Patent ID: 7736287

Claim:
A method for forming a vaginal applicator comprising the steps of: a. providing a forming mandrel, an applicator tube, and die; wherein said applicator tube has an applicator tube inner surface having an applicator tube inner circumference and an applicator tube outer surface opposing said applicator tube inner surface, said applicator tube outer surface having an applicator tube outer circumference; wherein said forming mandrel has a longitudinal axis and a forming mandrel circumference about said longitudinal axis of said forming mandrel; wherein said forming mandrel comprises a first sustaining ridge and a second sustaining ridge, each of which is disposed at least partially circumferentially about said forming mandrel; wherein said first sustaining ridge has a circumferential length L 1 measured about said forming mandrel circumference; wherein said second sustaining ridge has a circumferential length L 2 measured about said forming mandrel circumference; wherein said first sustaining ridge has an initiation end and a finish end; wherein said first sustaining ridge is radially spaced away from said second sustaining ridge; wherein L 1 is less than L 2 ; wherein L 2 minus L 1 equals said applicator tube inner circumference minus said forming mandrel circumference; wherein L 1 is greater than or equal to said applicator tube inner circumference minus said forming mandrel circumference; wherein L 1 is at least one-half L 2 ; wherein said forming mandrel circumference is less than said applicator tube inner circumference; and wherein said die comprises one or more grooves sized and dimensioned to engage with said first sustaining ridge and said second sustaining ridge; b. arranging said forming mandrel to be inside said applicator tube; and c. engaging said forming mandrel and said applicator tube with said die such that said forming mandrel, said applicator tube, and said die first engage with one another near said initiation end of said first sustaining ridge and moving said applicator tube outer surface and said die relative to one another while maintaining engagement of said forming mandrel, said applicator tube, and said die such that said applicator tube outer surface and said die travel relative to one another in a direction from said initiation end of said first sustaining ridge towards and beyond said finish end of said first sustaining ridge a tangential distance of at least said applicator tube outer circumference and not more than said applicator tube outer circumference plus L 1 .