Cuff for use with medical tubing and method and apparatus for making the same

1. A tube, comprising:

a forming tube comprising a tube wall; and

two or more cuffs formed from respective blown out portions of the tube wall, wherein the two or more cuffs are mirror images of each other and are configured to be separated from one another and to be incorporated onto respective endotracheal tubes as an endotracheal tube cuff.

2. The tube of claim 1 , wherein the forming tube is about 12 inches (30.48 cm) in length.

3. The tube of claim 1 , wherein the forming tube comprises a polymeric composition.

4. The tube of claim 3 , wherein the polymeric composition comprises polyurethane.

5. The tube of claim 1 , wherein the forming tube has an inner diameter between about 0.1708 inches and 0.296 inches (4.34 mm to 7.52 mm).

6. The tube of claim 1 wherein each cuff comprises wall that are 0.00086 inches (0.022 mm) thick or less.

7. The tube of claim 1 , wherein each cuff is tapered.

8. A blow molding system, comprising:

two or more molds, each comprising a cavity corresponding to a shape of a cuff, wherein the two or more molds are mirror images of each other, and wherein each cuff is configured to be separated from a forming tube and attached to a respective endotracheal tube body to form an endotracheal tube;

one or more heating/cooling jackets configured to secure the two or more molds and to actively heat and cool the two or more molds; and

two or more clamps, wherein the one or more heating/cooling jackets and the two or more molds are positioned between at least two of the clamps that are configured to move toward and away from the one or more heating/cooling jackets and the two or more molds.

9. The blow molding system of claim 8 , comprising a control station configured to control operation of the one or more heating/cooling jackets and the two or more clamps.

10. The blow molding system of claim 8 , wherein each mold is secured in a respective heating/cooling jacket.

11. The blow molding system of claim 8 , wherein at least two molds are secured in each heating/cooling jacket.

12. The blow molding system of claim 8 , wherein the two or more molds are arranged in series.

13. The blow molding system of claim 8 , wherein the two or more molds are arranged in parallel.

14. A mold assembly, comprising:

two or more molds, each comprising a cavity corresponding to a shape of a cuff, wherein the two or more molds are minor images of each other, and wherein each cuff is configured to be separated from a forming tube and attached to a respective endotracheal tube body to form an endotracheal tube; and

one or more heating/cooling jackets configured to secure the two or more molds and to actively heat and cool the two or more molds.

15. The mold assembly of claim 14 , wherein the two or more molds comprise beryllium copper.

16. The mold assembly of claim 14 , wherein the two or more molds are arranged in series in a heating/cooling jacket or in separate respective heating/cooling jackets.

17. The mold assembly of claim 14 , wherein the two or more molds are arranged in parallel in a heating/cooling jacket or in separate respective heating/cooling jackets.

18. The mold assembly of claim 14 , wherein four or more molds are arranged in series and in parallel in the one or more heating/cooling jackets such that a first subset of the molds are situated end-to-end with respect to one another but side-by-side with respect to a second subset of the molds.

19. A method of manufacturing two or more inflatable cuffs in a single operation comprising:

clamping each end of a forming tube, wherein portions of the forming tube are positioned within two or more molds, wherein the two or more molds are minor images of each other;

stretching the forming tube by pulling the ends of the forming tube away from the two or more molds;

increasing the pressure within the forming tube such that the portions of the forming tube within the two or more molds are blown outward to conform to the shape of the molds to form two or more cuffs, wherein each cuff is configured to be separated from the forming tube and attached to a respective endotracheal tube body to form an endotracheal tube;

heating the molds for an interval of time;

cooling the molds;

decreasing the pressure within the tube;

removing tension on the tube by moving the ends of the tube toward the two or more molds; and

releasing the ends of the tube.

20. A method of manufacturing two or more inflatable cuffs in a single operation comprising:

loading one or more tubes into a mold assembly comprising two or more molds, wherein the two or more molds are mirror images of each other;

initiating a blow molding program on a blow molding machine, wherein the blow molding program initiates and controls stretching, heating, pressurizing, and cooling operations performed by the blow molding machine such that a cuff is formed in a respective portion of tube disposed within each of the two or more molds;

removing the one or more tubes from the mold assembly, wherein each tube comprises at least two cuff regions; and

cutting the cuff regions from the one or more tubes to form two or more cuffs.

21. The method of claim 20 , comprising attaching each of the two or more cuffs to a respective endotracheal tube body to form respective endotracheal tubes.

22. A mold assembly, comprising:

two molds, each comprising a cavity corresponding to a shape of a cuff having a distal end and a proximal end, and wherein the two molds are arranged end to end such that the distal end of one cavity is adjacent to the proximal end of the other cavity, and wherein each cuff is configured to be separated from a forming tube and attached to a respective endotracheal tube body to form an endotracheal tube; and

one or more heating/cooling jackets configured to secure the two molds and to actively heat and cool the two molds.

23. The mold assembly of claim 22 , wherein each cavity is tapered.