Patent Publication Number: US-10758402-B2

Title: Mold for making a prophylactic having a textured pattern

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional of U.S. Non-Provisional application Ser. No. 13/666,925 filed Nov. 1, 2012, which is incorporated by reference in its entirety. 
    
    
     BACKGROUND 
     The present invention relates generally to prophylactic devices, and more particularly to a prophylactic device having a textured pattern. 
     A variety of different contraceptive devices are on the market today, but prophylactic devices, such as condoms, remain one of the most widely used and most popular contraceptives because of their convenience in use and ability to provide generally effective contraception and protection from sexually-transmitted diseases. Condoms can, however, have certain drawbacks and condom technology has made limited advances over the years. Some of the major contributors to the failure of condoms to provide contraception and disease protection include damage to or breakage of the condom and potential condom slippage during use. With a typical condom, if even a small tear is accidentally made (e.g., during usage of the condom or by a fingernail during application of the condom), the condom often will rip completely. The standard uniform latex design of the condom has no mechanism to prevent tears from propagating once started. Complete ripping of the condom during usage results in substantial and irreversible negative effects, with the condom losing most or all of its contraceptive or disease-protection ability. Other problems faced with condoms include the condom slipping off, since the typical smooth condom design can make it difficult to keep the condom securely in place. Condoms also sometimes fail to fit correctly and have an inability to provide a comfortable and secure fit regardless of the size of the wearer. Thus, there are multiple problems with current condom designs that still need to be solved. 
     SUMMARY 
     Embodiments include a prophylactic device having a textured pattern on the device that provides a variety of advantages. The textured pattern can increase the strength of the device and reduce the breakage rates, it can increase or decrease the elasticity of the device for different materials and different sections of the device, it can reduce slippage and provide better friction to help the device stay in place, and it can provide a tighter fit, regardless of the size of the wearer of the device. In addition, the textured pattern can make the device more pleasurable for its users. For example, the textured pattern around the pleasure glands can increase or decrease pleasure sensations, it can be present inside and/or outside the device to increase the comfort and sensitivity for the person wearing the device and for another person in contact with the outside of the device, and it can provide additional lasting lubrication, tingling sensations, spermicidal applications, and can sensitize or desensitize in a soluble way from the pattern itself. The textured pattern can also be in a gel or soluble form to protect against sexually-transmitted infections (STIs) or sexually-transmitted diseases (STDs), such as those caused by bacteria, viruses, fungi, parasites, and protozoans. Furthermore, the textured pattern can be used with or can itself include strength fibers or mesh members for increased strength of the prophylactic device. These are just a few examples of the advantages provided by the prophylactic device. 
     In one embodiment, the prophylactic device includes a closed distal tip for containing body fluids, a tubular body continuous with the distal tip, and an open proximal base continuous with the tubular body for receiving a portion of a body within. The tubular body includes at least one area comprising a textured pattern along the tubular body. The textured pattern comprises lines (e.g., markings, raised ridges, indentations, or other structures that provide a pattern in or on the device) running in at least three directions (e.g., vertically, horizontally, diagonally from left to right or from right to left, etc.) along the tubular body. The lines form shapes of the textured pattern (e.g., squares, triangles, circles, ellipses, rectangles, pentagons, hexagons, other polygons, etc.), and portions of the lines form the edges of the shapes. The textured pattern comprises a reinforcing mesh wrapping around the tubular body. This mesh enables containment of any breakage of the prophylactic device during use (e.g., while using the condom, while applying the condom, while removing the condom, etc.). 
     In an additional embodiment, there is a prophylactic device comprising a closed distal tip for containing body fluids therein, a tubular body continuous with the distal tip having at least one area comprising a textured pattern, and an open proximal base continuous with the tubular body for receiving a portion of a body within. The textured pattern is formed of a lattice of shapes having at least five sides, wherein the shapes are adapted to contain a tear of the prophylactic device within the sides of a single shape or within the sides of one or more other shapes adjoining the single shape. 
     The features and advantages described in this summary and the following detailed description are not all-inclusive. Many additional features and advantages will be apparent to one of ordinary skill in the art in view of the drawings, specification, and claims hereof. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side view of a prophylactic device, in accordance with embodiments of the invention. 
         FIG. 2  is an enlarged side view of a textured pattern of a prophylactic device, in accordance with embodiments of the invention. 
         FIGS. 3A-J  are enlarged side views of textured patterns of a prophylactic device, in accordance with embodiments of the invention. 
         FIG. 4  is an enlarged side view of a textured pattern showing directional lines, in accordance with embodiments of the invention. 
         FIG. 5  is an enlarged side view of a textured pattern showing contained breakage, in accordance with embodiments of the invention. 
         FIG. 6  is a side view of a prophylactic device with a pillow design, in accordance with embodiments of the invention. 
         FIG. 7  is an enlarged side view of a textured pattern of a prophylactic device with a pillow design, in accordance with embodiments of the invention. 
         FIG. 8  is an isometric view of a prophylactic device with a pillow design, in accordance with embodiments of the invention. 
     
    
    
     The figures depict various embodiments of the present invention for purposes of illustration only. One skilled in the art will readily recognize from the following discussion that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the invention described herein. 
     DETAILED DESCRIPTION 
     Referring first to  FIG. 1 , there is shown a diagram illustrating the components of a prophylactic device  100 , in accordance with an embodiment of the invention. In the embodiment of  FIG. 1 , the prophylactic device  100  includes a tip  102 , a tubular body  104 , and a base  106 . The tubular body  104  includes a textured pattern  108 . In some embodiments, the prophylactic device is a condom. 
     The tip  102  can be a closed distal tip for containing body fluids therein. The tip  102  has a narrowed portion  110  for containing body fluids. When the device  100  is applied to a portion of the body, such as the male penis, the tip of the body is inserted into the base  106 , through the tubular body  104 , and to the distal tip  102 . Thus, the narrowed portion  110  sits against the body open for catching and containing body fluids inside. 
     The base  106  can be an open proximal base continuous with the tubular body for receiving a portion of the body (e.g., the male penis) within. The body can be inserted into the opening  112  of the base. 
     The tubular body  104  is continuous with the distal tip  102  and has at least one area comprising a textured pattern  108  along the tubular body  104 . The portion of the body is contained within this tubular structure, and the textured pattern  108  thus wraps around this portion of the body. 
     The textured pattern  108  can cover any portion of the prophylactic device  100 . In the embodiment of  FIG. 1 , textured pattern is shown covering a middle portion of the device  100 . However, it can also cover a bottom or top portion of the device  100 . In some embodiments, the textured pattern  108  can extend all the way to the tip  102  of the device  100  and/or all the way to the base  106  of the device  100 , or it can be positioned as shown in  FIG. 1  with a space in between the pattern  108  and the base  106 /tip  102 . In some embodiments, the textured pattern  108  covers 50% or 75% of the device  100  or more than 50% or 75%, though other percentages of coverage are also possible (e.g., less than 1%, 2%, 10%, 20%, 30%, 45% 60%, 78%, 90%, 100%, or any values or fractional values in between these numbers, or any ranges including one or two of these numbers bounding the ranges). For example, the textured pattern  108  can wrap around and cover a middle one-half portion of the device  100 . The textured pattern  108  also may not be continuous, but can appear in disconnected portions along the device  100 , such as in strips along the device. The pattern  108  can further be focused on one side, such as a front or back of the device  100 . The pattern  108  can also appear in spots or pieces anywhere along the device  100 , such as circular or square patches that may be connected or not. These are just a few examples of how the textured pattern  108  can be arranged on the device  100 , though other designs are also possible. 
     The textured pattern  108  can be created in the prophylactic device  100  in a number of manners. In one embodiment, the textured pattern  108  is a pattern that is molded into the tubular body. For example, the pattern can be ridges or indentations formed on an inner or outer surface of the device  100 . This can be performed using a device mold, such as that described later in this application. In another embodiment, the textured pattern  108  is embedded within the device  100 . For example, the pattern can be made up of fibers or a mesh that is embedded within layers of the device  100 , or is placed on an outer or inner surface of the device  100 . The pattern can also be made with a separate mold and embedded or otherwise attached to the device  100 . 
     The prophylactic device can be made of various materials. In one embodiment, the entire device  100  is composed of latex, polyurethane, polyisoprene, natural skin or animal tissue (e.g., intestines), rubber, or other materials. The device  100  can also be composed of more than one material. For example, the device  100  may be composed of latex, but the textured pattern might be made up of a mesh or fibers of a different material. The textured pattern itself might include more than one material, including a material on the surface of the pattern and a different material embedded within the pattern. Different types of the device  100  can have different materials to provide varying elasticity to allow for sizing of the device  100 . Similarly, different portions of the same device can include different materials to provide varying elasticity within the device at different areas. 
     The textured pattern  108  can provide a number of advantages and can have a number of designs. For example, the textured pattern  108  can comprise fibers or a mesh within the tubular body  106 , enabling increased tensile strength to the prophylactic device  100  in comparison to a prophylactic device without the textured pattern. This thus makes the device  100  stronger than other prophylactic devices and less likely to break or tear. As another example, the textured pattern  108  can provide different elasticity to the device  100 . The portion of the prophylactic device  100  with the textured pattern  108  can have a different elasticity than the portion of the device  100  without the textured pattern  108 . The textured pattern  108  can also enable a tighter fit around the body in comparison to a device without the textured pattern. The textured pattern  108  can also enable a tighter fit around the body in comparison to a device without the textured pattern, or the pattern can be used to provide greater elasticity so that a one-size-fits-all design can be made. The textured pattern  108  can further be arranged to provide friction against the portion of the body inside the device  100  (e.g., a male penis) or a portion of a body outside of and in contact with the device (e.g., part of the female anatomy) to reduce slipping of the device  100  in comparison to a prophylactic device without the textured pattern. In addition, the textured pattern  108  can assist in preventing fluids from exiting the condom by providing structures or walls within the condom that prevent fluid from coming up from the tip. The textured pattern  108  can also help trap fluids in the textured areas (e.g., within the boundaries of the shapes formed in the pattern). Similarly, the textured pattern  108  can assist in keeping the condom lubricated by trapping lubricant in the textured areas or pockets in the textured pattern, which lowers the risk of damaging the condom while being carried in a pocket or wallet and provides a good feel to the condom. The textured pattern  108  can also be arranged on both an inside and an outside of the prophylactic device  100  to provide additional stimulation to the body within the device  100  touching the inner surface and to a body outside of and in contact with an outer surface of the device  100 . 
       FIG. 2  is an enlarged side view of a textured pattern of a prophylactic device, in accordance with an embodiment of the invention. The textured pattern  108  includes lines  202  running along the tubular body  104 . The lines form shapes  204  in the textured pattern  108 . The shapes shown in  FIG. 2  are diamond shapes, though other shapes are also possible, as are illustrated in  FIG. 3 . One or more of the lines can include solid lines, broken lines, dots or other structures formed as a line, or other designs for providing a structure that can form the edge of a shape. One or more of the lines can be straight or curved along all or any portion, they can be grouped together or separate, they can intersect or not, they can have different thicknesses or widths (e.g., thick enough to form a band or thin enough to be hair-like), different lengths, different heights (e.g., for ridges or indentation lines), and the width, length, and height can vary across a single device, among other design variations. 
     Portions of the lines  202  form edges of the shapes. In fact, two shapes can share a single line  202 , as is shown in  FIG. 2  with line  210  being shared between two diamond shapes  204 . The lines  202  can run in various directions or along various axes on the device. For example,  FIG. 2  shows diagonal lines  206  and  208  illustrating two directions in which the lines can run. Similarly, the lines can run vertically or horizontally. A line  202  can wrap all the way around the device  100  or only partially around the device. The lines  202  can run along an X, Y, or Z axis.  FIG. 2  shows continuous diagonal lines  206 ,  208  that wrap all the way around the device  100  to form a part of multiple diamond shapes  204 . However, the lines  202  can be shorter and form only a portion of one or two shapes, or of just a few shapes. In some embodiments, the lines  202  are formed as fibers or a reinforcing mesh wrapping around the tubular body  104  enabling containment of breakage of the prophylactic device during use, as is shown in later figures. 
       FIGS. 3A-J  are enlarged side views of textured patterns of a prophylactic device, in accordance with embodiments of the invention. Any of these patterns can be included on a prophylactic device, such as device  100  as textured pattern  108 . For example, the pattern  108  shown in  FIG. 1  could be replaced entirely or in part with the pattern of  FIG. 3G . These are just some examples of textured patterns, though other patterns can also be used, such as patterns that include pentagons, heptagons, octagons, and any other polygon. The shapes can be irregular or have unequal sides. A single pattern can include multiple shapes, such as hexagons and diamonds. The shapes can also be composed of shapes that include at least 3, 4, 5, 6, 7, 8, 9, 10 sides, among other examples. Any of the patterns can be turned in any direction such that the lines run at a different angle relative to the device than is shown. Any line angle relative to a vertical or horizontal axis of the device is possible (e.g., 5, 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 130, 150, 170 degree angles, or any values or fractional values in between or any ranges including any of these numbers). 
       FIGS. 3A  and B show patterns that include a number of triangles formed from lines running in three directions, two diagonal directions and one horizontal direction. These patterns are similar to the textured pattern  108  of  FIG. 1 , but the diamond shapes are bisected by horizontal lines wrapping around the device.  FIG. 3B  illustrates that the triangle shapes can be irregular in size, in this case with larger, vertically stretched triangles at the bottom in comparison to the top of the figure. The shapes in these figures are three-sided shapes. 
       FIGS. 3C  and D show patterns that are similar to the textured pattern  108  of  FIG. 1 , forming diamond shapes.  FIG. 3D  illustrates that these diamond shapes can be irregular or can be larger or more stretched in certain areas. Lines run diagonally in two directions opposite one another along the device to form the diamond shapes. The shapes in these figures are four-sided shapes. 
       FIGS. 3E  and F show patterns that are similar to the pattern  108  of  FIG. 1 , but the lines run vertically and horizontally instead of diagonally, and so the shapes formed are square shapes. These can also be rectangular shapes.  FIG. 3F  illustrates irregularity in the shapes, including some rectangles and some squares. The shapes in these figures are four-sided shapes. 
       FIGS. 3G  and H show patterns that are formed of hexagons. This pattern is a honeycomb lattice or chicken-wire design. The lines run in three directions including two diagonal directions and one vertical direction.  FIG. 3H  shows that the hexagons can be irregularly sized or stretched in certain areas. The shapes in these figures are six-sided shapes. 
       FIGS. 3I  and J show patterns that are formed of circles and/or ellipsoids. These round or ellipsoid shapes are formed of curved lines. The lines run in multiple directions to form the curved design of each shape. 
       FIG. 4  is an enlarged side view of a textured pattern showing directional lines, in accordance with embodiments of the invention. Specifically, the pattern illustrated is the one shown in  FIG. 3G  with the honeycomb lattice. This figure shows that the lines run in a first, second, and third direction  702 ,  704 ,  706 . Each line  708  forms a portion of at least two shapes in the pattern. Unlike the diamond pattern of  FIG. 1  that shows a single line wrapping around the device to form a portion of multiple diamonds, the lines  708  in this pattern are shorter and form only one side of two of the hexagons. The hexagon pattern could also be turned such that none of the lines run vertically, and they all run at an angle relative to a vertical or horizontal axis of the device, where the vertical axis runs from the tip to the base of the device, and the horizontal axis runs from side to side of the device (or wraps around the tubular body of the device). The hexagons in  FIG. 4  generally share six edges with other hexagons in the pattern. None of the edges are formed by a continuous line running in a single direction across more than one shape. 
       FIG. 5  is an enlarged side view of a textured pattern showing contained breakage, in accordance with embodiments of the invention. The upper break shows a start point  802  of the break at an edge of one of the hexagons. The tear has spread across the hexagon, but stopped at another edge of the hexagon. Thus, the break is contained within a single shape in the pattern. The lower break shows a start point  804  in the middle of one of the hexagons, and this break has spread in more than one direction and has spread across to an adjoining hexagon. However, the break is still contained within these two hexagons and has not propagated further in the device. In some embodiments, the textured pattern or a mesh or fibers in the pattern ensure that tears such as these do not propagate very far in the device. In some embodiments, the shapes are arranged such that breakage of the device within one of the shapes is contained within the edges of the shape or one or more other shapes adjoining the shape. In other embodiments, the breakage is contained within a certain number of the shapes, such as three, four, five, six, seven, and other numbers of shapes. In this manner, the contained breakage can prevent the device  100  from completely ripping or falling apart, allowing the device to still contain most or all of the fluids within. Thus, the safety of the device is enhanced, even if it is torn. 
       FIG. 6  is a side view of a prophylactic device with a pillow design, in accordance with an embodiment of the invention. The prophylactic device  600  includes a tip  602 , a tubular body  604 , and a base  606 . These structures can have generally the same features and characteristics as the tip  102 , the tubular body  104 , and the base  106  of  FIG. 1 , thus those features/characteristics are not re-described here. The device  600  also includes a textured pattern  608 , which can have generally the same features and characteristics of textured pattern  108 . In this case, however, the textured pattern  608  is raised in the center of each shape to form a pillow design. 
       FIG. 7  is an enlarged side view of a textured pattern of a prophylactic device with a pillow design, in accordance with an embodiment of the invention. This figure illustrates the lines  702  that form the shapes in the device  600  and illustrates the shapes  704  themselves. The shapes can be any of the shapes shown in  FIG. 3  and so the pattern  608  can be any of the  FIG. 3  patterns.  FIG. 7  also illustrates the raised portion  706  in the center of the diamond shapes of the pattern  608 , which tapers inward toward the four edges of the diamond. The pillow design provides additional texture to the device, which can provide stimulation to a body in contact with the texture. The pillows can be formed with the raised portion  706  facing outward, as shown in  FIG. 7 , facing inward, or both. Thus, the pillows can stimulate a body inside or outside of the device  600 . 
       FIG. 8  is an isometric view of a prophylactic device with a pillow design, in accordance with embodiments of the invention. In this prophylactic device  800 , there is again a pillow type textured pattern  808 , with the center of each shape raised. This figure also illustrates how the textured pattern  808  can wrap all the way from the tip of the device to the base, rather than being present only in a middle section of the device, as is shown in  FIG. 6 . 
     The prophylactic device can be made using a mold. In one embodiment, the mold includes a first area for receiving material and shaped to form the received material into at least a portion of a distal tip of a prophylactic device, a second area continuous with the first area for receiving material and shaped to form the received material into at least a portion of a tubular body continuous with the distal tip, and a third area continuous with the second area for receiving material and shaped to form the received material into at least a portion of a proximal base continuous with the tubular body. The mold can be a single structure into which material is poured to form an inner and outer surface of the device. The mold can also be a two-part structure (or a multi-part structure) with one side of the mold forming an outer surface of the device and the other part forming an inner surface. The prophylactic devices can also be made using a dipping process, and the texture of the condom achieved only by changing the mold. 
     The mold can be designed to form any of prophylactic devices  100 ,  600 , and  800 . The mold can be designed to be used in forming a device that has a textured pattern, such as those described above, including lines that run in at least two, three, four, five, etc. directions to form shapes with portions of the lines forming edges of the shapes. The textured pattern can form a reinforcing mesh on or in the tubular body for containment of breakage of the prophylactic device during use. 
     In some embodiments, the mold itself forms the textured pattern. The second area or another portion can include indentations or ridges capable of forming the received material into the textured pattern. In other embodiments, the textured pattern can be formed by adding a mesh or fibers to the device. Thus can be done in the mold or separate from the mold. The mesh/fibers can be positioned on an outer or inner surface of the device, or can be embedded within the device (e.g., between an outer and inner layer of the device). As one example, material can be placed into the mold to form an outer layer of the device, the mesh can be laid down on this material (possibly after it has solidified or dried somewhat or completely), and another layer of material can be placed on top of the mesh to form an inner layer of the device. Similarly, the mold could be dipped in material, a mesh added to the dipped material, and then a second dipping could occur to embed the mesh in the material. In further embodiments, a second mold or multiple other molds can be used to make the textured pattern, which can then be included in the device. In some embodiments, the condom can be made using standard condom making techniques, but the mold allows for the textured pattern to be provided on the condom. 
     While various embodiments have been described above, it should be understood that they have been presented by way of example only, and not limitation. For example, any of the components may employ any of the desired functionality set forth hereinabove. The functions can be distributed differently across the components or different functions can be combined into one component. The prophylactic devices and molds can be designed to have a variety of different shapes, sizes, designs, etc., and the embodiments shown herein are simply examples of some such shapes, sizes, and designs. Thus, the breadth and scope of a preferred embodiment should not be limited by any of the above-described exemplary embodiments.