External nasal dilator and methods
View Patent ↗Aspects of the present invention relate to methods of making an external nasal dilator amenable to continuous and automated manufacture. For example, in one embodiment of the method, a roll of a three-layered material is used as the starting material, the three layers consisting substantially and respectively of (1) a resilient sheet, (2) an adhesive-protecting sheet, and (3) an adhesive layer between the resilient sheet and the adhesive-protecting sheet. A series of dies are used to cut the three-layered material into the appropriate shape and (when necessary) to impress grooves in the resilient sheet.
1. A method of making an external nasal dilator, said method comprising the steps of:
providing a roll of a three-layered material, said three-layered material having a first layer, a second layer, and a third layer, said first layer consisting substantially of a resilient material, said second layer consisting substantially of an adhesive substance, and said third layer consisting substantially of an adhesive-protecting material;
drawing said three-layered material into a first set of rollers;
impressing at least one groove into said first layer, using said first set of rollers, by way of penetration through said second layer and said third layer, thereby yielding a first grooved three-layered material, said first grooved three-layered material comprising a perforated third layer;
drawing said first grooved three-layered material into a second set of rollers;
removing said perforated third layer using said second set of rollers, thereby yielding a grooved two-layered material;
drawing said grooved two-layered material into a third set of rollers;
adding an unperforated layer of an adhesive-protecting material to said grooved two-layered material using said third set of rollers, thereby yielding a second grooved three-layered material;
drawing said second grooved three-layered material into a fourth set of rollers; and
cutting said second grooved three-layered material, using said fourth set of rollers, into pieces having the perimeter shape of said external nasal dilator.
2. The method of claim 1 further including the step of kiss-cutting said unperforated layer of said second grooved three-layered material, using said fourth set of rollers.