Intravaginal device with fluid transport plates and methods of making

Abstract

Apparatus for producing an intravaginal device includes a forming tool having an aperture, a male tool having a plurality of forming blades arranged radially about an aperture, at least one bonding element, and at least one moveable pushrod. The forming tool includes a holding plate having a plurality of vacuum ports, and the aperture of the forming tool is located in the forming plate. The aperture of the forming tool has a plurality of slots connected to and extending therefrom. The bonding element is moveable toward the aperture in the forming tool. The apertures are aligned along a machine axis to permit the pushrod to move a fluid storage element through each aperture, the forming blades of the male tool are aligned with the slots of the forming tool, and guide edges of the forming blades accommodate a fluid storage element aligned with the aperture of the male tool.

1 . Apparatus for producing an intravaginal device comprising:
 a. a forming tool comprising:
 i. a holding plate having a plurality of vacuum ports formed in a face thereof; 
 ii. a substantially circular aperture disposed on the plate having a plurality of slots connected to and extending therefrom; 
   b. a male tool comprising a plurality of forming blades, each blade having a guide edge, arranged radially about an aperture;   c. At least one bonding element moveable toward the aperture in the forming tool; and   d. at least one pushrod moveable through the apertures of each of the forming tool and the male tool;   
       wherein the apertures of the forming tool and male tool are aligned along a machine axis to permit the pushrod to move fluid storage element through each aperture, the forming blades of the male tool are aligned with the slots of the forming tool, and the guide edges of the forming blades are arranged and configured to accommodate a fluid storage element aligned with the aperture of the male tool. 
     
     
         2 . Apparatus of  claim 1  wherein each forming blade has a pleating edge engageable with a sheet held on the face of the holding plate. 
     
     
         3 . Apparatus of  claim 2  wherein the pleating edge is adjacent the guide edge. 
     
     
         4 . Apparatus of  claim 2  wherein the pleating edge is separated from the guide edge by at least one intermediate portion of the forming blade. 
     
     
         5 . Apparatus of  claim 1  wherein the at least one bonding element is moveable in a plane parallel to the face of the holding plate. 
     
     
         6 . Apparatus of  claim 5 , wherein the at least one bonding element is moveable to extend into a space between adjacent forming blades when the forming tool and male tools are in an engaged position. 
     
     
         7 . Apparatus of  claim 1  wherein the at least one bonding element is a thermobonding element. 
     
     
         8 . Apparatus of  claim 1  wherein the fluid storage element has a length, and the guide edge of each forming blade has a length that is not greater than the length of the fluid storage element. 
     
     
         9 . Apparatus of  claim 1  wherein the fluid storage element has a length, and the guide edge of each forming blade has a length that is greater than the length of the fluid storage element.