion of said film;    cooling said center portion of said film with said mandrel;    drawing said film into said chamber by creating a vacuum to form the reservoir; and    removing the collector from said carrier plate.    
     
     
         3 . The method of  claim 2 , wherein said rim is formed by an injection molding process.  
     
     
         4 . The method of  claim 3 , wherein said rim is molded in a injection mold cavity comprising a hot runner system and small heated gates that leave at least one vestige formed on one side of said rim.  
     
     
         5 . The method of  claim 2 , wherein said rim has a compression hoop strength from about two hundred and fifty grams to about one thousand grams.  
     
     
         6 . The method of  claim 2 , wherein said rim has a Shore A hardness of approximately fifty five to approximately seventy five.  
     
     
         7 . The method according to  claim 6 , wherein said rim comprises polyethylene and a thermoplastic elastomer.  
     
     
         8 . An apparatus for the manufacture of a device having an elastomeric rim and a first elastomeric portion, said first elastomeric portion being formed in a nonplanar shape, said apparatus comprising: 
 a load station for loading said elastomeric rim onto a carrier plate;    a heat seal station for applying said first elastomeric portion to said elastomeric rim;    a preheat station to raise the temperature of said elastomeric rim and said first elastomeric portion from a first temperature to a second temperature;    a forming station for forming the first elastomeric portion of the device into a nonplanar shape; and    an unloading station for unloading said device.    
     
     
         9 . The apparatus according to  claim 8 , wherein said forming station is a vacuum form station for vacuum extracting the first elastomeric portion into a nonplanar shape.  
     
     
         10 . The apparatus according to  claim 9 , wherein said elastomeric rim is held in the carrier plate by a friction fit.  
     
     
         11 . The apparatus according to  claim 10 , wherein the carrier plate frictionally contacts the outer surface of said elastomeric rim.  
     
     
         12 . The apparatus according to  claim 11 , wherein the carrier plate has openings at the top and bottom of said elastomeric rim.  
     
     
         13 . The apparatus according to  claim 8 , wherein said loading station comprises a means to orient said elastomeric rim for placement into said carrier plate.  
     
     
         14 . The apparatus according to  claim 13 , wherein said means to orient said elastomeric rim comprises visual inspection means to orient said elastomeric rim so that a vestige formed on said elastomeric rim during the molding process are oriented in a predetermined direction.  
     
     
         15 . The apparatus according to  claim 14 , wherein said visual inspection means is arranged to visually inspect said elastomeric rim and relay a signal to an orienting device so that said elastomeric rim is oriented with the vestige facing upward in said carrier plate.  
     
     
         16 . The apparatus according to  claim 15 , wherein said visual inspection means includes a camera.  
     
     
         17 . The apparatus according to  claim 14 , wherein said apparatus additionally includes means to inspect the flatness and roundness of said elastomeric rims.  
     
     
         18 . The apparatus according to  claim 8 , wherein said first elastomeric portion is a film which is pulled over said carrier plate housing a plurality of said elastomeric rims.  
     
     
         19 . The apparatus according to  claim 18 , wherein said heat seal station comprises a means to weld said first elastomeric portion in a film to said elastomeric rim.  
     
     
         20 . The apparatus according to  claim 19 , wherein said heat seal station further comprises a means to cut the excess film away from said elastomeric rim.  
     
     
         21 . The apparatus according to  claim 20 , wherein said device is preheated from the first temperature to the second temperature in said pre-heat station while said first elastomeric portion is in the form of a film welded onto said elastomeric rim.  
     
     
         22 . The apparatus according to  claim 21 , wherein said first elastomeric portion is extracted into a nonplanar shape.  
     
     
         23 . The apparatus according to  claim 8 , wherein said apparatus additionally comprises a testing means to determine whether said device has been adequately formed.  
     
     
         24 . The apparatus according to  claim 23 , wherein said testing means comprise pressure testing means.