Title: Condom testing apparatus
Abstract: A condom testing apparatus having a plurality of electrically conductive mandrels having condoms loaded thereon, a first set of condom-contacting electrode members, a second set of condom-contacting electrode members, and a gapped electrical circuit between each of the mandrels and the first set of condom-contacting electrode members and between each of the mandrels and the second set of condom-contacting electrode members during testing, wherein defects within a condom being tested are detected by passage of current between the mandrels and the first and second sets of condom-contacting electrode members, wherein the first set of condom-contacting electrode members contacts less than 100 percent of the circumference of each of the condoms and the second set of condom-contacting electrode members contacts less than 100 percent of the circumference of each of the condoms, such that two condoms can be tested at once.
Patent Number: 6,984,992 Issued on 01/10/2006 to Whitten
| Inventors:
|
Whitten; James R. (Albany, GA)
|
| Assignee:
|
Agri Dynamics, Inc. (Albany, GA)
|
| Appl. No.:
|
886197 |
| Filed:
|
July 7, 2004 |
| Current U.S. Class: |
324/558; 324/557 |
| Current Intern'l Class: |
G01N 27/00 (20060101) |
| Field of Search: |
324/558,559,517
|
References Cited [Referenced By]
U.S. Patent Documents
Primary Examiner: Deb; Anjan
Assistant Examiner: Teresinski; John
Attorney, Agent or Firm: Saitta; Thomas C.
Claims
I claim:
1. A condom testing apparatus comprising:
a plurality of electrically conductive mandrels having condoms loaded thereon;
a first set of condom-contacting electrode members;
a second set of condom-contacting electrode members separated from said first
set of condom-contacting electrode members such that no one of said condoms contacts
both said first and said second sets of condom-contacting electrode members simultaneously;
a gapped electrical circuit between each of said mandrels and said first set
of condom-contacting electrode members and between each of said mandrels and said
second set of condom-contacting electrode members during testing;
means to sense the status of said electrical circuit between each of said mandrels
and said first set of condom-contacting electrode members and between each of said
mandrels and said second set of condom-contacting electrode members;
wherein said first set of condom-contacting electrode members tests less than
100 percent of the circumference of each of said condoms and said second set of
condom-contacting electrode members tests less than 100 percent of the circumference
of each of said condoms.
2. The apparatus of claim 1, wherein said first set of condom-contacting electrode
members comprises condom body contacting means and condom nipple contacting means.
3. The apparatus of claim 2, wherein said second set of condom-contacting electrode
members comprises condom body contacting means and condom nipple contacting means.
4. The apparatus of claim 3, wherein said condom body contacting means of said
first set of condom-contacting electrode members and said condom body contacting
means of said second set of condom-contacting electrode members each comprises
a conductive pad member.
5. The apparatus of claim 4, wherein said condom nipple contacting means of said
first set of condom-contacting electrode members and said condom nipple contacting
means of said second set of condom-contacting electrode members each comprises
a conductive brush member.
6. The apparatus of claim 5, wherein said condom body contacting means of said
first set of condom-contacting electrode members and said condom body contacting
means of said second set of condom-contacting electrode members each comprises
an upper pad member, a lower pad member, and a body brush member.
7. The apparatus of claim 6, further comprising mandrel rotating means to rotate
each of said mandrels during contact with each of said first set of condom-contacting
electrode members and said second set of condom-contacting electrode members.
8. The apparatus of claim 7, further comprising a rotating platform member, wherein
said mandrels are mounted on said rotating platform member.
9. The apparatus of claim 8, further comprising condom loading means to load
said condoms onto said mandrels, condom removal means to remove said condoms from
said mandrels, and condom sorting means to sort said condoms depending on whether
each of said condoms is detected to be defective.
10. A condom testing apparatus comprising:
a plurality of electrically conductive mandrels having condoms loaded thereon;
at least two sets of condom-contacting electrode members separated from each
other such that no one of said condoms contacts both said sets of condom-contacting
electrode members simultaneously;
a gapped electrical circuit between each of said mandrels and each of said at
least two sets of condom-contacting electrode members during testing;
means to sense the status of said electrical circuit between each of said mandrels
and each of said at least two sets of condom-contacting electrode members, wherein
defective said condoms allow passage of electrical current between said mandrels
and each of said at least two sets of condom-contacting electrode members, and
wherein non-defective said condoms prevent passage of electrical current between
said mandrels and each of said at least two sets of condom-contacting electrode members;
wherein each of said at least two sets of condom-contacting electrode members
contacts less than 100 percent of the circumference of each of said condoms during
testing, and wherein in combination said at least two sets of condom-contacting
electrode members contact greater than 100 percent of the circumference of each
of said condoms during testing.
11. The apparatus of claim 10, wherein each of said at least two sets of condom-contacting
electrode members is in contact with a different one of said condoms simultaneously.
12. The apparatus of claim 11, wherein said at least two sets of condom-contacting
electrode members comprises:
a first set of condom-contacting electrode members defining a first testing stage,
said first set being disposed to contact each of said condoms as each of said mandrels
travel past said first set; and
a second set of condom-contacting electrode members defining a second testing
stage, said second set being disposed to contact each of said condoms as each of
said mandrels travel past said second set.
13. The apparatus of claim 12, wherein said first set of condom-contacting electrode
members comprises condom body contacting means and condom nipple contacting means.
14. The apparatus of claim 13, wherein said second set of condom-contacting electrode
members comprises condom body contacting means and condom nipple contacting means.
15. The apparatus of claim 14, wherein said condom body contacting means of said
first set of condom-contacting electrode members and said condom body contacting
means of said second set of condom-contacting electrode members each comprises
a conductive pad member.
16. The apparatus of claim 15, wherein said condom nipple contacting means of
said first set of condom-contacting electrode members and said condom nipple contacting
means of said second set of condom-contacting electrode members each comprises
a conductive brush member.
17. The apparatus of claim 16, wherein said condom body contacting means of said
first set of condom-contacting electrode members and said condom body contacting
means of said second set of condom-contacting electrode members each comprises
an upper pad member, a lower pad member, and a body brush member.
18. The apparatus of claim 17, further comprising mandrel rotating means to rotate
each of said mandrels during contact with each of said first set of condom-contacting
electrode members and said second set of condom-contacting electrode members.
19. The apparatus of claim 18, further comprising a rotating platform member,
wherein said mandrels are mounted on said rotating platform member.
20. The apparatus of claim 19, further comprising condom loading means to load
said condoms onto said mandrels, condom removal means to remove said condoms from
said mandrels, and condom sorting means to sort said condoms depending on whether
each of said condoms is detected to be defective.
21. A condom testing apparatus comprising:
a first set of condom-contacting electrode members;
a second set of condom-contacting electrode members;
a rotating platform;
a plurality of electrically conductive mandrels mounted on said platform, each
of said mandrels receiving a condom thereon for testing, whereby each of said condoms
is brought into contact first with said first set of condom-contacting electrode
members and second with said second set of condom-contacting electrode members,
and wherein said mandrels are spaced on said platform member such that one of said
condoms is in contact with said second set of condom-contacting electrode members
at the same time that a second of said condoms is in contact with said first set
of condom-contacting electrode members, such that two of said condoms are tested simultaneously;
a gapped electrical circuit between each of said mandrels and said first set
of condom-contacting electrode members and between each of said mandrels and said
second set of condom-contacting electrode members during testing;
means to sense the status of said electrical circuit between each of said mandrels
and said first set of condom-contacting electrode members and between each of said
mandrels and said second set of condom-contacting electrode members, wherein said
condoms that are non-defective prevent passage of electrical current between said
mandrels and said first and second sets of condom-contacting electrode members;
wherein said first set of condom-contacting electrode members contacts less than
100 percent of the circumference of each of said condoms and said second set of
condom-contacting electrode members contacts less than 100 percent of the circumference
of each of said condoms, wherein the area of contact on each of said condoms of
said second set of condom-contacting electrode members overlaps two areas of contact
on each of said condoms of said first set of condom-contacting electrode members,
such that every point on the circumference of each of said condoms is contacted
by at least one of said first and said second sets of condom-contacting electrode
members during testing.
22. The apparatus of claim 21, wherein said first set of condom-contacting electrode
members comprises condom body contacting means and condom nipple contacting means.
23. The apparatus of claim 22, wherein said second set of condom-contacting electrode
members comprises condom body contacting means and condom nipple contacting means.
24. The apparatus of claim 23, wherein said condom body contacting means of said
first set of condom-contacting electrode members and said condom body contacting
means of said second set of condom-contacting electrode members each comprises
a conductive pad member.
25. The apparatus of claim 24, wherein said condom nipple contacting means of
said first set of condom-contacting electrode members and said condom nipple contacting
means of said second set of condom-contacting electrode members each comprises
a conductive brush member.
26. The apparatus of claim 25, wherein said condom body contacting means of said
first set of condom-contacting electrode members and said condom body contacting
means of said second set of condom-contacting electrode members each comprises
an upper pad member, a lower pad member, and a body brush member.
27. The apparatus of claim 26, further comprising mandrel rotating means to rotate
each of said mandrels during contact with each of said first set of condom-contacting
electrode members and said second set of condom-contacting electrode members.
28. The apparatus of claim 27, further comprising condom loading means to load
said condoms onto said mandrels, condom removal means to remove said condoms from
said mandrels, and condom sorting means to sort said condoms depending on whether
each of said condoms is detected to be defective.
29. A method for testing condoms for defects comprising:
providing a plurality of electrically conductive mandrels, at least a first set
of condom-contacting electrode members and a second set of condom-contacting electrode
members, wherein said second set of condom-contacting electrode members is separated
from said first set of condom-contacting electrode members such that a condom cannot
contact both said first and said second set of condom-contacting electrode members
simultaneously, a gapped electrical circuit between each of said mandrels and said
first set of condom-contacting electrode members and said second set of condom-contacting
electrode members, and means to sense the status of said electrical circuit;
loading condoms onto said mandrels;
passing each of said condoms through said first set of condom-contacting electrode
members and testing less than 100 percent of the circumference of each of said condoms;
sensing whether each of said condoms prevents or allows passage of electrical
current through said condom;
passing each of said condoms through said second set of condom-contacting electrode
members and testing less than 100 percent of the circumference of each of said condoms;
sensing whether each of said condoms prevents or allows passage of electrical
current through said condom;
removing and sorting said condoms.
30. The method of claim 29, further comprising simultaneously testing a first
of said condoms by said second set of condom-contacting electrode members and a
second of said condoms by said first set of condom-contacting electrode members.
31. The method of claim 29, further comprising mounting said mandrels on a platform
and rotating said platform to pass said condoms through said first and second sets
of condom-contacting electrode members.
32. The method of claim 31, further comprising individually rotating each said
mandrel about its central axis while passing said condoms through said first and
second sets of condom-contacting electrode members.
33. The method of claim 29, wherein said loading step is performed manually.
34. The method of claim 29, wherein said testing step by said second set of condom-contacting
electrode members comprises testing the portion of the circumference of the condoms
not tested by said first set of condom-contacting electrode members.
35. The method of claim 34, wherein said testing step by said second set of condom-contacting
electrode members further comprises testing at least two portions of the circumference
of the condoms tested by said first set of condom-contacting electrode members.
Description
BACKGROUND OF THE INVENTION
This invention relates generally to the field of machines, equipment or apparatuses
used to test condoms for holes, excessively thin walls or other imperfections prior
to packaging and distribution. More particularly, the invention relates to such
machines, equipment or apparatuses that utilize electrical current to determine
the presence of such imperfections.
Minute holes, tears, or excessively thin wall areas subject to failure during
use are unacceptable and render a condom defective. By virtue of their intended
use, it is absolutely essential that condoms provide a complete and impermeable
barrier. Minute holes undetectable under visual inspection and excessively thin
spots in the condom wall likely to fail in use must be discovered. Because the
manufacturing process produces huge numbers of condoms at a high rate and because
the material of construction, typically a latex or similar plastic, is purposely
very thin and elastic, there is always likely to be a relatively small number of
defective products in any production run. Because of this, every condom must be
tested prior to packaging and distribution for sale to insure that no defective
condoms are supplied to consumers.
One method to detect defective condoms is to utilize air or a vacuum, wherein
the passage of any air or gas through the condom wall is detected and indicates
a defect. A second method utilizes water to test for defects. Typically this involves
placing the condom on an electrically conductive mandrel, immersing the condom
in water containing an electrical lead and then attempting to pass a current through
the water to the mandrel. The condom material acts as an insulating barrier between
the water and the mandrel to prevent completion of the electrical circuit, but
any hole in the condom will allow the circuit to be completed, indicating that
the condom is defective. Advantages of this technique are that low electrical voltages
are required and the use of water as a conductive medium provides full contact
to all portions of the condom. The major drawback to this technique is that the
condoms must be dried prior to packaging. Another drawback is that the technique
does not provide an indication of excessively thin spots in the condom wall which
may tear in use, since the thin material is still sufficient to prevent passage
of current from the water to the mandrel.
A third method, and the method utilized in this invention, also takes advantage
of the fact that the condom is an electrical insulator. The condom is placed onto
a metal, i.e., electrically conductive, mandrel and the outer surface of the condom
is then brought into contact with another electrically conductive member, such
as a metal mesh, a pad or bristles. In some instances, the condoms are wetted prior
to testing, although this is not preferred for the reasons set forth above. The
condom prevents completion of a closed circuit to ground, unless there is a defect,
in which case the current will arc through the hole, tear or thin-walled area and
complete the circuit. This completed circuit indicates a defective condom, which
is then discarded. When a conductive mesh material is utilized, the mesh is constructed
so as to be very non-rigid so that it closely drapes against the condom on the
conductive mandrel. The mandrel and condom are rotated while contacting the electrified
mesh, and any defects will allow the current to pass through the condom to the
mandrel. A problem with this technique is that because the mesh must have a large
amount of open area to achieve the desired flexibility, direct contact against
every portion of the condom is not achieved, so a relatively high and thus dangerous
amount of electrical current must be used—typically greater than 50 watts—to
try to insure that the current will arc from the mandrel through a defect to the
nearest piece of mesh. The variation in distance from the condom to particular
points on the mesh as the condom is moved past the mesh also makes proper calibration
of the electrical current difficult. Another problem is presented by the nipple
portion of the condom. Because of this change in configuration from the generally
cylindrical main body portion of the condom, providing sufficient contact between
the mesh and the nipple material is problematic and defects can be missed. Examples
of testing equipment that utilizes this methodology are shown in U.S. Pat. No.
2,221,323 to Gammeter, U.S. Pat. No. 2,609,094 to Fry, and U.S. Pat. No. 2,649,960
to Gammeter.
An improved method and apparatus that utilizes completion of an electrical current
to indicate defects in a condom, but which does not utilize a mesh material as
one of the electrodes, is shown in U.S. Pat. No. 6,160,406 to Underwood et al.,
the disclosure of which is incorporated herein by reference. The exterior condom-contacting
members comprise in combination an electrically conductive fabric member and an
electrically conductive brush member, and may also comprise only fabric members
or only brush members. For the combination fabric and brush assembly, the fabric
member is positioned to contact the generally cylindrical main body portion of
the condom as it is brought across the fabric member. The fabric member is sufficiently
long in the mandrel direction of travel such that the condom is tested over its
full circumference of 360 degrees, and preferably is provided excessively long
such that more than one revolution of the condom is achieved during the test pass.
The fabric member is not positioned to contact the far end of the nipple portion,
as the friction from the rotational movement would twist and damage the condom.
The brush member is positioned along the nipple portion, preferably at an angle
to the central axis of the rotating mandrel, in order to contact the extreme end
of the nipple portion. In this manner every point of the condom is in direct contact
with either the conductive fabric member or the conductive brush member, such that
the electrical current will complete the circuit through any minute hole in the
condom to indicate a defective condom. Furthermore, because the contact between
the condom and both the fabric member and brush member is so extensive, and because
the fabric member and brush member are positioned relatively close to the mandrel
and at a relatively constant distance, the current strength can be adjusted such
that the circuit will be completed even through excessively thin-walled areas of
the condom, thus indicating a defective condom even where a hole is not present
initially. Alternatively, the fabric member may be omitted and the condom-contacting
means formed entirely of one or more conductive brush members appropriately arranged
to contact the full extent of the exposed condom on the mandrel. In this construction
means such as a geared or friction mechanism are required to rotate the mandrel
as it is passed across the brush member, since the coefficient of friction between
the brush members and the mandrel would be insufficient to rotate the mandrel unaided.
It is common in testing equipment of the various types described above to mount
a plurality of mandrels onto a rotating table, track or platform in a circular
pattern. With this construction, it is possible to provide a loading station, a
testing station and a removal station, each spaced along the travel pathway of
the mandrels, such that the table can be rotated continuously in a single direction.
The condoms are individually loaded onto empty mandrels, which then travel through
the testing zone to identify any defective condoms. The condoms are then removed
from the mandrels, with the defective condoms being separated and discarded. Loading
of the condoms onto the mandrels may be accomplished manually or by automated equipment.
Likewise, removal of the condoms may be accomplished manually or by automatic equipment,
although the use of automatic removal and separating equipment in communication
with the testing equipment is typical. Loading, removal and separating equipment
of various types are well known in the art.
In this type of condom defect testing equipment, the minimum distance between
adjacent mandrels on the platform, table or track is determined by the circumference
of the test mandrels themselves. A typical mandrel may be approximately 5.81 inches
in circumference, as it is necessary to provide a uniform stretch on the condom
during testing. Since the known condom testing equipment utilizes a single electrically
conductive mesh, pad or brush to test each individual condom, with the condom and
mandrel being rotated in excess of 360 degrees as it travels across the electrically
conductive mesh, pad or brush, the length of the mesh, pad or brush in the mandrel
travel direction must be of a distance in excess of the circumference of the loaded
mandrel. In practice, this length dimension must also include an additional distance
beyond the mandrel circumference as a safety factor to insure that the complete
circumference of each condom is tested, so that typically at least 125 percent
of the circumference is tested. Since more than one condom cannot be in contact
with the mesh, pad or brush during a given test procedure, the mandrels must also
be separated a distance greater than the length of the testing mesh, pad or brush.
This separation requirement limits the number of mandrels that can be positioned
on the rotating table, which in turns limits the testing rate for the condoms.
In a typical automatic loading test apparatus, for example, the mandrels are typically
separated a distance of approximately 10 inches and the maximum travel rate or
rate of rotation is about 12 inches per second.
Because the maximum travel rate is limited, especially with regard to manual
loading, an apparatus that enables the mandrels to be more closely spaced will
increase the number of condoms that can be tested over a given time period. Condom
testing equipment with automatic condom loading typically test about 100 condoms
per minute, while manually loaded testing equipment typically test about 50 to
60 condoms per minute. While increasing the testing rate of either type is desirable,
the manual loading test equipment is much cheaper and occupies significantly less
floor space than automatic loading test equipment, and thus it is especially desirable
to increase the testing rate on the manual loading apparatuses.
It is an object of this invention to provide an improved condom testing apparatus
and methodology which address the problems described above in terms of increasing
the testing rate of condoms, especially with regard to manual loading condom testing
apparatuses, in that the distance between condom-containing mandrels is minimized.
It is an object to provide such an apparatus wherein the defects in a condom are
detected upon passage of an electrical current between an electrically conductive
mandrel and multiple external condom-contacting electrode members through any defect
in the condom such that a closed circuit is formed. It is an object to provide
such an apparatus wherein the length of any of the condom-contacting electrode
members in the direction of travel of the mandrel is less than the circumference
of the mandrel, such that at least two sets of condom-contacting electrode members
are required to test the entire circumference of the condom, in that neither set
of condom-contacting electrode members individually tests the full circumference
of the condom. It is an object to provide such an apparatus wherein a second condom-containing
mandrel is tested on the first set of condom-contacting electrode members simultaneously
with a first condom-containing mandrel being tested on the second set of condom-contacting
electrode members, the first condom-contacting mandrel having been already tested
on the first set of condom-contacting electrode members and advanced to the second
set of condom-contacting electrode members. These objects, as well as objects not
expressly set forth, will be apparent upon examination of the disclosure that follows.
SUMMARY OF THE INVENTION
The invention is in general a condom defect testing apparatus that utilizes electrical
current to detect holes, tears or excessively thin-walled areas in a condom, wherein
the non-defective condom acts as an insulator to prevent current flow between external
condom-contacting electrode members and a conductive mandrel electrode member.
If the electrical circuit containing any one of the condom-contacting electrode
members and the conductive mandrel is closed due to the arcing of current through
a defect, this state is detected and the condom is deemed defective and is subsequently
discarded. The mandrels are mounted onto a rotating platform, track or table, typically
such that the travel path is circular, whereby the condoms are loaded onto the
mandrels at a loading station, the loaded mandrels are passed through a testing
zone in which the condoms are identified as being defective or non-defective, the
condoms are removed from the mandrels in a stripping station, with the defective
condoms being separated from the non-defective condoms, and the empty mandrels
are returned to the loading station. The rotation of the platform, track or table
is preferably a continuous rotation, although an indexed rotation would also be possible.
In order to minimize spacing of the test mandrels for the purpose of increasing
the testing rate, at least two sets of condom-contacting electrode members are
provided, wherein each individual set of condom-contacting electrode members tests
less than the full 360 degree circumference of the condom mounted on the mandrel.
Each condom is passed through a testing zone containing the at least two sets of
condom-contacting electrode members, and the mandrel is rotated as it passes through
the testing zone. In an embodiment wherein there are two sets of condom-contacting
electrode members, each set tests between 360 and 180 degrees of the condom circumference,
and the sets are spaced along the mandrel travel direction such that sufficient
rotation of the mandrel occurs during travel from the first set to the second set
to insure that the tested portions of the condom circumference overlap. Because
the sets of condom-contacting electrode members are spaced, a second condom loaded
mandrel is tested on the first set of condom-contacting electrode members simultaneously
with a first condom loaded mandrel being tested on the second set of condom-contacting
electrode members, thereby allowing the mandrels to be more closely spaced.
The sets of condom-contacting electrode members each comprise at least a condom
body contacting member and a condom nipple contacting member, wherein preferably
the condom body contacting member comprises an electrically conductive fabric or
pad member and the condom nipple contacting member comprises an electrically conductive
brush member. Most preferably three condom body contacting members are provided,
a pair of such condom body contacting members, preferably conductive pads or fabric
members, being separated perpendicularly relative to the mandrel axis of rotation,
with an additional condom body contacting member, preferably a conductive brush
member, being disposed on the opposing side of the mandrel along with the condom
nipple contacting member in order to test the area of the condom corresponding
to the gap between the two condom opposing condom body contacting members. With
this construction, different amounts of current may be passed through the independent
condom body contacting members to account for variations in wall thickness in the
condom body.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical view of an embodiment of the condom testing apparatus,
showing a portion of the rotating platform, wherein a tested condom-loaded mandrel
has exited the testing zone, a first condom-loaded mandrel is being tested on the
second set of condom-contacting electrode members, a second condom-loaded mandrel
is being tested on the first set of condom-contacting electrode members, and a
pre-testing condom-loaded mandrel is being advanced into the testing zone.
FIG. 2 is a side view of the invention showing one set of the condom-contacting
electrode members and the mandrel-contacting electrode member.
FIG. 3 is a side view of the invention similar to FIG. 2 but showing an alternative
embodiment having one set of the condom-contacting electrode members comprising
a pair of conductive pad members and an additional brush member.
FIG. 4 is a side view similar to FIG. 3, showing a second set of condom-contacting electrodes
FIG. 5 is a schematic diagram illustrating rotation of the condom-loaded mandrel
through the testing zone, showing the overlapping regions of contact with the condom-contacting
electrode members such that greater than 360 degrees of condom circumference are tested.
DETAILED DESCRIPTION OF THE INVENTION
With reference to the drawings, the invention will now be described in detail
with regard for the best mode and the preferred embodiment. For purposes of this
disclosure, the invention will be arbitrarily described such that the central axes
of the mandrels are oriented vertically with the nipple end of the mandrel and
condom on top, and such that the mandrels are positioned on a platform that rotates
or moves horizontally, such that any references to relative direction are based
on this construct. Furthermore, in this disclosure the individual mandrels are
described as rotating clockwise and the platform as rotating clockwise. It is understood,
however, that the orientation and rotation directions of the condom defect testing
apparatus may be varied without departing from the scope of the claimed invention.
In general, the invention is a condom defect testing apparatus for testing individual
condoms
50 for defects, such as holes, tears or thin-walled regions susceptible
to failure during use, such that any defective condoms
50 are identified
and destroyed prior to packaging and distribution. The testing apparatus is utilized
in conjunction with condom loading means for mounting individual condoms
50
onto test mandrels
40 and condom removal and sorting means for removing
the condoms
50 from the mandrels
40 and separating the defective
condoms from the non-defective condoms. The condom loading means may comprise mechanical
apparatuses for automatically mounting the condoms
50 on the mandrels
40,
or the condoms
50 may be loaded onto the mandrels
40 manually. The
condom removal and sorting means may also be automatic or manual, but automatic
systems in communication with the defect testing apparatus are most common. In
a representative removal and sorting system, a roller is used to roll up the condom
50 and a pair of brushes are used to knock the condom
50 off the
mandrel
40, one brush being activated for a defective condom
50 and
a different brush being activated for a non-defective condom
50, such that
the defective condoms
50 are expelled into separate conveyors or bins. Thus,
the condom defect testing apparatus as contemplated may be incorporated into existing
systems or the apparatus may comprise a complete system comprising the condom loading
means, the testing means as described in detail herein, and the removal and sorting means.
Electrically conductive mandrels
40 are known in the condom testing
art, and a typical mandrel
40 comprises a base
41, a cylindrical
extended body
42 and a nipple end
43, the nipple end
43 comprising
a transitional shoulder reducing the diameter of the mandrel
40 down to
a smaller tip. The shape of the mandrel
40 is chosen such that a condom
50 comprising a body
51 and a nipple end
52 is uniformly stretched
when loaded onto the mandrel
50. Mandrel mounting means
42 join the
mandrels
40 to a moving platform, track or table member
45, wherein
the mandrel mounting means
42 allows each mandrel
40 to rotate about
its central axis, and wherein the platform member
45 is typically rotated
by a motor such that the travel pathway
99 of the mandrels
40 is
circular. Mandrel mounting means
42 may comprise for example a cylindrical
pin member mounted below the base
41 that is received by a bore disposed
in the rotating platform member
45. Mandrel rotating means
46 is
provided to rotate the individual mandrels
40 about their central axes,
and may comprise a curved member that interacts frictionally or mechanically interfaces
with the base
41 of the mandrel
40 as it is brought through the testing
zone, such that controlled rotation of each mandrel
40 is achieved as it
proceeds along the mandrel travel pathway
99.
Mandrel contacting electrode means
47 are provided such that each
mandrel
40 is a component in the electrical testing circuitry of the condom
defect testing apparatus, the particular electrical conductors and pathways for
the testing circuitry being a matter of engineering choice well within the scope
of those skilled in the art. A suitable design for the testing circuitry involves
connecting the test mandrels
40 to ground via the mandrel contacting electrode
means
47, such that any current passing through a defect in a condom
50
closes the circuit, which state is then detected in known manner. As shown in FIGS.
2 through 4, a suitable embodiment for the mandrel contacting electrode means
47
comprises an electrically conductive grounding brush member
33 or
63
mounted by brush mounting means
34 or
64 to a framework
32
or
62 connected to a base
31, respectively. As the mandrel
40
is brought through the testing zone, the conductive brush member
33 or
63
remains in contact with the mandrel base
41, the brush member
33
or
63 extending longitudinally in the mandrel travel direction approximately
the same distance as the condom body contacting means
11 or
21 and
the condom nipple contacting means
12 or
22, respectively. For a
circular pathway
99 as illustrated, it is preferred that the contact surface
of the grounding brush member
33 or
63 be curved equivalent to the
circular arc of the mandrel travel pathway
99.
The condom defect testing apparatus comprises a first set of condom-contacting
electrode members
10 and at least a second set of condom-contacting electrode
members
20, with the condom body contacting means
21 and condom nipple
contacting means
22 of the second set
20 being physically separated
from the condom body contacting means
11 and condom nipple contacting means
12 of the second set
10, such that a gap is defined along the travel
pathway
99 during which a mandrel
40 and condom
50 are in
contact with neither the first set
10 nor the second set
20 in the
middle of the testing zone, thereby defining a first testing stage and a second
testing stage. The first set of condom-contacting electrode members
10 comprises
condom body contacting means
11 and condom nipple contacting means
12
that are components in the electrical testing circuitry whereby a current may independently
pass from either the condom body contacting means
11 or the condom nipple
contacting means
12 through a defect in the condom
50 and into the
mandrel
40 to ground, thereby closing or completing the electrical circuit,
which status is then detected by electrical circuit status sensing means as indication
that the condom
50 being tested is defective, the status sensing means then
operatively determining the sorting of the condom
50 upon removal from the
mandrel
40. The design of the particular electrical conductors, pathways
and status sensing means for the testing circuitry are a matter of engineering
choice well within the scope of those skilled in the art.
The condom body contacting means
11 preferably comprises a single or plural
electrically conductive pad member
13, typically formed of an electrically
conductive fabric material backed by a compressible internal member. The conductive
pad member
13 is mounted to a framework
32 such that the condom body
contacting means
11 remains stationary as the loaded mandrel
40 is
passed through the first testing stage. The pad contact surface
15 is curved
so as to correspond to the travel pathway
99, such that the pressure applied
to the condom
50 remains generally uniform as it passes. The rotational
rate of the mandrel
40 is set to match the travel speed of the mandrel along
the pathway
99 such that the frictional contact between the pad contact
surface
15 and the condom body
51 does not shift the condom
50
on the mandrel
40 nor stretch the condom body
51. The height of the
conductive pad member
13 must be sufficient to contact the majority of the
condom body
51.
In the preferred embodiment, as shown in FIG. 3, conductive pad member
13
comprises an upper pad member
17 and a lower pad member
18, physically
separated by a horizontally oriented gap. This allows the current passing through
the upper pad member
17 to be set at a different level from the current
passing through the lower pad member
18, which provides better results for
condoms
50 wherein the upper portion of the condom body
51 has a
different shape or wall thickness than the lower portion of the condom body
51.
When multiple pad members
17 and
18 are present, the condom body
contacting means
11 further comprises an electrically conductive body brush
member
19 located opposite from the pad members
17 and
18,
with the body brush member
19 being vertically positioned to cover and exceed
the gap area between the pad members
17 and
18. In this manner the
full longitudinal length of the condom body
51 is tested by the combination
of the condom body contacting pad members
17 and
18 and the body
brush member
19.
The nipple end
52 of the condom
40, which includes the transitional
shoulder portion, is tested for defects by condom nipple contacting means
12,
which preferably comprises an electrically conductive brush member
14 mounted
on the framework
32 on the opposite side from the body contacting means
11. The brush contact surface
16 extends from the top of the nipple
end
52, past the transition shoulder and overlaps a portion of the upper
end of the condom body
51 so that a portion of the condom body
51
is tested by both the condom nipple contacting means
12 and by the condom
body contacting means
11. Preferably the brush contact surface
16
is curved to correspond to the arc of the mandrel travel pathway
99.
The horizontal or longitudinal dimension of the condom body contacting means
11, i.e., the contact surface
15 the pad member
13 or the
combined pad members
17 and
18, and the horizontal or longitudinal
dimension of the condom nipple contacting means
12, i.e., the contact surface
16 of the brush member
14, in the direction along the mandrel travel
pathway
99, is less than the distance around the circumference of the mandrel
40. In this manner, the condom nipple contacting means
12 and by
the condom body contacting means
11 of the first set of condom-contacting
electrode members
10 will test less than 100 percent of the surface of the
condom
50 as the mandrel
40 passes through the first test stage.
For example, for a mandrel having a diameter of approximately 1.85 inches and therefore
a circumference of approximately 5.81 inches, the longitudinal dimensions of the
contact surface
16 of the condom nipple contacting means
12 and the
contact surface
15 of the condom body contacting means
11 cannot
exceed 5.81 inches.
The condom defect testing apparatus further comprises a second set of condom-contacting
electrode members
20 that are physically separated from the first set
10
and which define a second testing stage in the testing zone. The second set
20
comprises condom body contacting means
21 and condom nipple contacting means
22 which perform the functions equivalent to the corresponding means of
the first set
10. Preferably, the components of the second set
20
correspond directly to the components of the first set
10, such that the
second set
20 comprises a conductive pad member
23, or a pair of
upper and lower conductive pad members
27 and
28, a conductive brush
member
24, pad contact surface
25, brush contact surface
26,
frame
62, brush mounting means
64 and pad mounting means
65,
which are structurally and functionally equal or substantially similar to first
set
10 components conductive pad member
13, or a pair of upper and
lower conductive pad members
17 and
18, a conductive brush member
14, pad contact surface
15, brush contact surface
16, frame
32, brush mounting means
34 and pad mounting means
63. Such
similarities are illustrated by comparing FIGS. 3 and 4. As with first set
10,
the horizontal or longitudinal dimension of the condom body contacting means
21,
i.e., the contact surface
25 the pad member
23 or the combined pad
members
27 and
28, and the horizontal or longitudinal dimension of
the condom nipple contacting means
22, i.e., the contact surface
26
of the brush member
24, in the direction along the mandrel travel pathway
99, must be less than the distance around the circumference of the mandrel
40.
The first set of condom-contacting electrode members
10 defining the first
testing stage of the testing zone are separated from the second set of condom-contacting
electrode members
20 defining the second testing stage of the testing zone
a distance such that the rotation of the mandrel
40 about its central axis
caused by the mandrel rotating means
46 will result in the area of the condom
50 not tested by the first set
10 to be tested by the second set
20, along with a region of overlap that is tested by both the first set
10 and second set
20, as shown in FIG. 5. For example, it has been
found suitable to test approximately 260 degrees of the condom circumference on
the first set of condom-contacting electrode members
10, provide a separation
sufficient to allow for approximately 253 degrees of mandrel rotation between the
first set
10 and the second set
20, and then test approximately 260
degrees on the second set of condom-contacting electrode members
20. Because
the two testing stages overlap, more than 100 percent of the condom circumference
is tested, with approximately 200 degrees of the condom circumference being tested
once and approximately 160 degrees of the condom circumference being tested twice
in the overlapping regions. It is of course possible to structure the first and
second sets of condom-contacting electrodes
10 and
20 such that the
amount of overlap is smaller, or wherein one of the sets
10 or
20
is longer than the other in the horizontal testing direction.
FIG. 1 shows a portion of the rotating platform member
45 having condoms
50a,
50b,
50c and
50d mounted
on mandrels
50 rotatably mounted extended arms. Condom
50a has
already passed through the testing zone and is ready to be removed and sorted.
Condom
50d is about to enter the testing zone. Condom
50b
is passing through the second set of condom-contacting electrode members
20,
having already passed through the first set of condom-contacting electrode members
10. Under the example given above, approximately 260 degrees of the circumference
of the condom
50b was tested in the first set
10, the mandrel
40 was rotated approximately 253 degrees prior to reaching the second set,
and an overlapping 260 degrees is being tested in the second set
20. Condom
50c is passing through the first set of condom-contacting electrode
members
10 and approximately 260 degrees of circumference is being tested.
Because the first set
10 and second set
20 are separated, condom
50c can be tested at the same time as condom
50b, thereby
allowing the distance between the mandrels
40 to be reduced, such that more
condoms
40 will be tested in a given time period at the same rate of rotation
of platform member
45.
As a representative example, a platform member
45 approximately 3.75 feet
in diameter having mandrels
40 each with a circumference of approximately
5.81 inches may utilize a first set of condom-contacting electrode members
10
approximately 4.2 inches in longitudinal dimension along the mandrel travel pathway
99 and a second set of condom-contacting electrode members
10 approximately
4.2 inches in longitudinal dimension along the mandrel travel pathway
99,
the first set
10 and second set
20 being separated approximately
4.1 inches along the mandrel travel pathway
99. With this construction,
the mandrels
40 may be spaced approximately every 7.8 inches, which is a
significant decrease over known testing apparatuses. On a manual loading machine,
this increases the testing rate from about 50 to 60 condoms per minute to about
105 to 110 condoms per minute, while still allowing enough separation for manual
loading and maintaining a platform rotational speed of about 12 inches per second.
While the invention has been described with reference to a first set
10
and a second set
20 of condom-contacting electrode members defining a first
and second stage in the testing zone, it is understood that more than two sets
of condom-contacting electrode members may be utilized in succession, with the
dimensions in the longitudinal direction along the travel pathway
99 and
the separation distance between sets being reduced for each as required to insure
that multiple condoms
40 do not contact any given set simultaneously and
that sufficient rotation occurs to insure the full circumference of each condom
50 is tested.
It is understood that equivalents to certain elements set forth above may be
obvious
to those skilled in the art, and therefore the full scope and definition of the
invention is to be as set forth in the following claims.
*
