Methods of making laryngeal masks

1. A method of making a laryngeal airway of the type that includes a respiratory tube and an inflatable positioning shield, the shield having a base and a hollow, peripheral portion, the respiratory tube comprising a tubular body and a proximal end lumen, and a distal end lumen formed there through, the method comprising:

introducing at least one molding material into a mold;

wherein the mold has a cavity defined by internal walls;

wherein the mold has at least one core within its cavity, the core being adapted to form the proximal end lumen, tubular body and distal end lumen of the respiratory tube and the hollow, peripheral portion of the inflatable positioning shield;

wherein the internal walls of the mold conform to external walls of the laryngeal airway; and

allowing the molding material to cure about the internal walls of the mold and the at least one core, thereby forming the laryngeal airway in a non-inverted form.

2. The method of claim 1 wherein the molding material is a paste.

3. The method of claim 1 wherein the molding material is silicone.

4. The method of claim 1 wherein the at least one core comprises a proximal portion, a central portion, and a distal portion, the proximal portion adapted to form the proximal end lumen, the tubular body and a distal end of the respiratory tube, the central portion adapted to form the distal end lumen of the respiratory tube and the distal portion adapted to form the hollow peripheral portion of the inflatable positioning shield.

5. The method of claim 4 wherein the core comprises a handle.

6. The method of claim 4 comprising at least two cores.

7. The method of claim 1 further comprising connecting an additional respiratory tube to the proximal end of the respiratory tube.

8. The method of claim 1 wherein the molding material is a liquid.

9. The method of claim 1 comprising two cores.

10. The method of claim 1 wherein the internals walls of the mold conform to the external walls of a laryngeal mask comprising a hollow peripheral portion that has a recessed front portion.

11. The method of claim 1 wherein introducing the molding material into the mold comprises introducing the molding material into the mold using pressure.

12. The method of claim 7 wherein the connection is accomplished using heat, pressure, or an adhesive.

13. The method of claim 1 wherein introducing the molding material into the mold comprises pouring the molding material into the mold.

14. The method of claim 8 wherein the molding material is polyvinylchloride.

15. The method of claim 8 wherein the molding material is a plastic.

16. The method of claim 1 wherein the internal walls of the mold conform to the external walls of a laryngeal airway comprising an inflatable positioning shield and a respiratory tube, the inflatable positioning shield having a hollow peripheral portion in fluid communication with the base, the base having a recessed front portion, a shield recess formed after inflation of the peripheral portion, and a rear portion formed between the base and the peripheral portion after inflation of the peripheral portion, the respiratory tube having a proximal end lumen, a curved tubular body of sufficient size to permit passage of endotracheal tubes or related medical instruments therethrough, and a distal end passing through and secured to the rear portion of the positioning shield, the distal end terminating at a distal lumen, the distal lumen passing through and secured to the rear portion of the positioning shield, and wherein the at least one core is adapted to form the hollow portions of the laryngeal airway.

17. The method of claim 1 wherein the molding material is introduced into the mold in an amount that fills the cavity of the mold.

18. The method of claim 16 wherein the recessed front portion comprises a material that imparts sufficient pliability to facilitate cupping of a patients trachea after inflation of the positioning shield.

19. The method of claim 1 wherein the molding material is at least one selected from the group consisting of polyvinylchloride, silicone, polyurethane, EVA, TPE, polyether block amide, a flexible plastic, a rubber material and combinations or mixtures thereof.

20. The method of claim 1 wherein the step of introducing at least one molding material onto internal walls of a mold is repeated after the molding material is allowed to cure.

21. The method of claim 1 further comprising warming the mold prior to introducing the molding material therein.

22. The method of claim 1 further comprising cooling the mold prior to introducing the molding material therein.

23. The method of claim 1 further comprising cooling the mold after the molding material is introduced therein.

24. The method of claim 1 wherein the at least one core comprises a distal portion, the distal portion adapted to form the hollow peripheral portion of the inflatable positioning shield.

25. The method of claim 1 wherein an amount of molding material is introduced into the mold that is sufficient to form external walls of the inflatable peripheral portions of the laryngeal airway that are about 0.5 to about 1.5 millimeters thick.

26. The method of claim 1 wherein the inflatable peripheral portions of the laryngeal airway formed is about 0.5 to about 1.5 millimeters thick.

27. The method of claim 1 further comprising warming the mold after the molding material is introduced therein.

28. The method of claim 1 comprising three cores.

29. A method of making a laryngeal airway of the type that includes a respiratory tube and an inflatable positioning shield, the shield having a base and a hollow peripheral portion, the respiratory tube comprising a proximal end lumen, a tubular body of sufficient size to permit passage of endotracheal tubes or related medical instruments therethrough, a distal end, passing through and secured to the positioning shield and a distal end lumen passing though and secured to the positioning shield, the method comprising:

introducing at least one molding material into a mold;

wherein the mold has a cavity defined by internal walls;

wherein the mold has at least one core within its cavity, the core being adapted to form the respiratory tube and the hollow, peripheral portion of the positioning shield;

wherein the internal walls of the mold conform to external walls of the laryngeal airway;

wherein the at least one core comprises a proximal portion, central portion, and a distal portion, the proximal portion adapted to form the proximal end lumen, the tubular body, and the distal end of the respiratory tube, the central portion adapted to form the distal lumen of the respiratory tube and the distal portion adapted to form the hollow, peripheral portion of the inflatable positioning shield; and

allowing the molding material to cure about the internal walls of the mold and the at least one core, thereby forming the laryngeal airway in a non-inverted form.

30. A method of making a laryngeal airway of the type that includes a respiratory tube and an inflatable positioning shield, the shield having a base and a hollow peripheral portion, the respiratory tube comprising a proximal end lumen, a tubular body of sufficient size to permit passage of endotracheal tubes or related medical instruments therethrough, and a distal end secured to the positioning shield, the distal end terminating at a distal lumen, which is secured to the positioning shield, the method comprising:

introducing silicone into a mold;

wherein the mold has a cavity defined by internal walls;

wherein the mold has at least one core within its cavity, the core being adapted to form the respiratory tube and the hollow peripheral portion of the positioning shield;

wherein the internal walls of the mold conform to external walls of the laryngeal airway;

wherein the at least one core comprises a proximal portion, a central portion, and a distal portion, the proximal portion adapted to form the proximal end lumen, the tubular body, and the distal end of the respiratory tube, the central portion adapted to form the distal end lumen of the respiratory tube and the distal portion adapted to form the hollow peripheral portion of the inflatable positioning shield;

and allowing the silicone to cure about the internal walls of the mold and the at least one core, thereby forming the laryngeal airway in a non-inverted form.

31. A method of making a laryngeal airway of the type that includes an inflatable positioning shield, the shield having a base and a hollow peripheral portion, the method comprising:

introducing at least one molding material into a mold;

wherein the mold has a cavity defined by internal walls;

wherein the internal walls of the mold conform to external walls of the laryngeal airway;

wherein the mold has at least one core within its cavity, the core being adapted to form the hollow peripheral portion of the positioning shield; and

allowing the molding material to cure about the internal walls of the mold and the at least one core, thereby forming the laryngeal airway in a non-inverted form.

32. The method of claim 31 further comprising connecting a respiratory tube to the positioning shield.

33. The method of claim 31 further comprising introducing the base into the mold prior to introduction of the molding material therein.

34. The method of claim 31 wherein the base comprises a respiratory tube.

35. The method of claim 31 further comprising introducing a secondary base onto the base.

36. The method of claim 31 wherein the secondary base comprises a respiratory tube.