U.S. patent application number 15/817525 was filed with the patent office on 2018-03-15 for nasal dilator and methods of fabricating medical devices.
This patent application is currently assigned to Corbett Lair, Inc.. The applicant listed for this patent is Joseph Vincent IERULLI. Invention is credited to Joseph Vincent IERULLI.
Application Number | 20180071131 15/817525 |
Document ID | / |
Family ID | 46207779 |
Filed Date | 2018-03-15 |
United States Patent
Application |
20180071131 |
Kind Code |
A1 |
IERULLI; Joseph Vincent |
March 15, 2018 |
Nasal Dilator and Methods of Fabricating Medical Devices
Abstract
Methods are disclosed for converting on a mass scale elongated
material webs into finished parts or devices. Slits form strands in
a web, the strands comprising interconnected objects which
correspond to parts of finished devices. Strands are combined with
additional webs to form a material laminate from which finished
devices are die cut. The methods are suitable for a range of
converting applications including medical devices, particularly the
external nasal dilator. Complex dilator devices produced from the
methods are formed as a single body truss having horizontal regions
adapted to engage outer wall tissues of first and second nasal
passages of a nose. When in use the dilator stabilizes or expands
nasal outer wall tissues and prevents the outer wall tissues from
drawing inward during breathing. Methods of manufacture comprise
separate steps for fabricating and assembling the elements and
layers of finished dilator devices and for packaging finished
devices individually or in groups. Waste material is incorporated
into subsequent fabrication processes to produce the same or
complementary devices.
Inventors: |
IERULLI; Joseph Vincent;
(Bradenton, FL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
IERULLI; Joseph Vincent |
Bradenton |
FL |
US |
|
|
Assignee: |
Corbett Lair, Inc.
Bradenton
FL
|
Family ID: |
46207779 |
Appl. No.: |
15/817525 |
Filed: |
November 20, 2017 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
14139619 |
Dec 23, 2013 |
9844456 |
|
|
15817525 |
|
|
|
|
12964746 |
Dec 10, 2010 |
8641852 |
|
|
14139619 |
|
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
Y10T 156/1087 20150115;
Y10T 156/1075 20150115; Y10T 156/1085 20150115; Y10T 156/1074
20150115; A61F 5/08 20130101; A61M 2210/0618 20130101; Y10T
156/1069 20150115 |
International
Class: |
A61F 5/08 20060101
A61F005/08 |
Claims
1. A nasal dilator comprising: an engagement element comprising at
least one of a base member or a cover member; a functional element
comprising at least two discrete, adjacent, spaced apart,
substantially parallel resilient members, the resilient members
having mid-sections substantially parallel to a longitudinal
centerline of the nasal dilator, wherein at least one of the at
least two substantially parallel resilient members includes lateral
end portions that diverge obliquely away from the longitudinal
centerline of the nasal dilator and toward a nearest long edge of
the nasal dilator.
2. The dilator of claim 1 wherein a first resilient member of the
at least two resilient members extends from end to end in a
straight line, a second resilient member of the at least two
resilient members has opposite end portions that diverge obliquely
away from the longitudinal centerline toward a nearest long edge of
the nasal dilator; and wherein a plan view periphery of the nasal
dilator is symmetric about a lateral centerline of the nasal
dilator and asymmetric about the longitudinal centerline
thereof.
3. The dilator of claim 1 wherein at least a different one of the
at least two substantially parallel resilient members includes
lateral end portions that diverge obliquely away from the
longitudinal centerline of the nasal dilator and toward a different
nearest long edge of the nasal dilator, the dilator further
comprising: a third resilient member extending from end to end in a
straight line, said third resilient member positioned between the
at least two substantially parallel resilient members and parallel
to the longitudinal centerline.
4. The dilator of claim 1 wherein: the engagement element comprises
a base member having a first peripheral shape and a cover member
having a second peripheral shape; the functional element comprising
at least two substantially parallel resilient members forms a third
peripheral shape; and wherein each of the peripheral shapes are
different from each other, such that the cover member has a
greatest surface area, the base member has a lesser surface area
than the cover member, and a total surface area of all of the at
least two substantially parallel resilient members is less than or
equal to the lesser surface area of the base member.
5. The dilator of claim 1 wherein all of the resilient members have
opposite end portions that diverge obliquely in a common direction
toward a same long edge of the nasal dilator; and wherein a plan
view periphery of the nasal dilator is symmetric about a lateral
centerline of the nasal dilator and asymmetric about the
longitudinal centerline thereof.
6. The dilator of claim 1 wherein the lateral end portions of the
second resilient member are longer than a mid portion thereof.
7. The dilator of claim 1 wherein at least one resilient member has
a first length, a first width, and a first thickness, and at least
one other resilient member has a thickness exceeding the first
thickness, a width at least equal to the first width, and a length
at least equal to the first length.
8. The dilator of claim 1 wherein the engagement element comprises
a thin, supple plastic film, and the at least two resilient members
of the functional element are secured to a flat surface side
thereof.
9. The nasal dilator of claim 1, further comprising a protective
release liner having a periphery extending outboard at least a
portion of the nasal dilator periphery, the release liner periphery
including a lip thereat for grasping by a user preliminary to using
the dilator.
10. A nasal dilator comprising a laminate of vertically stacked
material layers, including: a base layer comprising a base member
having a first peripheral shape; a resilient layer comprising at
least one resilient member having a second peripheral shape; a
cover layer comprising a cover member having a third peripheral
shape; and wherein each of the peripheral shapes are different from
each other, such that the cover member has a greatest surface area,
the base member has a lesser surface area than the cover member,
and the at least one resilient member has a lesser surface area
than the base member.
11. The nasal dilator of claim 10, wherein the resilient layer
comprises from one to six discrete, laterally adjacent, spaced
apart, substantially parallel resilient members.
12. A nasal dilator comprising: an engagement layer comprising at
least one of a base member or a cover member; and at least one
oblong resilient member having roughly parallel long edges and a
longitudinal resilient member centerline therebetween, wherein the
longitudinal resilient member centerline includes curves bending
both left and right.
13. The nasal dilator of claim 12, wherein the at least one oblong
resilient member whose longitudinal resilient member centerline has
curves bending both left and right, forms a shape that is symmetric
about a lateral centerline of the dilator, such that a shape of the
oblong resilient member on one side of the lateral centerline is a
mirror image of a shape of the oblong resilient member on another
side of the lateral centerline.
Description
RELATED APPLICATIONS
[0001] This application is a Continuation of U.S. Non-Provisional
patent application Ser. No. 14/139,619 filed 23 Dec. 2013, which
was a Continuation of U.S. Non-Provisional patent application Ser.
No. 12/964,746 filed 10 Dec. 2010 (now U.S. Pat. No.
8,641,852).
FIELD OF THE INVENTION
[0002] The present invention relates generally to converting
elongated material webs into finished parts or devices such as may
be used in the medical, high-technology, electronics, automotive or
aerospace industries. The methods are particularly suited to the
converting of elongated sheets or rolls of thin flexible materials
such as papers, films, foils, tapes, synthetic fabrics and the
like, including those having an adhesive substance disposed
thereon, into mass produced medical devices such as electrodes,
transdermal devices, wound care dressings and closures, etc. The
present invention specifically relates to apparatus and methods of
dilating external tissue in humans, including methods of
fabricating tissue dilator devices. As disclosed and taught in the
preferred embodiments, the tissue dilator devices and methods of
fabricating medical devices and tissue dilators are particularly
suitable for, and are directed primarily to, external nasal
dilators for supporting, stabilizing, and dilating nasal outer wall
tissues adjacent and overlying nasal airway passages of the human
nose, including the nasal valve and the nasal vestibule areas
thereof. The United States Food and Drug Administration classifies
the external nasal dilator as a Class I Medical Device.
BACKGROUND OF THE INVENTION
[0003] A portion of the human population has some malformation of
the nasal passages which interferes with breathing, including
deviated septa, swelling due to infection or allergic reactions, or
inflammation due to changes in atmospheric humidity. A portion of
the interior nasal passage wall may draw in during inhalation to
substantially block the flow of air. Blockage of the nasal passages
as a result of malformation, symptoms of the common cold or
seasonal allergies are particularly uncomfortable at night, and can
lead to sleep disturbances, irregularities and general
discomfort.
[0004] In use the external nasal dilator is flexed across the
bridge of the nose, extending over the nasal passage outer wall
tissues on each side of the bridge, and held thereto by an
adhesive. A resilient member (also referred to as a spring member,
resilient band, or spring band) is embedded in, or affixed to, the
device. The resilient member may be bisected lengthwise into two
closely parallel members. Flexure creates spring biasing forces in
the resilient member, extending from the middle to the opposite end
regions of the device, pulling outwardly to dilate or otherwise
stabilize the outer wall tissues of the nasal airway passages. This
decreases airflow resistance within the nasal passages and produces
a corresponding ease or improvement in nasal breathing.
[0005] The resilient member typically produces between 15 grams and
35 grams of resiliency or spring biasing force. Constructing a
nasal dilator with less than 15 grams of spring biasing force may
not provide suitable stabilization or dilation, while greater than
35 grams would be uncomfortable for most users. Using a more
aggressive adhesive, a greater amount of adhesive, or greater
adhesive surface area so as to withstand greater spring biasing
increases the likelihood of damage to the tissue upon removal of
the device.
[0006] Examples of present external nasal dilators are disclosed in
U.S. Pat. Nos. 6,453,901, D379513, D429332, D430295, D432652,
D434146, D437641 and U.S. patent application Ser. Nos. 08/855,103,
12/024,763, 12/106,289, and 12/402,214, the entire disclosures of
which are incorporated by reference herein. A minority of the
external nasal dilator prior art is adaptable for mass production
and thus commercialization in the present consumer retail market.
Examples of commercialized nasal dilators, know collectively as
nasal strips, include devices disclosed in U.S. Pat. Nos. D379513,
6453901, 5533503, 5546929, RE35408, 7114495 and certain devices
based upon Spanish Utility Model 289-561 for Orthopaedic
Adhesive.
[0007] While these example devices provide dilation or
stabilization to nasal outer wall tissues in a majority of users,
there is a need in the art both to provide variety and complexity
in commercially feasible dilator devices and to overcome certain
inherent limitations of nasal dilation, including: limited skin
surface area adjacent the nasal passages to engage a dilator
device; a limited range of spring biasing force that is both
effective and comfortable; the dynamic relationship between
adhesive engagement and spring biasing peel forces as affects
efficacy, comfort and engagement duration; and economically
producing complex dilator devices on a mass scale. The present
invention discloses novel dilator devices and methods of
manufacturing dilator devices which address unmet needs in the art
and the limitations of nasal dilation.
[0008] A particular inherent limitation of the external nasal
dilator is that spring biasing creates peel forces at its opposite
end regions, together with some tensile forces, which act to
disengage the device from the skin surface. Dilator devices
disclosed in U.S. Pat. Nos. 5,533,503 and 6,453,901, and U.S.
patent application Ser. No. 12/106,289 include design attributes to
mitigate the effect of peel forces or to otherwise shift at least a
portion of peel forces into sheer forces. Accordingly, a dynamic
relationship exists between dilator design, its flexed spring
biasing force, and its efficacy. The present invention builds upon
the prior art to address this relationship and further enhance
dilator function and comfort.
[0009] Nasal dilator devices in the prior art are typically
symmetric on each side of the device centerline, which is aligned
to the centerline of the bridge of the nose. Each half of the
dilator on each side of the centerline is the mirror image of the
other. Similarly, each long half of the device, bisected along its
length, is typically the mirror image of the other. However,
symmetry has not been generally incorporated into dilator design so
as to gain manufacturing economy. Of limited exception is where a
plurality of dilator devices are die cut on common lines
corresponding to their long edges. However, this technique is
facilitated by the device having a constant width along its length;
a dilator design having wider end regions and a narrower mid
section is generally more comfortable and more effective. The
present invention discloses novel means of using symmetry in
medical device design, and incorporates symmetry into methods of
manufacturing dilator devices on common longitudinal lines.
[0010] There has also been a continuing need in the art to develop
efficient ways of fabricating complex nasal dilator resilient
members and incorporating them into mass produced nasal dilators.
Complex resilient members are disclosed in the prior art, but not
generally practiced in commercially available nasal strip products.
For example, FIGS. 12, 17, 20 and 22 of U.S. Pat. No. 6,453,901
illustrate complex resilient member structures in dilator devices,
including a method (illustrated in FIG. 16) of forming continuous
interconnected resilient members. However, a significant quantity
of material extending around and between the interconnected
resilient members is lost. The preferred and commonly used material
from which resilient members are fabricated carries a significantly
greater cost per unit of measure than other materials used in the
device. Accordingly, simple resilient member structures prevail in
commercialized dilator devices. The present invention discloses
means by which to economically mass produce complex resilient
member structures with a material usage-to-waste ratio consistent
with the fabrication of simpler structures.
[0011] The total cost of a medical device is generally the sum of
the cost to manufacture (or convert) the device plus the cost of
the material used. Material cost includes that which goes into the
finished device plus that which is wasted in the converting
process. A dynamic relationship exists between converting cost
(setup, calibration, registration and alignment, material handling
and fabrication time), and material cost; manufacturers (or
converters) often obtain efficiency in one area at the expense of
the other. Medical devices are typically die cut in cookie-cutter
fashion to reduce converting time, but at the expense of material
waste extending around and between finished parts. The present
invention discloses various methods to reduce material waste while
minimizing any additional converting time.
[0012] A common practice is to fabricate external nasal dilators
having a material layer above as well as below the resilient
member. The two layers are die cut simultaneously, largely to
shorten converting time. Thus each material layer comprises about
1.66 square inches of material (based on average overall device
dimensions of about 2.63''L.times.0.63''W), for a total of about
3.31 square inches of material per device. The present invention
discloses means to reduce material in at least one of the layers
with only a modest increase in corresponding converting time.
[0013] Similarly, nasal dilator resilient members are traditionally
formed from a continuous strand of material equal to each member's
finished width. A plurality of strands are slit along common long
edges, then separated and repositioned laterally across the
fabrication matrix. Repositioning may constitute a separate and
additional converting operation, which carries a cost. The present
invention discloses means whereby to slit and position strands in
the converting process simultaneously, without a separate and
additional operation. The present invention further discloses means
to re-incorporate potentially unavoidable resilient member material
waste into a subsequent fabrication process which yields additional
or complementary dilator devices.
[0014] Where a nasal dilator resilient member is fabricated to be
centered within the peripheral edges of the finished device,
material waste can be up to 73%. This manufacturing technique
(called island placement) simultaneously die cuts and registers a
plurality of spaced apart components along a material strip, or
across and along a material web, so that each component (i.e., the
resilient member) is centered within the perimeter edges of another
plurality of similarly registered components (material layers which
form the rest of the dilator). Island placement requires additional
material extending along each side of the finished resilient member
plus material extending between successive devices fabricated
lengthwise end to end. The additional material is used as a matrix
by which to space the finished resilient members apart; the wider
the matrix, the poorer the usage-to-waste ratio. Once the resilient
members are die cut, the matrix is removed as a whole from around
and between the spaced apart resilient members and discarded as
necessary waste.
[0015] By example, a finished resilient member may be about 2.25''
long.times.about 0.24'' wide, for a total of 0.54 square inches of
material. Where resilient members are formed from a continuous
strip of material, adding 0.125'' to each long edge of the strip
increases strip width to 0.49''. Individual resilient members must
also be spaced apart lengthwise by about 3'' from center to center
to allow adequate perimeter space to form a finished dilator device
being about 2.63'' long. This means 1.47'' sq. (3''.times.0.49'')
of material is used to fabricate and position a resilient member
comprising 0.54'' sq. of material. The resulting usage-to-waste
ratio is nearly 1:4, where about 27% of the material is used for
the finished resilient member and about 73% of the material is
wasted. The present invention discloses means to improve resilient
member material waste, particularly in the fabrication of complex
resilient member structures, where the higher per unit material
cost has the greatest impact on manufacturing economy.
[0016] Similar to the fabrication of island-placed components,
finished nasal strip devices are typically manufactured in a
continuous process which spaces one device from another by about
0.125'' on all sides so that material not devoted to the device
itself (the waste matrix) can be removed as a whole. Finished
devices meant to be packaged in the same operation are spaced even
farther apart to provide a suitable contact perimeter around each
unit so that upper and lower packaging material webs may form an
adequate seal. Again, material from which finished devices or
device elements are fabricated is often used as the matrix by which
to space finished devices apart. Nasal strips fabricated in closer
proximity to each other in order to avoid that material waste are
often packaged in a separate, dedicated operation, thus incurring a
corresponding cost. The present invention discloses means to
fabricate medical devices so as to reduce waste, and to
simultaneously space finished devices apart so as to seal the
devices between packaging webs, without incurring a separate
operational cost or the traditional amount of material waste.
SUMMARY OF THE INVENTION
[0017] The present invention discloses methods for converting
elongated material webs. The methods are particularly suited to
mass producing medical devices, particularly the external nasal
dilator. Methods are determined in part by device design and device
design is shaped by methods so as to create efficiencies and extend
material yield. While the manufacturing methods of the present
invention are suitable or adaptable to a range of converting
applications, and particularly to medical devices, the preferred
embodiments are primarily directed to producing complex external
nasal dilator devices economically on a mass scale.
[0018] Manufacturing methods of the present invention revolve
around forming continuous slits in an elongated flexible material
web. The slits alter the material web into a plurality of adjacent,
or laterally contiguous, elongated strands. The strands are
separated from the material web and combined with at least one
additional material web in a continuous process which forms a
material laminate. The strands may also be combined with other
strands slit from a different material web and then combined with
another material web to form a material laminate. The material
laminate may be die cut into finished devices or it may be slit
into laminate strands which are subsequently die cut into finished
devices. Laminate strands may also be combined with another
material web and then die cut into finished devices. The material
laminate or laminate strands may be combined with upper and lower
packaging material webs so as die cut and package the finished
devices concurrently.
[0019] An elongated flexible material web generally consists of a
single material layer with an adhesive substance disposed on one
surface and a protective paper liner releasably secured to the
adhesive. A material web may also comprise more than one material
layer. The continuous slits extend vertically through at least a
portion of the elongated material web and longitudinally along, or
generally consistent with, the machine direction of the web without
intersecting the outside long edges or an adjacent slit. Otherwise
the slits may be straight or may have divergent, angled or curved
segments. The slits may be parallel to each other or may diverge
laterally from one another. Two adjacent slits define a strand, and
the strand may thus be straight, divergent, have a gradient width
or a varying width.
[0020] An elongated strand or laminate strand consists of a
plurality of interconnected objects integrated into the strand. The
objects correspond to an element, layer, member or component of a
medical device. Accordingly, the continuous slits follow criteria
determined by the design of the object and the design of the
medical device to which the object is a part. That criteria
includes: forming the object to dimensions appropriate to the
element, layer, member, component or finished device; defining at
least a portion of the peripheral dimensions of the object or
finished device; pre-positioning or aligning objects to each other
or to a registration point where the finished device will be die
cut; and creating a predetermined lateral spacing between strands,
and ultimately objects, as the strands are separated from a
material web and combined into a material laminate. Predetermined
spacing is a function of strand width and/or the collective width
of a group of strands.
[0021] Since a strand or laminate strand consists of a plurality of
interconnected objects, then each continuous slit in an elongated
web or material laminate thus forms, as well as defines, at least a
portion of one long edge of two objects adjacent each other (one to
each side of the slit). At least portions of these long edges of
adjacent objects or finished devices are thus formed on common
lines. Again, the interconnected objects correspond to an element,
layer, member or component of a medical device, or the device
itself.
[0022] The interconnected objects of a strand or laminate strand
are completed by severing, such as by cross slits extending between
the long edges of a strand or laminate strand, or by die cut lines
contained at least in part within the width of a strand or laminate
strand, or by enclosed die cut lines formed in a material laminate
or laminate strand. Die cut lines generally form finished or
semi-finished devices in a material laminate or laminate strand,
but die cut lines may also form, in whole or in part, elements,
layers, members, or components of a finished device in a material
web, a strand, or some combination of material webs and elongated
strands.
[0023] One purpose of forming and combining strands and material
webs into material laminates and laminate strands is to eliminate
material waste and extend material yield without increasing
converting time to the point of offsetting savings gained.
Particularly effective is forming strands of the most expensive
materials, then separating or dividing these strands into multiple
material laminates consisting of less expensive materials. Forming
strands in a material web and dividing them into multiple laminates
is also an effective alternative to using the web as a matrix by
which to space apart a plurality of components to be die cut
therefrom.
[0024] The present invention discloses means for separating strands
from a material web without having to reposition them in a
separate, dedicated operation. Continuous slits form a plurality of
adjacent, or laterally contiguous, strands in a material web such
that the plurality consists of consecutive, or adjacent, groups of
strands. One or more select strands is separated from each group
(e.g., every other, every one-in-three, every two-in-eight, etc.)
such that the separated strands are laterally spaced apart, and
thus pre-positioned, or registered, when combined with other
material webs. The individual widths of the separated strands and
the collective width of one or more of the consecutive groups of
strands defines the spacing between the separated strands. That
spacing, together with strand width, corresponds to dimensions and
other design attributes of finished devices or the objects which
make up finished devices.
[0025] The present invention further teaches, depicts, enables,
illustrates, describes and claims new, useful, and non-obvious
apparatus for dilating external tissue. The present invention
builds upon the prior art and addresses unmet needs in the art. The
nasal dilator of the present invention comprises an engagement
element, a functional element, and a directional element. The
functional element of the dilator comprises resilient means
including at least one resilient member extending along its length
and which provides the spring biasing force of the device. In use,
the engagement element affixes the dilator to the nose of a user
through engagement means. The directional element affects, alters,
directs or redirects the spring biasing properties of the dilator
so as to increase its overall efficacy, useful duration, comfort,
and ease of use.
[0026] Nasal dilators of the present invention comprise a laminate
of vertically stacked material layers which form the dilator as a
unitary, single body truss. Dilator layers are formed in whole or
part from elongated material webs, elongated strands, material
laminates or laminate strands. Dilator layers are preferably
secured to one another by an adhesive substance disposed on at
least portions of at least one flat surface side of at least one
layer, and the resulting laminate forms a unitary, or single body,
truss. Each layer includes one or more members, and a member may
further include one or more components. Each of the engagement,
functional, and directional elements is defined by at least a
portion of at least one layer of the device.
[0027] The single body truss comprises horizontal regions,
including first and second end regions adapted to engage outer wall
tissues of first and second nasal passages, respectively, and an
intermediate region adapted to traverse a portion of a nose located
between the first and second nasal passages and joining the end
regions. The truss is capable of resilient deformation such that
when flexed it returns substantially to its pre-flexed state. In
use the dilator stabilizes nasal outer wall tissues, and may
further expand or dilate the nasal outer walls to prevent tissues
thereof from drawing inward during breathing. The truss is
configured to be comfortable on the skin surfaces engaged and to be
easily removed with little or no stress thereto.
[0028] It is the principal objective of the present invention to
provide novel methods of converting elongated flexible material
webs so as to reduce manufacturing cost, to return a greater number
of finished devices or parts thereof per a given quantity of
material and to minimize the percentage of material discarded as
waste. A more specific objective of the present invention is to
fabricate at least portions of finished medical devices or portions
thereof on common longitudinal lines in a continuous repeating
process. A further objective of the present invention is to provide
novel nasal dilator devices having complex functional element
structures, manufactured using novel, and non-obvious methods
having greater efficiency and economy than traditional methods.
[0029] It will be apparent to the skilled person in the art of
medical device design or converting that the manufacturing methods
of the present invention rely on well established rotary techniques
for winding, unwinding, slitting, peeling, separating, laminating,
etc., and the die cutting or punching of material webs using rotary
or flat-bed machinery. It is understood that fluid or pneumatic
modular automation for material feed or handling, including
components and systems, and electronic or computerized controls may
also be applicable.
[0030] The present invention is not limited to the illustrated or
described embodiments as these are intended to assist the reader in
understanding the subject matter of the invention. The preferred
embodiments are examples of forms of the invention comprehended by
that which is taught, enabled, described, illustrated and claimed
herein. All structures and methods which embody similar
functionality are intended to be covered hereby. The manufacturing
methods depicted, taught, enabled and disclosed herein, while
particularly suitable for dilator devices, may be applied to a
range of medical devices. The nasal dilators depicted, taught,
enabled and disclosed herein represent families of new, useful and
non-obvious devices having a variety of alternate embodiments.
Dilator elements, layers, members, components, materials, or
regions may be of differing size, area, thickness, length, width or
shape than that illustrated or described while still remaining
within the purview and scope of the present invention. The
preferred embodiments include, without limitation, the following
numbered discrete forms of the invention, as more fully described
below.
[0031] Some embodiments of the present invention are arranged in
groups so as to illustrate manufacturing steps. Each group builds
upon the previous by introducing a new or subsequent element,
technique, or variation thereof. Accordingly, later embodiments
frequently refer to, or cross reference, previous embodiments. It
will be obvious to the skilled person in the art that techniques,
methods, processes, etc., may be applied, interchanged or combined
from one embodiment or group thereof to another. The width of
material webs in the drawings are generally shown only wide enough
to illustrate the subject at hand. In practice, said widths may be
generally greater, and in some cases lesser. The longitudinal
extents of material webs are shown fragmentary.
[0032] For descriptive clarity, certain terms are used consistently
in the specification and claims: Vertical refers to a direction
parallel to thickness, such as the thickness of a finished device,
a material web, material layers, or a material laminate. Horizontal
refers to the length of a finished device or a direction parallel
thereto. Lateral refers to width, such as that of a finished device
or a material web, and to a direction parallel to the cross
direction (XD) of a material web. Longitudinal refers to length,
such as that of a finished device, or the length or machine
direction (MD) of a material web, or a direction perpendicular to
width or lateral extent. A longitudinal centerline is consistent
with the long axis of a finished device or material web, bisecting
its width midway between the long edges. A lateral centerline
bisects the long edges of a finished device or material web midway
along its length, and is perpendicular to the longitudinal
centerline. An object or objects referred to as adjacent or
consecutive another generally means laterally, consistent with the
width of a finished device or a material web. Objects referred to
as successive are generally oriented lengthwise, end to end,
parallel to the machine direction (MD) of a material web.
[0033] Broken or dashed lines are used in the drawings to aid in
describing relationships or circumstances with regard to objects. A
dash followed by three short spaces with two short dashes
therebetween indicates separation for illustrative purposes, such
as in an exploded view, or to indicate an object or objects removed
or separated from one or more other objects for clarity, or as the
result of a process or method. A line of successive short dashes
with short spaces therebetween may indicate a hidden object, such
as one underneath another; or for clarity, to illustrate a
location, such as the space an object will occupy, would occupy, or
did occupy; or for illustrative purposes, to indicate an object as
`invisible` so that objects underneath it may be seen. A long dash
followed by a short space, a short dash and another short space is
used to call out a centerline or an angle, or to indicate
alignment; when accompanied by a bracket, to call out a section,
segment or portion of an object or a group of objects, or to
illustrate a spatial relationship between one or more objects or
groups of objects.
[0034] In the drawings which accompany this disclosure, like
objects are generally referred to with common reference numerals,
except where variations of an object must be distinguished from one
another. In describing manufacturing methods, Machine Direction is
indicated in the drawings by the letters `MD` adjacent a
directional arrow: a single arrowhead indicates preferred
direction; a double arrowhead indicates flow may be in either
direction. Drawings are not rendered to scale, and where shown, the
thickness of objects is generally exaggerated for illustrative
clarity.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0035] FIG. 1 is a perspective view of a portion of a face with a
nasal dilator in accordance with the present invention engaged to
the nose.
[0036] FIG. 2 is an exploded perspective view of the nasal dilator
of FIG. 1.
[0037] FIG. 3 is a perspective view of the nasal dilator of FIG.
2.
[0038] FIG. 4 is a plan view of a pair of the nasal dilator of FIG.
3 including fragmentary portions of where successive dilator units
may be included therebetween.
[0039] FIG. 5a is a fragmentary plan view of a resilient layer
material web illustrating the initial step of a first form of
manufacturing method in accordance with the present invention.
[0040] FIGS. 5b-5d are fragmentary perspective views illustrating
subsequent and final manufacturing steps to the first form of
manufacturing method.
[0041] FIGS. 6a-6c are fragmentary perspective views illustrating
alternative steps to those of FIGS. 5b-5d.
[0042] FIG. 7 is an exploded perspective view of a variation of the
dilator of FIGS. 1-4, produced from the alternative steps
illustrated in FIGS. 6a-6c.
[0043] FIG. 8 is a plan view of the nasal dilator of FIG. 7.
[0044] FIGS. 9a-9c are fragmentary exploded perspective views
illustrating the initial steps of a second form of manufacturing
method in accordance with the present invention.
[0045] FIGS. 9d-9e are fragmentary plan views illustrating the
final steps of the second form of manufacturing method.
[0046] FIG. 10 is an exploded perspective view of a second form of
nasal dilator embodying features of the present invention, produced
from the second form of manufacturing method.
[0047] FIG. 11 is an exploded perspective view of a variation of
the second form of nasal dilator produced from the method of FIGS.
12 and 13.
[0048] FIG. 12 is an exploded fragmentary perspective view
illustrating the initial steps of a variation to the second form of
manufacturing method illustrated in FIGS. 9a-9e.
[0049] FIG. 13 is a fragmentary plan view illustrating the final
steps of the variation to the second form of manufacturing method
illustrated in FIG. 12.
[0050] FIG. 14 is an exploded perspective view illustrating a third
form of dilator device in accordance with the present invention
produced from a manufacturing method described with regard to FIGS.
15a-15g.
[0051] FIG. 15a is a fragmentary perspective view illustrating the
initial steps of a third form of manufacturing method in accordance
with the present invention whereby to manufacture the dilator of
FIG. 14.
[0052] FIG. 15b is an exploded fragmentary perspective view
illustrating intermediate steps of the third form of manufacturing
method.
[0053] FIGS. 15c-15f are fragmentary plan views illustrating
subsequent intermediate steps of the third form of manufacturing
method.
[0054] FIG. 15g is an exploded fragmentary perspective view
illustrating the final steps of the third form of manufacturing
method.
[0055] FIG. 16 is a fragmentary plan view illustrating an overview
of a fourth form of manufacturing method in accordance with the
present invention.
[0056] FIG. 17a is a fragmentary plan view illustrating the initial
steps of the fourth form of manufacturing method.
[0057] FIG. 17b-17d are fragmentary perspective views illustrating
the intermediate and final steps of the fourth form of
manufacturing method.
[0058] FIG. 18 is an exploded perspective view of a fourth form of
nasal dilator in accordance with the present invention, produced
from the method of FIGS. 16-17d.
[0059] FIG. 19 is a plan view of the nasal dilator of FIG. 18.
[0060] FIG. 20 is an exploded perspective view of a variation of
the fourth form of nasal dilator.
[0061] FIG. 21 is a plan view of the nasal dilator of FIG. 20.
[0062] FIG. 22 is an exploded perspective view of a fifth form of
nasal dilator in accordance with the present invention, produced as
complementary device from the method of FIGS. 23a-23d.
[0063] FIG. 23a is a fragmentary plan view illustrating an overview
of a fifth form of manufacturing method in accordance with the
present invention.
[0064] FIG. 23b is an exploded fragmentary perspective view
illustrating the separation of elongated material strands into two
groups as an optional initial step of the fifth form of
manufacturing method.
[0065] FIGS. 23c-23d are exploded fragmentary perspective views
illustrating the initial steps of the fifth form of manufacturing
method.
[0066] FIGS. 23e-23f are fragmentary plan views illustrating the
final steps of the fifth form of manufacturing method.
[0067] FIG. 24a is a fragmentary plan view illustrating an
alternative to the initial steps of the fifth form of manufacturing
method.
[0068] FIG. 24b is an exploded fragmentary perspective view
illustrating elongated material strands from FIG. 24a separated
into two groups.
[0069] FIG. 25a is a fragmentary plan view illustrating an overview
of a first variation of the fifth form of manufacturing method.
[0070] FIG. 25b is an exploded fragmentary perspective view
illustrating the separation of elongated material strands of FIG.
25a into two groups.
[0071] FIG. 26 is a plan view of a sixth form of nasal dilator in
accordance with the present invention, produced from the method of
FIGS. 25a and 25b.
[0072] FIG. 27 is a fragmentary plan view illustrating an overview
of a second variation of the fifth form of manufacturing
method.
[0073] FIG. 28 is a fragmentary plan view illustrating a
relationship between seventh and eighth forms of nasal dilator
devices in accordance with the present invention, produced from the
manufacturing method of FIG. 27.
[0074] FIG. 29 is a fragmentary plan view illustrating a
relationship between ninth and seventh forms of nasal dilator
devices in accordance with the present invention, produced from the
manufacturing method of FIG. 27.
[0075] FIG. 30 is a fragmentary plan view illustrating an
arrangement of material webs to facilitate optional steps of the
second variation, shown in FIG. 27, to the fifth form of
manufacturing method.
[0076] FIGS. 31a and 31b are fragmentary plan views illustrating
the subsequent steps of the optional steps begun in FIG. 30.
[0077] FIG. 32 is fragmentary plan view of a tenth form of nasal
dilator in accordance with the present invention, produced from the
optional steps described with regard to FIGS. 30-31b.
[0078] FIG. 33 is a fragmentary plan view illustrating an overview
of a third variation of the fifth form of manufacturing method,
including an eleventh form nasal dilator in accordance with the
present invention produced therefrom.
[0079] FIG. 34 is a fragmentary plan view illustrating initial
steps of the third variation of method described with respect to
FIG. 33 whereby to produce the eleventh form of dilator device.
[0080] FIG. 35 is a fragmentary plan view illustrating subsequent
steps of the third variation of method described with respect to
FIG. 33 whereby to produce the eleventh form of dilator device.
[0081] FIG. 36 is a fragmentary plan view illustrating initial
steps involved in the third variation of method of FIG. 33 whereby
to produce complementary dilator devices.
[0082] FIG. 37 is a fragmentary plan view illustrating subsequent
steps involved in the third variation of method of FIG. 33 whereby
to produce a complementary dilator device.
[0083] FIG. 38 is a plan view illustrating two versions of a
twelfth form of nasal dilator in accordance with the present
invention, produced as complementary devices from the third
variation of method illustrated with respect to FIGS. 36 and
37.
[0084] FIG. 39 is an exploded perspective view of the eleventh form
of nasal dilator produced from the variation of method described
with regard to FIGS. 33-35.
[0085] FIG. 40 is a plan view illustrating a comparison of
resilient member structures.
[0086] FIG. 41 is a fragmentary plan view illustrating an initial
step of a sixth form of manufacturing method in accordance with the
present invention, based on the methods of FIGS. 5a, 9a-9b, and
23a, and on the comparison of resilient bands shown in FIG. 40.
[0087] FIGS. 42a and 42b are fragmentary plan views illustrating an
overview of a first set of subsequent steps to the sixth form of
manufacturing method.
[0088] FIG. 43 is a fragmentary plan view illustrating an overview
of a second set of subsequent steps to the sixth form of
manufacturing method.
[0089] FIG. 44 is a plan view of a thirteenth form of nasal dilator
in accordance with the present invention, produced from the method
described with regard to FIGS. 41-42b.
[0090] FIG. 45 is a plan view of a common form of nasal dilator,
produced as a second, complementary, device from the method
described with regard to FIGS. 41-42a.
[0091] FIG. 46 is a plan view of a fourteenth form of nasal dilator
in accordance with the present invention, produced from the method
described with regard to FIGS. 41 and 43.
[0092] FIG. 47 is a fragmentary plan view illustrating an overview
of initial steps to a variation of the sixth form of manufacturing
method whereby to produce arcuately shaped dilator devices.
[0093] FIG. 48 is a fragmentary plan view illustrating subsequent
steps to the variation of the sixth form of manufacturing method
whereby to produce arcuately shaped dilator devices.
[0094] FIG. 49 is a plan view of an alternative form of the nasal
dilator of FIGS. 26 and 47, produced from the method described with
regard to FIG. 48.
[0095] FIGS. 50a-50c are fragmentary plan views illustrating a
seventh form of manufacturing method in accordance with the present
invention for producing arcuately shaped devices.
[0096] FIG. 51 is a plan view of a fifteenth form of nasal dilator
in accordance with the present invention produced from the material
laminate shown in FIG. 50a.
[0097] FIG. 52 is a plan view of a sixteenth form of nasal dilator
in accordance with the present invention produced from the upper of
two material laminates shown in FIG. 50b.
[0098] FIG. 53 is a plan view of a variation of the nasal dilator
seen in FIG. 28, produced from the lower of two material laminates
shown in FIG. 50b.
[0099] FIG. 54 is a plan view of a four-band version of the nasal
dilators seen in FIGS. 51 and 52, produced from the material
laminate shown in FIG. 50c.
[0100] FIG. 55 is a fragmentary plan view illustrating an overview
of an eighth form of manufacturing method in accordance with the
present invention whereby to produce arcuate-like dilator devices
along common lines corresponding to their upper long edges.
[0101] FIG. 56 is a plan view of a seventeenth form of nasal
dilator in accordance with the present invention produced from the
method described with regard to FIG. 57.
[0102] FIG. 57 is a fragmentary plan view illustrating a variation
of the manufacturing methods shown in FIGS. 5b-5c and 50a, whereby
to produce arcuately shaped dilator devices on common longitudinal
lines.
DETAILED DESCRIPTION OF THE INVENTION
[0103] An embodiment of a nasal dilator, 10, in accordance with the
present invention is illustrated in FIG. 1. Seen in use, dilator 10
is affixed by its engagement element to a nose, 11, illustrated as
a portion of a human face. Dilator 10 includes a directional
element in the form of a horizontal protrusion, 12, which separates
slightly from the skin thereat as a result of the device's
functional element applying spring biasing forces to the nasal wall
tissues when dilator 10 is flexed across the bridge of the
nose.
[0104] FIG. 2 shows that dilator 10 comprises a laminate of
vertically stacked layers, indicated by a broken line, v, the
layers including: a base layer comprising at least one base member,
14, a resilient layer comprising at least one resilient member, 22,
and a cover layer comprising at least one cover member, 18. A base,
resilient or cover member may further include one or more
components as part thereof. Portions of one layer may overlap
another layer. A protective layer of release paper, 15, removably
covers exposed adhesive from any other layer preliminary to using
the dilator. The shape and dimensions of release paper 15 may
correspond to the periphery of dilator 10 or may exceed the
periphery of one or more dilators 10. Release paper 15 may be
bisected into two parts, which may overlap or abut, so as to
facilitate removal from the dilator prior to use. Dilator layers
may be secured to each other by any suitable means such as
stitching or fastening, heat or pressure bonding, ultrasonic
welding, or the like, but are preferably laminated by an adhesive
substance disposed on at least one flat surface side of at least
one layer. At least a portion of one flat surface of the base or
cover layer is preferably laminated to one of two flat surfaces of
the resilient layer. Dilator layers are preferably aligned along a
longitudinal centerline, a, shown by a broken line.
[0105] The peripheral dimensions of dilator 10 are defined by the
cover layer, but may also be defined by the base layer, or a
combination of layers or portions thereof. The base and cover
layers may have the same dimension or peripheral shape as each
other, or the base and resilient layers may be identical, or all
three layers may have different peripheral dimensions. The base and
cover layers of dilator 10 may be interchanged, or one or the other
may be eliminated in whole or in part.
[0106] All or part of the base and cover layers, either separately
or combined, together with a biocompatible adhesive thereon for
affixing dilator 10 to the skin, provide the primary engagement
element of dilator 10. Adhesive may also be used on the functional
element, should it contact the skin directly, to thus aid
engagement of the device to the skin. The engagement element, by
itself, does not provide nasal dilation, although depending on the
material used, could provide some tissue stabilization. The
functional element, by itself and affixed to the skin by adhesive,
will not generally remain engaged thereto. Accordingly, nasal
dilators of the present invention combine separate functional and
engagement elements in a single body device.
[0107] Where the base layer has a significantly lesser surface area
than the cover layer, adhesive on the skin-engaging side of the
base layer may be optionally eliminated. With or without adhesive,
the base layer may also serve as a compressible buffer between the
device and the skin, as has been historically common in medical
devices which remain in contact with the skin for any length of
time. Dilators of the present invention are designed so that no
portion of a layer extends substantially onto the skin surface
areas of the cheek.
[0108] The preferred material for the base and cover layers is from
a group of widely available medical grade flexible nonwoven
synthetic fabrics that are breathable and comfortable on the skin.
Any suitable fabric or thermoplastic film, including various clear
films, may be used. A pressure sensitive adhesive, biocompatible
with external human tissue, is preferably disposed on at least one
flat surface side of the material. A protective layer of release
paper liner covers the adhesive. The preferred materials are
typically available in rolls wound in the machine direction (MD) or
warp, which is perpendicular to the cross direction (XD) or fill,
of the material. The manufacturing methods of the present invention
have the base and cover layers fabricated parallel to the machine
direction of the material, but they may be fabricated parallel to
either the warp or fill of the material.
[0109] The preferred material for the resilient layer is a widely
available biaxially oriented polyester resin (PET), a thermoplastic
film having suitable spring biasing properties across both its warp
and fill. PET is used in a number of medical device applications
and is particularly suitable for nasal dilator devices. The film
may have a pressure sensitive adhesive disposed on one or both
surfaces with a protective layer of release paper liner covering
the adhesive. PET may be laminated to the preferred base layer
material, from the adhesive side thereof to the non-adhesive side
of the base layer material, so that the resilient and base layers
of dilator 10 may be fabricated simultaneously to the same
peripheral shape.
[0110] The functional element of dilator 10 is configured to
provide spring return biasing force within a suitable range as
described hereinbefore. Spring biasing force is generated from the
resilient layer of dilator 10, the amount of which is determined by
configuration of the resilient member or members, and the length,
width and thickness thereof. The resilient layer preferably has an
adhesive substance disposed on at least a portion of at least one
of two opposite flat surface sides for engaging or laminating it to
other layers, members or components of dilator 10, or for adhering
to the nasal outer wall tissues. FIG. 2 shows resilient member 22
having terminal end portions, 23, which align with a portion of the
end edges of dilator 10, conforming substantially to protrusion 12
as shown in FIGS. 1, 3 and 4.
[0111] FIGS. 3 and 4 show that the layers of dilator 10 form a
unitary, or single body, truss, 30, having a horizontal length, or
longitudinal extent, c, indicated by a bracket. Truss 30 has
contiguous regions indicated approximately by broken lines and
brackets, including a first end region, 32, a second end region,
34, and an intermediate region, 36, which joins first end region 32
to second end region 34. The width of intermediate region 36 is
preferably narrower than the width of end regions 32 and 34.
Portions of any layer may define a region of the truss or a portion
thereof. The layers, members or components of dilator 10 may extend
from one region to another. End regions 32 and 34 are adapted to
engage outer wall tissues of the first and second nasal passages
respectively. Each end region has an end edge, 33.
[0112] Dilator 10 may further include a directional element through
configuration or modification to its layers or to the material webs
from which the layers are fabricated. A directional element may be
formed by cuts, notches, openings, or the like, to create a
discontinuity of shape of material, a material separation, or a
protrusion. A material separation may be formed in a dilator layer
or a corresponding material web in the course of fabricating a
layer, or formed in a material laminate, or formed as dilator 10 or
its layers are die cut from a material laminate. End edge 33
includes a directional element in the form of a material
separation, 13, formed as a back cut extending inward from each end
edge 33 and positioned between one long edge of terminal end
portion 23 and the corresponding upper or lower tab extension, 35,
adjacent thereto. Material separations 13 and terminal end portion
23 together define protrusion 12 at end regions 32 and 34 of truss
30. Tab extensions 35 preferably extend horizontally beyond
protrusion 12.
[0113] As a directional element defined by material separations 13,
protrusion 12 separates slightly from the skin when dilator 10 is
engaged to nose 11, as illustrated previously in FIG. 1. Material
separations 13 allow a change in the angle of focused spring
biasing forces, at least in part, and thus shifts or transforms at
least some of these forces from primarily peel and tensile forces
into primarily shear forces. Said change in angle further
redistributes or imparts said transformed forces to tissue engaging
surface areas of the end regions, such as tab extensions 35,
extending beyond the material separation. Spring biasing forces are
thus imparted to the lateral width and longitudinal extent of end
regions 32 and 34, as opposed to a greater delaminating tendency,
such as that from peel forces, being imparted to a lesser extent.
Shear forces are more easily withstood by the tissue engaging
adhesives disposed on the engagement element of dilator 10 than are
peel forces.
[0114] A directional element may also be formed in the resilient
layer by: varying the dimensions of the resilient layer or a member
or component thereof, such as by forming a gradiently tapered
width; by the peripheral shape of the resilient member or divergent
components extending therefrom; or by utilizing a plurality of
resilient members, including resilient members of different
thickness or width, with each contributing, to differing degrees, a
portion of the total spring biasing force of dilator 10. Multiple
resilient members of different widths and thickness affect, or
direct, the functional element relative to the dilator's overall
peripheral dimensions, the dimensions of the resilient layer, and
the total number of resilient member bands. Multiple resilient
bands of varied width or thickness also allow greater versatility
and precision in achieving a desired spring biasing force,
particularly where three or more resilient bands are used.
[0115] As seen in FIG. 4, the truss is symmetric on both sides of
its lateral centerline, b, and symmetric on both sides of its
longitudinal centerline a, both sides being the mirror image of the
other. The upper and lower dilators 10 shown in FIG. 4 are
laterally spaced apart, as indicated by a bracket, d, extending
between their respective centerlines a. That amount of lateral
spacing is typical in nasal dilator converting, as discussed
hereinbefore, where material from which finished devices or device
elements are fabricated is also used as a matrix by which to space
finished devices apart.
[0116] A bracket and broken lines indicates an example of the
dynamic relationship between device design and manufacturing method
in the present invention: devices are fabricated to be staggered
lengthwise so that portions of long edges corresponding
approximately to the end regions thereof are fabricated on common
die cut lines. Additionally, the device is configured so that two
opposing end regions of two successive device peripheries fit into
the space between, and substantially on common lines with, the long
edges of the device extending between opposite tab extensions 35.
Embodiments of the present invention disclose means for fabricating
medical devices on common lines or otherwise in close proximity,
followed by means to space rows of finished devices apart to
facilitate the packaging thereof. FIG. 4 illustrates how material
extending between what would otherwise be laterally spaced devices
can be utilized in device construction so as to gain manufacturing
efficiency.
[0117] FIGS. 5a-5d illustrate a first manufacturing method in
accordance with the present invention, applicable to a variety of
medical devices, but particularly suited to a dilator device as
seen in FIG. 4. FIG. 5a shows a plurality of a continuous slit, 25,
formed in an elongated web of resilient layer film, 24, spaced
across the width thereof. Slits 25 form a plurality of an elongated
resilient layer strand, 26. Strands 26 are laterally contiguous, as
shown by a bracket, d, their long edges formed on common
longitudinal lines. Continuous slits 25 extend vertically through
resilient layer film 24 and parallel to the machine direction
thereof. Slits 25 are straight, and strands 26 are shown uniform in
width.
[0118] Each strand 26 effectively consists of a successive
plurality of interconnected resilient members. The width of strand
26 is configured to form resilient members having suitable spring
biasing properties when cut to finished length, but also configured
so that a predetermined number of laterally contiguous strands 26
have a predetermined collective width. In the present instance,
resilient layer film 24 includes a base layer material laminated
thereto, so strands 26 also consist of a plurality of
interconnected base layer members. The base layer of finished
dilators 10 will thus have the same dimension as the resilient
layer. Accordingly, an adhesive substance is not required on the
exposed side of the base layer material opposite resilient layer
film 24, since the cover layer of the finished dilator device may
adequately serve as the engagement element.
[0119] As seen in FIG. 5b, a plurality of an abbreviated slit,
undercut 38, is formed at intervals in a separate elongated web of
release paper liner, 41. Each undercut 38 is positioned to
correspond approximately to the lateral centerline of where a
finished dilator will be die cut. Three adjacent, laterally
contiguous resilient layer strands 26 form a group, 29, as
indicated by broken lines and brackets. While maintaining position
relative to the other strands, one strand 26 from each group 29 is
separated from resilient layer film 24 and combined with paper
liner 41 and an elongated web of cover layer material, 44 to form
an elongated material laminate, 40.
[0120] Predetermined strands 26 are registered in a lateral, spaced
apart, relationship across the width of material laminate 40, the
intervals determined by the width of group 29. Cover layer material
44 is laminated by its adhesive side onto separated resilient layer
strands 26 and separate release paper liner 41. The remaining
strands from repeating groups 29, illustrated by dashed lines, are
in position to be separated onto paper liners and the process
repeated.
[0121] The skilled converter will see that if the base layer
material laminated to resilient layer film 24 includes an adhesive
layer on the opposite side thereof, the protective release paper
liner which covers it must be handled in one of two ways: If slits
25 extend through the paper liner, then respective portions thereof
are removed from each of the strands 26 as they are layered onto
separate paper liner 41. In this way strands 26 not so separated
may be rewound for later processing with their respective paper
liners intact. Alternatively, slits 25 may extend through resilient
layer film 24 to, but not through, the paper liner (i.e., a kiss
cut technique), in which case strands 26 are peeled therefrom and
directly onto separate paper liner 41.
[0122] Dilator devices of the present invention are manufactured
lengthwise, parallel to the machine direction of the materials. To
continue the present method, FIG. 5c shows a plurality of a
continuous slit, 45, extending vertically through laminate 40 and
longitudinally along the machine direction thereof, diverging
laterally in a repeating pattern without intersecting the outside
long edges of laminate 40 or an adjacent slit 45. Two adjacent
slits 45 extend along opposite long edges of each resilient layer
strand 26, preferably spaced equidistant therefrom. Slit 45
adjacent each long edge of laminate 40 together form an outside
waste strand, 47.
[0123] Each slit 45 forms the respective long edges of
longitudinally staggered and laterally adjacent finished dilator
devices. Cross slits, 48, bisect material laminate 40 at prescribed
intervals between adjacent slits 45 to form dilator end edges.
Cross slits 48 sever strands 26 to form resilient members 22,
protrusions 12, terminal end portions 23 and material separations
13. Continuous slits 45 and cross slits 48 may be formed
simultaneously. Cross slits 48 should not cut into the resilient
layer strand at material separations 13. End edges 33 could be of a
simpler configuration so as to increase the margin of error in this
regard. (Less preferable, a single cross slit 48 could be used
instead of two, thus forming opposite end edges 33 of two
successive finished dilators on a common die cut line.)
[0124] As seen more clearly in FIG. 5d, continuous slits 45 and
cross slits 48 separate material laminate 40 into a plurality of
loose finished dilator units, waste pieces, 49, and waste strands
47 (all of which are shown slightly separated for visual clarity).
Adjacent dilators 10 are formed laterally contiguous where their
long edges abut, as previously illustrated in FIG. 4. The lateral
spacing of resilient layer strands 26, determined by the individual
and collective widths thereof, also defines parameters for the
width of finished dilator devices and the lateral spacing of slits
45. Waste pieces 49 are preferably punched through laminate 40 and
collected, while waste strands 47 may be re-wound. The resultant
plurality of finished individual nasal dilators 10 are then
captured in bulk.
[0125] FIGS. 6a-6c illustrate alternative steps to those
illustrated in FIGS. 5c and 5d. FIG. 6a shows resilient layer
strands 26 separated from groups 29 and incorporated into material
laminate 40 as before. In this instance, however, the resilient
layer film from which resilient layer strands 26 are slit does not
include a base layer material laminated thereto, but preferably
does include an adhesive layer on one side.
[0126] Strands 26 are combined with elongated webs of base layer
material, 42, and cover layer material 44, illustrated by dashed
lines, to form material laminate 40. Base layer material 42 has an
adhesive substance disposed on what will be the skin-engaging side,
protected by a paper liner. Enclosed die cut lines, 52, represented
by dashed lines in FIGS. 6a and 6b, form finished dilator units as
more particularly illustrated in FIG. 6c. Undercut 38, illustrated
by dashed lines, may be formed in the paper liner of base layer
material 42 in advance, or concurrent with the formation of die cut
lines 52.
[0127] FIG. 6b illustrates that continuous slits 45 divide material
laminate 40 into a plurality of adjacent, laterally contiguous,
laminate strands, 46. For illustrative clarity, laminate strands 46
are shown slightly separated from each other in the drawing figure.
Each slit 45 also defines long edges, 45', of two laterally
adjacent laminate strands 46. Slit 45 adjacent each outside long
edge of laminate 40 defines one long edge of a laminate strand 46,
and together with the long edge of laminate 40 forms outside waste
strand 47.
[0128] FIG. 6c shows every other laminate strand 46, while
maintaining its position by the width of the strand 46
therebetween, represented by dashed lines, is separated from
laminate 40 and layered an elongated or continuous packaging
material web, 60a, to form a fabrication matrix, 50. The remaining
laminate strands 46, having the same lateral spacing therebetween,
are positioned to be layered onto a packaging material web as
well.
[0129] FIG. 6c further illustrates that enclosed die cut lines 52
form finished dilators in cookie-cutter fashion within the
perimeter of laminate strand 46 at prescribed intervals along the
length thereof. Die cut lines 52 extend vertically through laminate
strand 46, to, but not through, packaging web 60a. The skilled
converter will note that, generally, either of two packaging
material webs may form the foundation of fabrication matrix 50 to
which finished devices are kiss cut, and that cutting may extend
vertically through material laminate 40 from either side, as
dictated by preference or machine setup.
[0130] Die cut lines 52 sever resilient layer strands 26 into
resilient members 22, and form end edges 33, protrusions 12,
terminal end portions 23 and material separations 13 of dilator 10
as described previously. Material from around and between die cut
lines 52 extending to the opposite long edges 45' of laminate
strand 46 is removed as a continuous waste matrix, 53, leaving a
plurality of spaced apart finished dilators on packaging web 60a.
Separating every other laminate strand 46 creates lateral spacing
between finished devices so that the second of two packaging webs,
60b, may form an adequate perimeter seal with packaging web 60a
around and between dilators 10, encapsulating them therebetween.
Packaging webs may be of any suitable material, such as paper or
thermoplastic film, and may be sealed by adhesive, heat bonding,
compression, or the like. The sealed packaging webs may be cut,
slit, perforated or scored between one or more individual dilators
10 as a means to segment dilators individually or into groups.
[0131] The preceding method of fabricating dilator 10 incurs more
waste material, in the form of matrix 53, than that shown in FIG.
5d. However, the advantage is that finished devices are packaged in
the same operation as that from which they are fabricated, with
minimal increase in converting cost. FIGS. 7 and 8 more
particularly illustrate the finished dilator device. The base layer
of dilator 10 has the same periphery as the cover layer. Its
bowtie-like shape places progressively more tissue-engaging surface
area along the lateral and longitudinal extents of each end region
of the truss, similar to the dilator of FIGS. 2-4. Dilator 10
further features a rectangular resilient member 22 having material
separations 13 and protrusions 12 as described hereinbefore.
[0132] FIGS. 9a-9e illustrate a second form of manufacturing
method, in accordance with the present invention, applicable to a
variety of medical devices, but particularly suited to a dilator
device as seen in FIG. 10. In FIG. 9a a plurality of continuous
slits 45 in base layer material 42 form adjacent, laterally
contiguous base layer strands, 43. Continuous slits 45 extend
longitudinally along the machine direction of base layer material
42, and extend vertically to the paper liner, 42', on one side
thereof. Slits 45 diverge laterally in a repeating pattern without
intersecting the outside long edges or an adjacent slit 45. Slit 45
adjacent each long edge of base layer material 42 together form
outside waste strand 47. Strands 43 effectively consists of a
successive plurality of interconnected base members. Strands 43 are
configured to form base members to design criteria suitable to the
finished device, and also configured to have a predetermined
collective width which facilitates alignment to a plurality of
resilient layer strands.
[0133] As further seen in FIG. 9a, three adjacent pairs of
resilient layer strands 26 form group 29. Strands 26 are slit from
resilient layer film substantially as described hereinbefore, with
the exception that three waste strands (not shown) are formed and
discarded to create a narrow space in between the long edges of
each pair of the six strands in each group 29. The resilient layer
film preferably has an adhesive substance disposed on one side, and
thus strands 26 are laminated to one side of base layer strands 43.
The width of strand 26 is configured so as to have suitable spring
biasing properties when cut to finished length, and also configured
so that group 29 has a collective width such that one pair of
resilient layer strands 26 from each group 29 align to the
longitudinal centerlines of every other base layer strand 43.
[0134] Configuring elongated strands to different widths and from
separate material webs to meet required device design criteria,
then aligning the strands to each other, may require adjustments to
the alignment process. In this instance, FIG. 9a shows that only
one pair of strands 26 at a time, from each group 29, align to
respective centerlines of base layer strands 43. Groups 29,
collectively, as a unit, must then be shifted laterally so that the
second of three pairs of strands 26 align to the longitudinal
centerlines of the remaining base layer strands 43, as more clearly
seen in FIG. 9b. The second of pairs of strands 26 are combined
thereon as just described. The third, leftover, three pairs of
strands 26 may be recoiled, or may follow the previous strands onto
the base layer material, or may be combined with a subsequent base
layer material web. The skilled converter will see that this 3:2
ratio of strands (three pairs of strands 26 to two adjacent strands
43), respectively, is constant regardless of the width of base
layer material 42 or the total number of elongated strands.
[0135] As further seen in FIG. 9b, every other base layer strand
43, including the pair of resilient layer strands 26 aligned
thereon, is separated from paper liner 42', as indicated by broken
lines, and layered onto a separate release paper liner 41. Both
first and second sets of paired strands 26 from groups 29 may be
aligned to base layer strands 43 before separating combined strands
onto paper liner 41, as described, or alternatively, the first set
of paired strands 26 may be combined with strands 43 and removed
onto paper liner 41 before proceeding to the second set.
Regardless, all of the combined strands 26 and 43 maintain lateral
spacing therebetween.
[0136] The preceding steps apply whether or not base layer material
42 includes an adhesive layer thereon, covered by paper liner 42'.
In the event base layer material 42 does not include adhesive,
first and second sets of resilient layer strands 26 may be
laminated to base layer material 42 before forming base layer
strands 43 (it being understood that the cutting knife height be
sufficient to accommodate the thickness of strands 26). Strands 26
will inhibit any inadvertent stretching of the base layer strands
43 as combined strands 26 and 43 are removed onto separate release
paper liner 41. In the event base layer material 42 includes an
adhesive layer, slits 45 may alternatively extend through paper
liner 42', in which case each base layer strand 43 would have the
paper liner portion removed as the combined strands 26 and 43 are
layered onto separate paper liner 41.
[0137] Concurrent with separating combined strands 26 and 43 onto
separate release paper liner 41, FIG. 9c, shows two webs of
elongated cover layer material 44 laminated by their adhesive sides
to exposed surfaces of resilient layer strands 26, base layer
strands 43 and paper liners 41 and 42' to form two material
laminates 40. At this point, paper liner 42' is effectively the
same as separate release paper liner 41, and for simplicity is
referenced accordingly in the drawing. Combined resilient layer
strands 26 and base layer strands 43 are effectively divided onto
separate paper liners, positioned in a spaced apart relationship.
That spacing is determined by the configuration of base layer
strands 43 and the width of group 29. Each laminate 40 thus
comprises release paper liner 41, base layer strands 43, resilient
layer strands 26, and cover layer material 44. Paper liner 41 is
the foundation of laminate 40, providing the surface against which
dilators 10 are kiss cut, as illustrated in FIGS. 9d and 9e.
[0138] Base layer material 42 generally carries a lower cost per
unit of measure than the resilient layer film, but a greater cost
than cover layer material 44. While it is often expedient to form
the base and cover layer members simultaneously to the same
periphery, the present method forms and separates base layer
strands 43 to create a partial base layer in the finished device,
and thus extending the yield of base layer material 42. The
technique doubles the number of base layer members per unit of
material, with only a modest increase in converting time to
separate base layer strands onto paper liners 41.
[0139] Returning now to FIG. 9d, enclosed die cut lines 52 extend
vertically through material laminate 40 to, but not through,
release paper liner 41 at prescribed intervals to form rows of
successive finished dilator units. Die cut lines 52 are preferably
aligned laterally to the centerlines of base layer strands 43 and
aligned longitudinally to the wider portions thereof, so that said
wider portions correspond substantially to the intermediate region
of finished dilator units.
[0140] FIG. 9e shows continuous waste matrix 53 removed from around
and between die cut lines 52, leaving a plurality of spaced apart
finished dilators 10 releasably secured to release paper liner 41.
Waste matrix 53 is separated as a single matrix by virtue that
cover layer material 44 extends across the width of paper liner 41.
Waste matrix 53 includes greater portions of cover layer material,
extending around and between finished dilators, and lesser portions
of base layer and resilient layer material, extending between
successive finished dilators. (As noted, cover layer material 44
generally carries a lower cost than base layer and resilient layer
materials.) Paper liner 41 may be bisected, as shown in FIG. 9e, or
otherwise slit, perforated or scored between one or more individual
dilators 10 as a means to segment dilators individually or into
groups. The segments may be further encapsulated between packaging
webs, 60b and 60a, as shown in FIG. 10.
[0141] FIG. 10 more particularly illustrates a plurality of
finished dilators 10 releasably secured to a single release paper
15, the periphery of which extends slightly beyond their collective
surface area. Dilator 10 features two parallel resilient members
22, wherein terminal end portions 23 correspond to a single
protrusion 12. Base member 14 has less surface area than the cover
layer, but a greater surface area than the resilient layer, and is
positioned where it contributes most to device efficacy: interposed
between at least the peripheral extent of resilient layer and the
skin surfaces engaged by dilator 10, substantially where the device
contacts the bridge of the nose. This leaves less surface area at
the device end regions and a single material layer at the device
tab extensions, allowing greater moisture vapor transmission from
the skin surfaces thereat which contributes to user comfort.
[0142] A dilator device shown in FIG. 11 also features a base layer
having a periphery greater than the resilient layer and lesser than
the cover layer. Base member 14 is interposed between at least the
peripheral extent of resilient layer and the skin surfaces engaged
by dilator 10, and eliminated from the tab extensions. The dilator
devices of both FIGS. 10 and 11 feature substantially rectangular
resilient members, having material separations 13 adjacent terminal
end portions thereof, together with protrusions 12 as described
hereinbefore.
[0143] FIG. 12 illustrates a variation to the second form of
manufacturing method described with regard to FIGS. 9a-9e, wherein
elongated strands are formed from both base layer and cover layer
material webs. This variation of method is applicable to a variety
of medical devices of which the dilator seen in FIG. 11 is an
example. Continuous slits form laterally contiguous resilient layer
strands 26 and base layer strands 43 from respective material webs
as described hereinbefore. Elongated strips, 44', are slit from
cover layer material 44 and may be divided by every other strip
into two groups. The widths of strands 26 are configured to have
suitable spring biasing properties when cut to finished length, and
the widths of strands 43 and strips 44' meet design requirements
for the base and cover layers of finished dilator devices. Strands
26 and 43 and strips 44' are also configured to individual and
collective widths which facilitate predetermined strands and strips
aligning to each other by their longitudinal centerlines.
[0144] There is a 3:2:1 ratio of three pairs of strands 26 to two
adjacent strands 43 to one strip 44'. The first one of each three
laterally consecutive resilient layer strands 26 align to the
longitudinal centerline of each first of two laterally consecutive
base layer strands 43. Broken lines indicate where every other of
combined strands 26 and 43 are layered onto a separate release
paper liner 41. Cover layer material strips 44' are then layered
onto the combined strands 26 and 43 on each release paper liner 41,
forming respective material laminates. The material laminates
further include a first packaging web 60a to complete respective
fabrication matrices 50. The remaining second and third out of
three resilient layer strands 26 must be shifted laterally, as
described hereinbefore, to re-align to the longitudinal centerlines
of the remaining second of two base layer strands 43 to repeat the
process.
[0145] Strips 44' are configured to encompass the width of a
finished device, and dashed lines represent where die cut lines 52
extend vertically through fabrication matrices 50 to form rows of
successive finished dilators. Die cut lines may extend vertically
through the material laminate from either side, kiss cutting
against either packaging web 60a or 60b, as dictated by the die
cutting machinery. A plurality of undercut 38 is preferably formed
at intervals in paper liner 41, as described hereinbefore.
[0146] Combining strands 26 and 43 and strips 44' by forming,
separating and aligning them onto separate paper liners 41 extends
material yield and creates lateral spacing between the rows
finished devices so packaging material webs 60a and 60b form an
adequate perimeter seal. FIG. 13 shows waste matrix 53 removed from
fabrication matrix 50 (the fabrication matrices are identical, only
one is shown), leaving a plurality of finished dilator units on
packaging web 60a to be sealed with packaging web 60b. Waste matrix
53 consists primarily of paper, and is separated as a single matrix
by virtue that release paper liner 41 extends across the width of
fabrication matrix 50. The cost of paper liner 41 and packaging
material webs 60a and 60b is considerably lower per unit of measure
than the base, resilient and cover layer materials which form
finished dilator devices.
[0147] FIG. 14 illustrates an embodiment of a third form of dilator
10 in accordance with the present invention, the fabrication of
which is illustrated in FIGS. 15a-15f to follow. The device
features a partial base layer and a single rectangular resilient
member. The device end edges are angled inward to correspond
generally to the line where the nose meets the cheek of the user.
By virtue of the manufacturing method used, release paper 15 is not
bisected into two parts. Instead, its width exceeds the periphery
of dilator 10, providing a lip thereat together with a lateral
protrusion, 16, on each side of intermediate region 36 that a user
can grasp to separate dilator 10 from release paper 15 prior to
use.
[0148] FIGS. 15a-15g illustrate a third form of manufacturing
method, in accordance with the present invention, applicable to a
variety of medical devices, but particularly suited to the dilator
device of FIG. 14. FIG. 15a shows where continuous slits 45 form
adjacent, laterally contiguous base layer strands 43 in base layer
material 42 as described hereinbefore. Again, resilient layer
strands 26 and base layer strands 43 are configured to meet design
criteria for the device produced, and also configured to
predetermined widths that allow select strands to be separated from
their respective elongated material webs in a predetermined spaced
apart relationship. Every other resilient layer strand 26 aligns to
the longitudinal centerline of each consecutive strand 43 and is
combined thereon. For illustrative clarity, outside waste strands
47 are shown separated from paper liner 42'.
[0149] FIG. 15b illustrates every other of the combined resilient
layer strands 26 and base layer strands 43 separated from paper
liner 42' and layered onto a separate release paper liner 41.
Dashed lines between remaining strands 43 represent from where
every other of combined strands 26 and 43 were removed.
Concurrently, two webs of cover layer material 44 are laminated by
their adhesive sides to exposed surfaces of resilient layer strands
26, base layer strands 43 and paper liners 41 and 42' to form
material laminates 40. As discussed previously with regard to FIGS.
9b and 12, the process effectively divides combined resilient layer
strands 26 and base layer strands 43 onto separate paper liners.
And again, absent waste strands 47, paper liner 42' is effectively
the same as separate release paper liner 41, and for clarity is
referenced as such in the drawing.
[0150] As seen in FIG. 15c, continuous slits 45 extend
longitudinally along the machine direction of laminate 40 (for
simplicity, only one material laminate 40 is shown), and vertically
to, but not through, release paper liner 41 to form a plurality of
laterally adjacent laminate strands 46. Slits 45 diverge laterally
so as to form portions of the long edges of strands 46 on a common
line. Portions of slits 45 also extend along the wider portions of
base layer strands 43. Slit 45 adjacent each outside long edge of
laminate 40 together form outside waste strands 47. Laminate
strands 46 are releasably secured to paper liner 41 by at least the
adhesive substance disposed on one side of at least cover layer
material 44. Each strand 46 includes combined base layer strand 43
and resilient layer strand 26, and a portion of cover layer
material 44. Strands 46 are laterally contiguous at those portions
formed on a common line.
[0151] FIG. 15d illustrates laminate strands 46 removed from
material laminate 40 leaving a waste matrix remnant thereof. For
illustrative clarity, every other laminate strand 46 is represented
by dashed lines, so that the configuration of laminate strand 46 is
clearly seen. The waste matrix comprises a plurality of
intermittent waste pieces 49 and outside waste strands 47
releasably secured to continuous release paper liner 41.
[0152] The skilled converter will again see that slits 45 could
alternatively extend vertically through paper liner 41, in which
case each laminate strand 46 would include a corresponding paper
liner portion that would be removed prior to the next step, shown
in FIG. 15e. The inherent tensile strength of the paper liner
portion, together with the tensile strength of resilient layer
strand 26, would help prevent inadvertent longitudinal stretching
of the base and cover layer materials of laminate strand 46 as they
are separated from laminate 40. The waste remnant of laminate 40
would then comprise outside waste strands 47 and a plurality of
individual waste pieces 49, rather than the continuous waste matrix
shown.
[0153] The disposition of paper liner material notwithstanding,
FIG. 15e shows every other strand 46 layered onto additional
separate release paper liners 41. A plurality of laminate strands
46 are divided and distributed onto a plurality of paper liners 41,
laterally spaced apart by a distance equal to the width of a strand
46 therebetween, as represented by dashed lines. This technique
extends cover layer material yield in the same manner as in
extending the base layer and resilient layer materials discussed
previously. FIG. 15e further illustrates that each combination of
strands 46 and paper liner 41 are layered onto packaging material
web 60a to form fabrication matrix 50.
[0154] FIG. 15f shows that die cut lines 52 kiss cut vertically
through fabrication matrix 50 to packaging web 60a. The long edges
of die cut lines 52 extend vertically through release paper liner
41, outboard and adjacent long edges 45' of laminate strand 46. The
lateral portions of die cut lines 52 bisect laminate strand 46
between long edges 45'. Thus edges 45' of laminate strand 46 come
to define the long edges of successive finished dilator units,
while die cut lines 52 form end edges 33 thereof and the long edges
and outside corners of release papers 15 which correspond to each
finished dilator 10.
[0155] To complete the process, FIG. 15g shows continuous waste
matrix 53 separated from fabrication matrix 50, leaving a plurality
of spaced apart finished dilators on packaging web 60a. Waste
matrix 53 includes paper liner 41 and sections of laminate strands
46 from around and between successive dilators 10. Again, waste
matrix 53 consists almost entirely of low-cost paper, separated as
a single matrix by virtue that release paper liner 41 extends
across the width of fabrication matrix 50 (as more clearly seen in
FIG. 15e). Packaging webs 60a and 60b encapsulate finished dilators
10 therebetween, as described hereinbefore.
[0156] FIGS. 16 and 17a-17d illustrate a fourth form of
manufacturing method and a fourth form of dilator 10 in accordance
with the present invention. By way of an overview, FIG. 16 shows a
plurality of resilient layer strands 26 and 26a formed on common
longitudinal lines by slits 25 from respective webs of resilient
layer film 24 and 24' (substantially as shown in FIG. 5a).
Continuous slits 25 extend vertically through webs 24 and 24',
longitudinally along the machine direction thereof, diverging
laterally in a repeating pattern without intersecting the outside
long edges of the resilient layer film web or an adjacent slit
25.
[0157] Strands 26 and 26a are formed identical, but as the mirror
image of each other: in web 24 strands 26 diverge to one side, in
web 24' strands 26a diverge to the opposite side. Slit 25 adjacent
each long edge of webs 24 and 24' together form an outside waste
strand, 27. Slits 25 are parallel to each other and uniformly
spaced, though strand widths may otherwise vary according to the
desired design attributes for the medical device to be fabricated.
It should also be noted that by virtue of integrating strands 26
and 26a from separate webs of resilient layer film 24 and 24', one
material web may be of a different thickness than the other,
resulting in resilient layer strands of different thickness.
[0158] FIG. 16 also shows resilient layer strands 26 and 26a
combined with base layer material 42, which has an adhesive
substance disposed on one side, covered by paper liner 42'. Strands
26 and 26a are taken as pairs from respective webs 24 and 24' and
combined with base layer material 42 so as to be in a
predetermined, laterally spaced arrangement, the technique for
doing so illustrated in FIG. 17a. Cover layer material 44, shown in
dashed lines, having substantially the same width as material 42,
is laminated by its adhesive side on top thereof to complete
material laminate 40. Enclosed die cut lines 52, represented by
dashed lines, show where finished dilator units will be die
cut.
[0159] As discussed hereinbefore. resilient layer strands 26 and
26a consist of a plurality of resilient members integrated into an
elongated strand. In the present embodiment, strands 26 and 26a
have segments, 28a, 28b, 28c, 28d, as indicated by broken lines and
brackets, which repeat in a continuous pattern. Segments 28a and
28c correspond generally to end regions 32 and 34 of the truss,
diverging from segments 28b and 28d. Segment 28b corresponds
generally to intermediate region 36. Segment 28d interconnects
successive resilient members and also sets the spacing, at least in
part, between successive die cut lines 52.
[0160] As further seen in FIG. 16, enclosed die cut lines 52 form
rows of successive dilators 10, each row registered laterally with
paired resilient layer strands 26 and 26a. Die cut lines 52 are
longitudinally positioned along segments 28a, 28b and 28c.
Alternating pairs of strands 26 and 26a are longitudinally
staggered so that the long edges of adjacent rows of dilator
peripheries have substantially even spacing therebetween. That
spacing serves an intended purpose, as will become apparent in
subsequent steps. The widest portions of die cut lines 52 are
formed along a common imaginary line, as indicated in the drawing
by a broken line.
[0161] Now to begin the fabrication process, FIG. 17a illustrates
fragmentary portions of two groups of resilient layer film webs 24
and 24' (absent outside waste strands 27). The webs are aligned to
other elongated webs which will form material laminate 40. While
the width of each resilient layer film web is shown fragmentary,
however, each web includes a plurality of adjacent, contiguous
strands 26 or 26a. The webs are positioned in a staggered,
overlapping relationship as indicated by brackets. The webs are
aligned such that individual strands 26 and 26a are peeled from
their respective webs and combined with base layer material 42 in
the spaced apart arrangement illustrated in FIG. 16. For
illustrative clarity, webs of resilient layer film 24 are shown to
the left side of base layer material 42 and webs of resilient layer
film 24' to the right side. In practice, the material webs would be
positioned according to machine setup.
[0162] Broken lines indicate the first of each strand 26 and 26a
from respective webs of resilient layer film 24 and 24' layered
onto base layer material 42. As each resilient layer strand 26 or
26a is layered onto base layer material 42, the two groups of webs
24 and 24', collectively, are shifted laterally, as indicated by
directional arrows, by a distance equal to the width of one
resilient layer strand, to align the next strands to the positions
formerly occupied by the strands just separated. Once the desired
resilient layer strands 26 and 26a are combined with base layer
material 42, cover layer material 44, shown by dashed lines, is
laminated by its adhesive side on top thereof to complete material
laminate 40.
[0163] FIG. 17b shows where enclosed die cut lines 52 form of a
plurality of dilator units, defining the peripheries thereof at
staggered, spaced apart intervals, as illustrated in FIG. 16. Die
cut lines 52 extend vertically to, but not through, paper liner 42'
on the underside of base layer material 42 of laminate 40. (Paper
liner 42' is shown slightly enlarged in the drawing for clarity.)
The waste material matrix extending around and between die cut
lines 52 is removed, leaving a plurality of finished spaced apart
dilators 10 releasably secured to paper liner 42', as illustrated
in FIG. 17c.
[0164] At this point in the process, a plurality of finished
dilator devices are effectively captured in bulk on a contiguous
paper liner. That may be adequate for many medical device
applications. However, to segment finished devices, FIG. 17c
further illustrates continuous slits 45 extending vertically
through paper liner 42' and longitudinally along the machine
direction thereof. Slit 45 is formed in the spaces between the long
edges of laterally adjacent dilators 10. Slit 45 does not intersect
a finished dilator, or the outside long edges of paper liner 42' or
an adjacent slit 45. Slits 45 may extend between finished dilators
in any configuration, however, to seal finished devices between
packaging material webs, slits 45 divide paper liner 42' into a
plurality of an elongated finished strand, 39. Each strand 39 has
rows of successive finished dilators 10 releasably secured thereon.
Each slit 45 thus forms opposing long edges 45' of two laterally
adjacent finished strands 39. Slit 45 adjacent each outside long
edge of paper liner 42' defines one long edge of strand 39, and
together with each outside long edge of paper liner 42' forms
outside waste strands 47.
[0165] To package finished devices, FIG. 17d shows finished strands
39 separated onto one or more packaging material webs 60a. Strands
39 maintain lateral spacing equal to the width of the strand 39
formerly therebetween, as represented by dashed lines. Cross slits
48 extend laterally between long edges 45' and vertically to, but
not through, packaging web 60a, bisecting the release paper liner
of strand 39 into sections with waste pieces 49 therebetween. Thus
substantial portions of long edges 45' of strand 39 define the long
edges of successive release papers 15 corresponding to successive
dilators 10.
[0166] The peripheral edges of release paper 15 are outbound the
periphery of each dilator 10, providing a lip thereat and a lateral
protrusion 16 on each side of intermediate region 36 that a user
may grasp to separate dilator 10 therefrom. Waste pieces 49 (shown
slightly separated for illustrative clarity) are removed from the
surface of packaging web 60a in between dilators 10 by any suitable
means such as suction or targeted forced air. Packaging web 60b
then forms a seal with packaging web 60a around and between
dilators 10 as described hereinbefore.
[0167] FIGS. 18 and 19 more particularly illustrate the finished
device. FIG. 18 shows adjacent resilient members 22 each having
divergent components, 22', extending laterally from a rectangular
mid section. Resilient member components 22' constitute a
directional element, spreading spring biasing forces to a greater
lateral surface area of the device end regions. A component 22' may
be shorter, longer, of different width, gradient, curved, etc., and
may be configured differently in each end region.
[0168] As more clearly seen in FIG. 19, dilator 10 is symmetric on
both sides of its lateral centerline, b, and symmetric on both
sides of its longitudinal centerline a. A material separation,
valley 21, extends inward from each end edge 33, interposed between
resilient member terminal end portions 23. Valley 21 may be of any
shape, and like material separations 13, is configured to
facilitate the separation of protrusion 12 and the shifting of
spring biasing peel forces to shear forces as described
hereinbefore. FIG. 19 further shows by dashed lines that the
peripheral shape of dilator 10 is conducive to common line die
cutting, as discussed previously with regard to FIG. 4.
[0169] FIGS. 20-21 and FIG. 22 illustrate two dilator devices
produced from a manufacturing method described with respect to
FIGS. 23a-23f to follow. The dilator of FIGS. 20 and 21 is a
variation of the device of FIGS. 18-19, it's resilient members also
having divergent components 22'. The dilator of FIG. 22 is a fifth
form of nasal dilator 10 in accordance with the present invention,
produced as a complementary device. It features a resilient member
having long edges which taper from a wider rectangular portion to
narrower terminal end portions, the extent of which corresponds
generally to the device end regions. The tapered portions
constitute a directional element, reducing the spring biasing force
of the truss thereat. Base member 14 of both dilator devices is
shown having the same peripheral shape as cover member 18.
Alternatively, base member 14 could have the same peripheral shape
as the resilient member(s).
[0170] FIG. 23a illustrates an overview of a fifth form of
manufacturing method, in accordance with the present invention,
applicable to a variety of medical devices, but particularly suited
to dilator devices like those seen in FIGS. 20-22. Slits 25 form
different configurations of resilient layer strands from a web of
resilient layer film 24. Resilient layer film 24 may alternatively
include a base layer material laminated thereto, as described
hereinbefore. Continuous slits 25 extend vertically through web 24,
longitudinally along the machine direction thereof, diverging
laterally in a repeating pattern without intersecting the outside
long edges or an adjacent slit 25. Slit 25 adjacent each long edge
of resilient layer film 24 together form outside waste strand
27.
[0171] Slits 25 are configured to form two laterally spaced apart
strands 26, which may be combined in the fabrication of the dilator
device represented by dashed lines at the top of FIG. 23a. To avoid
waste material between opposing strands 26, a second strand, 26b,
is formed therebetween. Strand 26b, which might otherwise be waste
material, is instead processed into a complementary dilator device
as shown by dashed lines at the bottom of FIG. 23a.
[0172] Strands 26 and 26b alternate consecutively across the width
of resilient layer film 24; the configuration of one strand
defines, at least in part, the configuration of the strand adjacent
to it on either side. Similarly, the width of a strand defines the
lateral spacing between the two strands adjacent on either side.
The strands are configured so that resilient layer structures
formed therefrom meet functional and directional element criteria
for the dilator device produced, and to predetermined widths that
allow select strands to be separated from resilient layer film 24
in a predetermined spaced apart relationship, as discussed
hereinbefore.
[0173] As noted previously, resilient layer strands 26 and 26b
consist of a successive plurality of resilient members integrated
into an elongated strand. Broken lines and brackets in FIG. 23a
indicate segments 28a, 28b, 28c, 28d which repeat in a continuous
pattern. Segments 28a and 28c correspond to dilator device end
regions, and segment 28b corresponds generally to the intermediate
region. Segment 28d interconnects successive resilient members and
also sets the spacing between successive die cut lines 52. Segments
28b and 28d are the same length, thus each consecutive resilient
layer strand 26 may be viewed as either the mirror image of the
previous, alternating in succession, or as identical, but
longitudinally staggered. Each consecutive strand 26b is identical
and longitudinally staggered from the previous.
[0174] FIG. 23b illustrates lateral spacing between resilient layer
strands 26 and 26b when the strands are separated. Dashed lines
represent where strands 26b formerly occupied the spaces between
adjacent strands 26. Strands 26 are registered in a laterally
spaced apart relationship determined by the width of strands 26b
and vice versa. Separating strands into respective groups is not
required for the manufacturing process; select strands 26 and 26b
may be peeled from resilient layer film 24 and combined into a
material laminate without first being separated into respective
groups.
[0175] FIG. 23c shows resilient layer strands 26 combined with
elongated webs of base layer material 42 and cover layer material
44 to form material laminate 40. Group 29 comprises two pairs of
strands 26. One pair from each group is layered onto base layer
material 42. Pairs not layered are represented by dashed lines, and
may be combined into a second material laminate, or follow the
first pairs of strands into the first material laminate. Cover
layer material 44, preferably having substantially the same width
as base layer material 42, is laminated by its adhesive side onto
exposed surfaces of strands 26 and base layer material 42 to
complete material laminate 40. Dashed lines represent where die cut
lines 52 will form finished dilator units, as more particularly
illustrated in FIG. 23f.
[0176] FIG. 23d shows the first and third strands 26b from each
group 29 combined with laterally consecutive base layer strands 43.
Base layer strands are formed in an elongated web of base layer
material having an adhesive layer thereon covered by paper liner
42', as described hereinbefore. Similar to combining elongated
strands shown in FIG. 12, the collective width of four laterally
spaced strands 26b, which make up group 29, corresponds to the
collective width of two adjacent, contiguous, base layer strands
43. The second and fourth strands 26b from each group 29, shown in
dashed lines for illustrative clarity, may be recoiled for later
processing, or combined with base layer and cover layer material in
the same manner as the first and third strands 26b.
[0177] Broken lines indicate every other base layer strand 43,
including resilient layer strand 26b aligned thereon, separated
from paper liner 42' and layered onto a separate release paper
liner 41. (Dashed lines illustrate the spaces formerly occupied by
the separated strands.) Combined strands 26 and 43 are thus
laterally spaced apart on separate release paper liners 41 and 42',
respectively. Cover layer material 44, having substantially the
same width as the paper liners, is laminated by its adhesive side
to exposed surfaces of strands 43, strands 26 and paper liners 41
and 42', to complete each material laminate 40.
[0178] FIGS. 23e and 23f show each material laminate 40 combined
with packaging material web 60a to form fabrication matrix 50. Die
cut lines 52 extend through laminate 40 to packaging web 60a,
forming rows of finished devices. Waste matrix 53 is removed,
leaving a plurality of spaced apart finished devices such that
packaging webs may form a perimeter seal between finished
devices.
[0179] In FIG. 23e, waste matrix 53 includes portions of cover
layer material 44 extending around die cut lines 52, and portion of
base layer material strands 43 and resilient layer strands 26b
extending between successive die cut lines 52. Similarly, waste
matrix 53 shown in FIG. 23f includes portions of cover layer
material 44 and base layer material 42 extending around die cut
lines 52, and portions of strands 26 extending between successive
die cut lines 52. The sealed, finished devices may be further
segmented by cuts or scores extending through the packaging webs in
between one or more encapsulated devices.
[0180] The preceding method forms elongated resilient layer strands
26 and 26b in equal numbers. By combining each two resilient layer
strands 26 into a pair, there are twice as many of the
complementary device produced from the method, shown in FIG. 22, as
the primary device, shown in FIGS. 20 and 21. Assuming that equal
numbers of both devices are desired, FIGS. 24a and 24b illustrate
an alternative method of forming resilient layer strands so that
one pair of strands 26 are produced for each single strand 26b.
[0181] FIG. 24a shows slits 25 formed in resilient layer film 24
such that two strands 26 are laterally followed by strand 26b,
followed by two opposing strands 26, and again followed by strand
26b. The upper set of brackets show segments 28a-28d of strand 26;
the lower set of brackets show segments 28a-28d of strand 26b. FIG.
24b shows resilient layer strands 26 and 26b separated into two
groups to illustrate twice the number of individual strands 26
(sixteen) separated from (eight) individual strands 26b, thus
making equal pairs of strands 26 to individual strands 26b. For
visual clarity, dashed lines are used to illustrate some
strands.
[0182] FIGS. 25a and 25b illustrate the first of several
variations, from myriad possible, to the fifth form of
manufacturing method discussed with regard to FIGS. 23a and 23b.
Like the resilient layer strands shown in FIGS. 24a and 24b,
strands 26 and 26b of the present embodiment are formed in equal
numbers, alternating across the width of resilient layer film 24.
So as not to repeat previous disclosure, FIG. 25a is limited to
illustrating resilient layer strand configuration and the matching
of resilient strands to dilator devices. It is understood that the
strands maintain their lateral spacing as illustrated when combined
into a material laminate, as described hereinbefore, and that a
material laminate is formed as previously disclosed.
[0183] Broken lines and brackets indicate segments 28a-28c of
resilient layer strand 26 aligning with the horizontal regions of a
first dilator device, shown by dashed lines at the top of FIG. 25a.
Strand 26 is configured wide enough so that a single resilient
member in the finished device has suitable spring biasing
properties. Broken lines and brackets indicate segments 28a-28c of
resilient layer strand 26b aligning with the horizontal regions of
a complementary dilator device, shown by dashed lines at the bottom
of FIG. 25a. FIG. 25b shows equal numbers of strands 26 and 26b
separated into two groups. Dashed lines represent where strands 26b
formerly occupied the spaces in between strands 26.
[0184] FIG. 26 more particularly illustrates the finished dilator
devices. The first device, shown at the top of the figure has
divergent resilient member components 22' corresponding
substantially to respective end regions of the truss. The truss end
regions also diverge laterally in the same manner. The
complementary device is a variation on the dilator of FIG. 22,
featuring a resilient member having long edges which taper
gradiently from a wider rectangular portion to narrower terminal
end portions 23. The longitudinal extent of the tapered portions
correspond to the device end regions, and terminal end portions
correspond to protrusions 12, with material separations 13 adjacent
thereto.
[0185] FIGS. 27-31b illustrate a second variation to the preceding
fifth form of manufacturing method. This variation forms three
different configurations of resilient layer strands from a web of
resilient layer film to produce complementary dilator devices. FIG.
27 shows an overview wherein continuous slits 25 form resilient
layer strands 26, 26a and 26b in resilient layer film 24 as
described hereinbefore. The strands are formed in an alternating
pattern which repeats laterally between the longitudinal
centerlines of consecutive strands 26, as indicated by brackets and
broken lines to the left of the drawing figure. Strand 26 is
substantially straight and slightly wider than strand 26a. Strand
26 has portions which diverge laterally, and strand 26b is formed
in between strands 26 and 26a.
[0186] As seen at the top of FIG. 27, horizontal brackets with
broken lines indicate segments 28a-28c of resilient layer strands
26, 26a and 26b corresponding to the intermediate and end regions
of truss 30. Strands 26 and 26a may be combined in the fabrication
of at least two distinct devices, one larger and one smaller, as
shown by dashed lines. Where two strands 26b are separated
laterally therebetween by strand 26, strands 26b may be combined in
the fabrication of another device, optionally including strand 26
therebetween, illustrated by dashed lines per the lower set of
brackets at the bottom of FIG. 27. Segment 28d of all strands
determines, at least in part, the spacing between die cut lines
which form finished devices.
[0187] So as not to repeat previous disclosure, FIG. 27 is limited
to illustrating resilient layer strand configuration and the
matching of resilient strands to dilator devices. It is understood
that the strands maintain their lateral spacing as illustrated when
combined into a material laminate, as described hereinbefore, and
that the material laminates are formed by way of techniques
described hereinbefore.
[0188] FIGS. 28 and 29 illustrate the dynamic relationship between
strand widths, strand spacing, and the resilient layer structures
of finished dilator devices produced by the present method. Broken
lines in FIG. 28 indicate the width of the resilient layer strand
(26), which forms the upper resilient member 22 of dilator 10 on
the right, corresponding to the spacing between upper and lower
resilient members 22 of dilator 10 on the left. The width of the
former determines the spacing of the latter, and vice versa.
Similarly, broken lines in FIG. 29 indicate the configuration of
the resilient layer strands (26b), which form adjacent resilient
members 22 of dilator 10 on the right. That configuration affects
the spacing and divergent portions of uppermost and lowermost
resilient members 22 of dilator 10 on the left. The configuration
of the former determines, in part, the configuration of the latter,
and vice versa. A third resilient member, in between the uppermost
and lowermost resilient members in the dilator on the left, may be
optional in both dilator devices, right and left.
[0189] FIGS. 28-29 also illustrate features of diverse dilator
devices which may be produced from the present method. Dilator 10
to the right in FIG. 28 is horizontally symmetric but laterally
asymmetric. Each horizontal half of the truss on each side of
lateral centerline b is a mirror image of the other. The upper half
of the truss is formed parallel to longitudinal centerline a. The
lower half diverges from longitudinal centerline a at each end
region of the truss. Upper resilient member 22 aligns with the
nasal valve, while lower resilient member 22 has resilient member
components 22' to better engage outer wall tissues of the nostril
or nasal vestibule. Lower tab extension 35 correspond to components
22'. Each of two resilient members 22 may have a different width,
the upper member being, in this case, slightly wider than the
lower. Valley 21 is formed as a narrow elongated opening between
upper and lower resilient members.
[0190] The dilator to the left in FIG. 28 has identical adjacent
resilient members each having tapered portions extending generally
along end regions 32 and 34 to terminal end portions 23 and
protrusions 12. Were there an optional third resilient layer strand
(26) remaining therebetween, the resilient layer would have three
laterally contiguous resilient members absent any separation
between their respective long edges. In either case, the resilient
members' collective width applies spring biasing forces to a
slightly greater vertical surface of the nose given the device's
shape and size. Dilator 10 to the left in FIG. 29 is
proportionately larger than its counterparts, and thus more suited
for larger noses. Its spring biasing forces are spread widely at
end regions 32 and 34 by virtue of divergent components 22'.
Material separation 13 is adjacent each tab extension 35, and
valley 21 is positioned between the middle protrusion 12 and upper
and lower protrusions 12 to either side thereof.
[0191] Referring momentarily back to FIG. 27, opposing strands 26b
are the mirror image of each other and longitudinally staggered
where separated laterally therebetween by strand 26a. That
configuration is also illustrated at the top of FIG. 30. Strands
26b may be combined to form another useful resilient layer
structure by shifting every other strand 26b longitudinally so as
to align segments 28b opposite each other, as indicated by broken
lines, brackets, and a directional arrow. To align strands 26b in
this manner, separate resilient layer film webs 24 are arranged as
shown at the bottom of FIG. 30. The webs must overlap one another,
and may be staggered longitudinally, as indicated by directional
arrows. A bracket with broken lines extending across the width of
webs 24 indicates the desired alignment. For illustrative clarity,
some of the strands in the resilient layer film webs are
represented by dashed lines.
[0192] The overlapping arrangement of resilient layer film webs 24
allows opposing strands 26b to be peeled away in matching pairs, as
seen in FIG. 31a. (The technique is the same, in principle, as that
discussed previously with respect to FIG. 17a.) FIG. 31b shows how
every other pair is combined into respective material laminates 40
using means described hereinbefore. Dashed lines illustrate where
die cut lines 52 form rows of finished dilators suitably spaced
apart for sealing between packaging webs.
[0193] FIG. 32 more particularly illustrates the finished dilator
device as having adjacent resilient members 22 positioned closely
along their respective shorter long edges. The tapered portion
extends from inward, near the longitudinal centerline of truss 30,
to outward, forming a directional element which reduces the spring
biasing force of the truss. The gradient edges also create a space
in which to form valley 21. Protrusions 12 are thus positioned
immediately adjacent material separations 13 and tab extensions 35.
This end edge structure is conducive to the desirable design
practice of shifting peel forces to sheer forces, as described
hereinbefore.
[0194] FIG. 32 further illustrates that the truss is symmetric on
both sides of its lateral centerline, b, and symmetric on both
sides of its longitudinal centerline a. Both sides are the mirror
image of the other. Laterally adjacent dilators may be staggered
lengthwise so that substantially all of their long edges are
fabricated on a common die cut line, as illustrated by dashed lines
and described previously with regard to FIG. 4. To facilitate
common die cut line fabrication, the inside lateral edges of upper
and lower tab extensions 35 are formed to the same angle and corner
radius. Additionally, the truss regions are configured so that the
long edges of two opposing end regions of two successive dilator
peripheries fit into the space between, and on a common line with,
the inside lateral edges of tab extensions and the long edge of the
truss between the tab extensions of the dilator peripheries
adjoining on either side.
[0195] The device of FIG. 32 may be mass produced in a spaced apart
relationship, as illustrated in FIGS. 30-31b. FIG. 32 illustrates
that the device is also configured to be fabricated contiguously on
common die cut lines. The skilled person in the art may observe
that the configuration of resilient layer strands 26b in FIGS. 31a
and 31b precludes common line die cutting as shown in FIG. 32.
However, a different resilient layer strand configuration, such as
that discussed previously with regard to FIG. 5b, 6b, 12, or 17a,
may be adapted for the purpose.
[0196] FIG. 33 illustrates a third variation of the fifth form of
manufacturing method of the present invention. Continuous slits 25
form resilient layer strands 26, 26a, 26b, as described
hereinbefore, plus an inside waste strand, 27'. The strands are
formed in a repeating pattern across the width in resilient layer
film 24. Waste strand 27' is formed in between two parallel strands
26a at each point where the pattern is repeated, as indicated by
broken lines and brackets to the left of the drawing figure. Strand
26 is straight, while strands 26a diverge laterally. Each opposing
pair of strands 26b are laterally separated by a strand 26
therebetween.
[0197] Upper and lower sets of horizontal brackets with broken
lines indicate segments 28a-28c of the resilient layer strands
aligning with dilator devices. As seen in the upper set of
brackets, dashed lines illustrate strand 26 and opposing strands
26a aligning with dilator regions so as to form a triple resilient
band resilient layer structure. The finished device is depicted to
the right thereof, showing divergent upper and lower resilient
members and a straight middle resilient member. Material
separations 13 are adjacent each upper and lower protrusion 12, and
valley 21 is positioned between the middle protrusion 12 and the
upper and lower protrusion 12 on either side.
[0198] In the lower set of brackets dashed lines illustrate two
opposing strands 26b, which would otherwise be waste material,
combined to form resilient layer structures of two additional
complementary devices. Strand 26 may be included between opposing
strands 26b in one of the two complementary devices shown, and as
more particularly illustrated in FIG. 38.
[0199] FIGS. 34-35 and FIGS. 36-37, respectively, illustrate
resilient layer strands combined into respective material
laminates. The lateral spacing between strands is determined by the
width and configuration of strands separated from the spaces
therebetween: FIG. 34 shows group 29 comprising one resilient layer
strand 26 with opposing strands 26a adjacent either side. Strands
26 and 26a are laterally separated by the width of strands 26b
formerly therebetween, and adjacent groups 29 are separated by a
the width of waste strand 27' formerly therebetween. Waste strand
27' is removed and discarded as necessary waste, and strands 26b
are combined into another material laminate (as illustrated in
FIGS. 36 and 37). This leaves groups 29 laterally positioned for
combining with base layer strands and a cover layer material web
into material laminate 40.
[0200] FIG. 34 shows each group 29 separated from resilient layer
film 24 and layered onto base layer strands 43, the latter having
been formed in base layer material 42 by continuous slits 45 as
described hereinbefore. Strands 43 are configured to conform to
device requirements and to align with groups 29. Every other strand
43, each with a group 29 thereon, are separated onto one or more
separate release paper liners 41 as shown in FIG. 35 (in the same
manner as described previously with respect to FIGS. 9a-9c and
15a-15b). Cover layer material 44, shown by dashed lines, is
laminated by its adhesive side onto the resilient layer strands,
base layer strands 43 and separate release paper liner 41 to
complete material laminate 40. Dashed lines illustrate where
enclosed die cut lines 52 form rows of successive finished dilators
10 as described hereinbefore.
[0201] FIG. 36 illustrates two pairs of opposing strands 26b
separated by the collective widths of inside waste strand 27' and
strands 26a (the former represented by dashed lines, and the latter
not represented for illustrative clarity). However, strand 26 may
be included between some of the opposing pairs of strands 26b as
more clearly seen in FIG. 37. FIG. 37 shows every other of paired
strands 26b combined into material laminate 40. Pairs of strands
not so combined are represented by dashed lines, and these may be
combined into a separate material laminate. Enclosed die cut lines
52 form peripheries corresponding to finished dilator units in a
spaced apart relationship suitable for sealing between packaging
webs. Two similar, complementary, dilator devices are thus formed
in material laminate 40 by die cut lines 52. One of the two devices
includes a third resilient member provided by strand 26.
[0202] FIG. 38 more particularly illustrates the two complementary
dilator devices having similar narrow peripheries. The devices are
comparatively smaller and lighter than their larger counterpart
produced by this process, and thus more suited for smaller noses.
One device has a triple band resilient layer structure, and one
device is formed as a double resilient band structure. Adjacent
resilient members taper in the same manner as shown previously.
Resilient member terminal end portions 23 of the double resilient
member band device correspond to respective protrusions 12, with
valley 21 therebetween, at each end edge of the truss. The terminal
end portions of the device having three laterally contiguous
resilient members correspond to a single protrusion 12 at each end
edge of the truss.
[0203] FIG. 39 more particularly illustrates dilator 10, as
previously shown in FIG. 33, die cut from material laminate 40
shown in FIG. 35. Base member 14 is interposed between at least the
peripheral extent of resilient layer and the skin surfaces engaged
by dilator 10, its periphery corresponding substantially to the
resilient layer, yet distinct from both the resilient layer and the
cover layer. The resilient layer features three resilient members;
the upper and lower resilient bands feature divergent components
22' extending laterally from the intermediate region through end
regions 32 and 34. The resilient layer further has a substantially
rectangular center resilient member band interposed between the
upper and lower resilient bands.
[0204] FIG. 40 illustrates several examples of rectangular single
resilient band and multiple resilient band structures. For
simplicity, multiple bands are shown substantially the same width
and arranged closely parallel each other. At the top of the figure,
a single resilient band and the pair of resilient bands below it
represent average or typical configuration found in nasal dilator
art. Below that, a three band structure may be used to increase, by
some degree or percentage, the amount of spring biasing force over
that which is generally found in a single band or double band
structure. The same or similar spring biasing of from one to three
bands may also be spread across four narrower bands. And the
increased spring biasing generated by one to four bands may be
generated by a five or six still narrower bands. Additionally, one
or more individual bands may be of a different width or thickness.
Elongated resilient layer strands combined from separate resilient
layer film webs, as illustrated herein, facilitates formation of
resilient layer structures having multiple bands of both different
thickness and width.
[0205] FIGS. 41-43 illustrate a sixth form of manufacturing method,
in accordance with the present invention, applicable to a variety
of medical devices, but particularly suited to dilator devices
having multiple parallel resilient bands. So as not to repeat
previous disclosure, FIGS. 50a-50c illustrate resilient layer
strand configuration, the combining thereof into material
laminates, and the positioning of die cut lines in the laminates.
Resilient layer strands are produced from webs of resilient layer
film and distributed to the material laminates as required. It is
understood that the strands maintain their lateral spacing as
illustrated when combined into a material laminate, as described
hereinbefore, and the material laminates are understood to be
completed by way of techniques described herein.
[0206] As seen in FIG. 41, alternating wider and narrower resilient
layer strands 26 and 26', respectively, are slit from a web of
resilient layer film (or alternatively, from two or more webs of
different thickness) as described hereinbefore. Slits 25 are
preferably straight and respective strands 26 and 26' preferably
uniform in width.
[0207] FIGS. 42a, 42b and 43 show resilient layer strands 26 and
26' separated from resilient layer film 24 into respective material
laminates. The strands in each material laminate are identical;
each strand laterally spaced apart by the width of the strand
formerly therebetween. As discussed previously, rather than
resilient layer strands 26' being waste material by which to
laterally space strands 26 apart, slits 25 configure both strands
26 and 26' to be used in complementary devices.
[0208] FIGS. 42a and 42b illustrate that resilient layer strands 26
may be incorporated into material laminate 40 in two different
ways. To the left in FIG. 42a, groups 29 comprise five strands 26
each. The first three adjacent strands are incorporated into a
first material laminate 40 and the following two adjacent strands
are placed into a second material laminate 40 (shown next to the
first laminate 40). Enclosed die cut lines 52 form rows of dilator
devices: Every other row of die cut lines 52 in the first laminate
40 is flipped laterally and is longitudinally staggered so that
finished devices are positioned laterally closer thereby using less
engagement element material. In the second laminate 40, die cut
lines 52 form a smaller complementary device having two parallel
resilient bands.
[0209] Alternatively, FIG. 42b shows group 29 comprising three
resilient layer strands 26. Each one in three adjacent groups 29 is
combined into material laminate 40 so that rows of successive die
cut lines 52 have suitable lateral spacing for packaging material
webs to form a perimeter seal. Additionally, strips of cover layer
material 44, having a width slightly greater than that of the
peripheries formed by die cut lines 52, may be aligned with the
longitudinal centerline of group 29 or die cut lines 52 (similar to
that discussed previously with regard to FIG. 12).
[0210] FIG. 43 shows a first plurality of resilient layer strands
26' evenly spaced apart as seen in FIG. 41. The spacing is equal to
the width of strands 26 formerly therebetween, as represented by
dashed lines. A second plurality of strands 26' are intermingled
with the first plurality, positioned in the spaces therebetween and
corresponding to the same longitudinal centerlines as did strands
26. Two pluralities of strands 26' are thus intermixed and
laterally spaced as evenly as practicable. Group 29 comprises six
adjacent strands 26'. Every other adjacent group 29 is combined
into material laminate 40.
[0211] FIG. 43 further illustrates by dashed lines where enclosed
die cut lines 52 (only fragmentary portions thereof are shown) form
longitudinally staggered dilator peripheries, similar to that shown
in FIG. 42a. Additionally, continuous slits 45 are placed in
material laminate 40 in the spaces between the long edges of
adjacent rows of die cut lines 52 to form elongated finished
strands from which finished dilators are die cut (as described
previously with regard to FIGS. 17b-17d). The skilled person in the
art will recognize that groups 29 in FIG. 43 may be configured with
different numbers of resilient strands so as to match a variety of
dilator device sizes and widths.
[0212] FIGS. 42 and 43 each illustrate resilient layer strands
having identical width. The strands may be of different widths, and
if slit from separate resilient layer film, of different thickness.
Forming resilient layer strands of different thickness allows both
width and thickness to be design variables together with the number
of resilient members which form the dilator resilient layer.
[0213] FIGS. 44-46 more particularly illustrate finished dilator
devices produced from the method of FIGS. 41-43. FIG. 44 shows
dilator 10 produced from the material laminate shown in FIG. 42a,
or alternatively, from the material laminate shown in FIG. 42b. The
device has three parallel resilient members 22 of progressively
less length. If the resilient members are the same width and
thickness, a shorter band will have more spring biasing force than
a longer band. The elements of end edges 33 (protrusions 12,
valleys 21, separations 13 and tab extensions 35) correspond
generally to an inward angle, as indicated by broken lines,
established by the resilient bands' lengths. That angle also
corresponds generally to the line where the nose meets the
cheek.
[0214] FIG. 45 shows dilator 10 fabricated from the material
laminate shown in FIG. 42a. Dilator 10 is a conventional double
band design, formed as a complementary device to dilator 10 of FIG.
44. It is smaller in size than its counterpart, and thus suitable
for smaller noses. The dilator of FIG. 46, produced from the
material laminate shown in FIG. 43, has six narrow parallel
resilient members 22. Three protrusions 12 at each end edge 33,
separated therebetween by two valleys 21, correspond to terminal
end portions 23 of two adjacent resilient members 22. Material
separations 13 are adjacent the upper corners of the uppermost
resilient member band and the lower corners of the lowermost
resilient member band, respectively.
[0215] FIGS. 47-48 illustrate an overview of an alternative to the
sixth form of manufacturing method whereby to produce dilator
devices having an arcuate-like shape (an example thereof
illustrated in FIG. 26). The intermediate region of an arcuate
dilator device rests slightly higher on the bridge of the nose, its
end regions positioned correspondingly lower than that of
horizontally straight dilator devices, so as to engage outer wall
tissues adjacent both the nasal valve and the nasal vestibule.
[0216] So as not to repeat previous disclosure, FIGS. 47-48
illustrate resilient layer strand configuration, the combining
thereof into material laminates, and the positioning of die cut
lines in the laminates. Resilient layer strands are produced from
webs of resilient layer film and distributed to the material
laminates as required. It is understood that the strands maintain
their lateral spacing as illustrated when combined into a material
laminate, as described hereinbefore, and the material laminates are
understood to be completed by way of techniques described
herein.
[0217] FIG. 47 shows two sets of alternating wider and narrower
resilient layer strands 26a and 26a' slit from an elongated web of
resilient layer film (or alternatively, from two or more webs of
different thickness), similar to that illustrated with respect to
FIG. 41. The strands diverge laterally in a continuous repeating
pattern. Strands 26a and 26a' may be combined into separate
material laminates without first being divided into respective
groups of identical strands. Every other pair of adjacent resilient
layer strands 26a are combined into material laminate 40. Dashed
lines illustrate die cut lines 52 forming adjacent rows of
successive finished dilator units, similar in appearance to the
dilator of FIG. 26, where the end regions diverge as do the
resilient members, giving the finished dilator the appearance of an
arcuate shape.
[0218] FIG. 48 shows a first plurality of resilient layer strands
26a', separated from strands 26a as seen in FIG. 47. Each strand
26a' is laterally spaced apart by a distance equal to the width of
strand 26a formerly therebetween, as represented by dashed lines. A
second plurality of strands 26' are intermingled with the first
plurality, positioned in the spaces between each strand 26' and
corresponding to the same longitudinal centerlines, indicated by a
broken line, as strands 26a. Both pluralities of strands 26' are
thus laterally spaced as evenly as practicable.
[0219] Every other adjacent group 29, comprising four resilient
layer strands 26a' each, is combined into material laminate 40. Die
cut lines 52 form finished dilator devices, similar to that shown
in FIG. 47, where the end regions of the truss correspond to the
divergent segments of strands 26a'. As noted previously, strands 26
and 26a' may be formed from webs having different thickness. For
example, resilient layer strands of the above referenced second
plurality, having a second thickness, may be intermingled with the
first plurality of strands having a first thickness. The four band
resilient layer structure of the finished device, more particularly
illustrated in FIG. 49, would thus have every other resilient
member being one thickness or the other.
[0220] FIGS. 50a-50c illustrate a seventh form of manufacturing
method, in accordance with the present invention, applicable to a
variety of medical devices, but particularly suited to arcuate
dilator devices. So as not to repeat previous disclosure, FIGS.
50a-50c illustrate resilient layer strand configuration, the
combining thereof into material laminates, and the positioning of
die cut lines in the laminates. Resilient layer strands are
produced from webs of resilient layer film and distributed to the
material laminates as required. It is understood that the strands
maintain their lateral spacing as illustrated when combined into a
material laminate, as described hereinbefore, and the material
laminates are understood to be completed by way of techniques
described herein.
[0221] FIG. 50a shows alternating wider and narrower resilient
layer strands 26a and 26a', similar to that illustrated with
respect to FIGS. 41 and 47, slit from a web of resilient layer film
(or alternatively, from two or more webs of different thickness) as
described hereinbefore. Strands 26a and 26a' diverge laterally in a
repeating pattern of successive curved segments. Broken lines
indicate that strands 26a and 26a' are separated into several
material laminates.
[0222] FIG. 50a further illustrates the first two of each three
consecutive resilient layer strands 26a combined as pairs with
material laminate 40, shown in dashed lines. Dashed lines also
illustrate where die cut lines 52 form successive, laterally
contiguous, rows of arcuate device peripheries on common
longitudinal lines. The overall curvature of each periphery
substantially follows the curvature of the resilient layer strands.
To further facilitate common die cut line formation, every other
row of peripheries is flipped laterally so that the lower long
edges of one periphery are formed on a common die cut line with the
lower long edges of the periphery adjacent thereto, and the upper
long edges of one periphery are formed on a common die cut line
with the upper long edges of the periphery adjacent thereto. The
pattern repeats laterally across the width of laminate 40.
[0223] FIG. 51 more particularly illustrates dilator 10 produced
from material laminate 40 shown in FIG. 50a. The device is
symmetric on each side of lateral centerline b, but asymmetric on
each side of longitudinal centerline a. To accommodate the
continuous repeating curvature used in the fabrication process, and
to form substantial portions of the truss long edges on common
lines, upper tab extensions 35 have a slightly dissimilar
peripheral shape than lower tab extensions 35. Additionally, as
indicated by broken lines and brackets, the upper long edge of
intermediate region 36 is shorter than the lower long edge thereof.
Also, the upper half of respective end regions 32 and 34 have a
greater longitudinal extent than the lower half. To follow the
repeating curvature of the resilient layer strands, the long edges
of the end regions are formed to have the same radius, but reverse
curvature, of the intermediate region: the long edges of upper tab
extensions 35 and the lower long edge of intermediate region 36
curve laterally inward, and the long edges of lower tab extensions
35 and upper long edge of the intermediate region 36 curve
laterally outward.
[0224] Returning now to FIG. 50b, broken lines indicate the third
of each three consecutive resilient layer strands 26a from FIG. 50a
separated as a first plurality from strands 26a'. The strands are
combined into the upper of two material laminates 40 shown in FIG.
50b. The first plurality of strands 26a is followed by a second
plurality thereof, intermingled with the first plurality so as to
form pairs of strands laterally spaced apart. Every other pair of
strands is then combined into material laminate 40. Dashed lines
illustrate where die cut lines 52 form rows of finished dilators
suitably spaced apart for sealing between packaging webs. The
finished dilator device is generally illustrated in FIG. 52.
[0225] Additionally, or alternatively, broken lines indicate that
the third of each three consecutive resilient layer strands 26a
from FIG. 50a may also be combined into the lower of two material
laminates 40 shown in FIG. 50b. The strands are combined with
strands 26 slit from a separate resilient layer film web, which may
optionally be of a different thickness. Each one in four select
strands 26, from contiguous groups 29, are combined with strands
26a to form pairs. Each pair comprises a curved strand 26a and a
straight strand 26. The pairs of strands are laterally spaced
apart, with every other pair combined into material laminate 40.
Dashed lines illustrate where die cut lines 52 form rows of
finished dilators suitably spaced apart for sealing between
packaging webs. The finished dilator device is illustrated in FIG.
53.
[0226] As seen in FIG. 50c, broken lines and brackets also indicate
where strands 26a' from FIG. 50a are separated as a first plurality
from strands 26a, to be combined into material laminate 40. The
first plurality of strands 26a' is followed by a second plurality
thereof, intermingled with the first plurality so as to form
laterally spaced groups of four strands 26a' each. Every other
group of four strands is then combined into material laminate 40.
Dashed lines illustrate where die cut lines 52 form rows of
finished dilators suitably spaced apart for sealing between
packaging webs. The finished dilator device is illustrated in FIG.
54.
[0227] FIG. 52 illustrates a representative example of the arcuate
dilator device produced from material laminate 40 seen at the top
of FIG. 50b. The long edges of the truss, particularly at the
intermediate region, substantially follow the same curvature as two
parallel resilient members. The long edges of upper and lower tab
extensions 35 may curve in the same or similar manner. The lower
resilient member is longer than the upper member, and lower tab
extensions 35 extend slightly beyond the upper tab extensions 35.
The truss's end edge elements thus angle inward, as indicated by
broken lines, to correspond generally to the line where the nose
meets the cheek.
[0228] FIG. 53 illustrates the semi-arcuate dilator device produced
from material laminate 40 seen at the bottom of FIG. 50b. The
device is particularly similar to the dilator shown to the right in
FIG. 28, being horizontally symmetric and laterally asymmetric.
Upper tab extensions 35 and upper resilient member 22 are parallel
to the longitudinal centerline of the truss, intended to align with
the tissues immediately adjacent the nasal valve. The divergent
portions of the arcuate resilient member align with the nasal outer
wall tissues adjacent the nostrils or nasal vestibule. Lower tab
extensions 35 diverge in the same manner, and may extend slightly
beyond upper tab extensions 35. The truss's end edge elements thus
angle inward, as indicated by broken lines, to correspond generally
to the line where the nose meets the cheek.
[0229] FIG. 54 illustrates the arcuate dilator device produced from
material laminate 40 seen in FIG. 50c. The device is a four-band
resilient layer version of the dilator device shown in FIG. 52, and
is also similar to the dilator of FIG. 49. The arcuate shape of the
truss substantially follows the curvature of the four parallel
resilient members. The truss's end edge elements are angled inward,
as indicated by broken lines, following the resilient members'
progressively shorter length. Spring biasing is thus slightly
greater toward the upper part of the device. Terminal end portions
23 correspond to respective protrusions 12, with valleys 21
therebetween, at each end edge of the truss.
[0230] The manufacturing method of FIGS. 50a-50c is particularly
suitable for continuous rotary die press converting. The skilled
converter may note that alternatively, an arcuate device and its
constituent elements, members or components could be formed in a
circular pattern within a material sheet of fixed size, such as
that used in a flat bed press system. Flat bed systems are more
suited to successive individual material sheets being fed into the
press, as described hereinbefore.
[0231] In a variation of the manufacturing method shown in FIG. 47,
FIG. 55 shows material laminate 40, having pairs of resilient layer
strands combined therein. The strands diverge laterally in a
continuous repeating pattern and are laterally spaced across the
width of material laminate 40. Die cut lines 52 form rows of device
peripheries, such that two rows of peripheries are formed
substantially on a common die cut line: the upper long edges of the
peripheries of one row on a common line with the upper long edges
of peripheries of the adjacent row. Each two rows of peripheries
align with, and correspond to, two pairs of resilient layer
strands. Of necessity, each two rows of peripheries are spaced from
the paired rows adjacent thereto, since the device peripheries are
configured so as to form only the upper long edges thereof on a
common line.
[0232] FIG. 55 further illustrates the divergent segments of the
strands corresponding to the longitudinal extent of finished
dilator device end regions, while a comparatively shorter
longitudinal segment corresponds to the shorter intermediate region
36 (more particularly illustrated in FIG. 56). Another shorter
longitudinal segment corresponds to the space between successive
die cut line peripheries. To facilitate common die cut lines, the
truss is configured so that the long edges of two opposing end
regions of two successive dilator peripheries fit into the space
between the lateral edges of the upper tab extensions, and the
upper long edge of the truss between the tab extensions, of the
adjacent periphery. FIG. 56 more particularly illustrates the
finished device, where the truss is symmetric on both sides of
lateral centerline b, and each end region, by itself, is symmetric
on each side of its longitudinal centerline a.
[0233] FIG. 57 illustrates a variation of the manufacturing method
shown in FIG. 50a. Resilient layer strands 26 have both straight
and curved segments, the former corresponding to finished dilator
end regions and the latter corresponding to the intermediate
region. Resilient layer strand 26 curves laterally from a
horizontal segment to form a comparatively short radial protrusion,
then curves laterally in the reverse direction back to a
longitudinally straight segment. Straight segments also correspond
the space between successive dilator peripheries formed by die cut
lines 52. Adjacent groups 29 each comprise three laterally
contiguous resilient layer strands 26. As described hereinbefore,
the widths of group 29 and device peripheries are each configured
to suitable design parameters and so that one strand 26 from each
consecutive group 29 aligns with each row of die cut line
peripheries.
[0234] Die cut lines 52 form dilator peripheries having identical
opposing long edges, which also conform to the long edges of
strands 26. Finished devices are die cut entirely on common
longitudinal lines. Accordingly, the finished device does not have
end edge elements such as tab extensions or material separations.
Rather, the long edges of the truss extend from one end region
through the intermediate region to opposite end region on an
unbroken line. Similarly, the truss end edges extend in a straight
line from the upper outside corner to the lower outside corner
thereof. Dashed lines illustrate that material laminate 40 may be
bisected between successive finished devices to segment and
encapsulate finished devices between packaging webs, as illustrated
previously with respect to FIGS. 9e and 10.
[0235] As illustrated and described in examples of the preferred
embodiments, the present invention provides methods of
manufacturing medical devices, particularly devices for dilating
external tissue, including a wide range of diverse and complex
nasal dilator devices.
* * * * *