Economical nasal dilator and method of manufacture
A nasal dilator comprises a laminate of vertically-stacked layers that form a unitary truss. The truss features end regions that engage outer wall tissues of a user's nasal passages, joined by an interconnecting region that traverses the bridge of the nose. The dilator acts to stabilize nasal outer wall tissues and prevent them from drawing inward during breathing. Dilator components are sized and shaped to engage the nose and provide effective dilation, and to facilitate lateral and longitudinal registration during manufacture, while reducing material waste. Methods of manufacture include progressive steps to fabricate and assemble components into finished devices. Some partially-assembled embodiments include a final assembly step performed by the user to create a dilator with a customized truss length.
1. A method of assembling and affixing a nasal dilator, comprising:
selecting a first self-adhesive end region component and a second self-adhesive end region component from a plurality of such end region components;
selecting a resilient member from a plurality of new resilient members, said new resilient members neither formerly nor independently functional as a nasal dilator;
adhering the resilient member to the first self-adhesive end region component so that the first self-adhesive end region is secured near a corresponding first terminal end edge of the resilient member;
adhering the resilient member to the second self-adhesive end region component so that the second self-adhesive end region component is secured near a corresponding second terminal end edge of the resilient member;
affixing the first self-adhesive end region to skin over a first nasal passage of a user; and
affixing the second self-adhesive end region to skin over a second nasal passage of the user, wherein a second-performed one of the two affixing operations causes the resilient member to be flexed out-of-plane across a bridge of a nose of the user.
2. The method of claim 1 wherein all of the selecting, adhering and affixing operations are performed manually by the user.
3. The method of claim 1 , further comprising:
affixing a first end-region cover over the first end region and at least a portion of the first terminal end edge of the resilient member; and
affixing a second end-region cover over the second end region and at least a portion of the second terminal end edge of the resilient member.
4. The method of claim 1 , further comprising:
lifting one of the first or second self-adhesive end region components off of a release paper liner after a first of the two adhering operations and before a second of the two adhering operations.
5. A method of assembling and affixing a nasal dilator, comprising:
manually bringing a terminal end edge of a new, pre-cut resilient member into proximity with a separate, pre-cut end region component, at least one of the terminal end edge or the pre-cut end region component provided with an adhesive interface material;
adhering the terminal end edge of the pre-cut resilient member to one side of the pre-cut end region component by the adhesive interface material; and
affixing another side of the pre-cut end region component to skin adjacent a nasal passage of a user,
wherein said new, pre-cut resilient member is neither formerly nor independently functional as a nasal dilator.
6. The method of claim 5 , further comprising:
repeating the bringing and adhering operations with a second terminal end edge of the new, pre-cut resilient member and a second separate pre-cut end region component; and
affixing the second separate pre-cut end region component to skin adjacent a second nasal passage of the user so that the new, pre-cut resilient member is flexed across a bridge of a nose of the user.
7. The method of claim 5 , further comprising:
adhering a pre-cut cover layer member over at least one of the pre-cut end region components.
8. The method of claim 5 wherein the terminal end edge of the new, pre-cut resilient member is bifurcated into a plurality of spring fingers.
9. The method of claim 8 wherein the adhering operation adheres the plurality of spring fingers to the end region components.
10. The method of claim 5 wherein the pre-cut end region component is a single member that extends from one end of an assembled dilator, across a bridge of a nose of the user, and to another end of the assembled dilator.
11. A method of assembling a nasal dilator by hand from a plurality of pre-fabricated nasal dilator components, comprising the steps of:
a) selecting and separating a new resilient member component from a plurality thereof, said new resilient member component neither formerly nor independently functional as a nasal dilator;
b) selecting and separating first and second end region components from a plurality thereof; and
c) bonding first and second resilient member end portions to the selected first and second end region components.
12. The method of claim 11 wherein:
the bonding of the first and second resilient member end portions sets a length of the dilator, the resilient member terminal ends extending past or short of first and second end region component lateral end edges, the terminal ends thus being variably aligned thereto so as to accommodate a wider range of dimensions of a nose.
13. The method of claim 11 , further comprising:
affixing at least one additional end region component to at least a portion of at least one of the first and second end region components.
14. The method of claim 11 wherein the bonding operation of the first and second resilient member end portions is performed, at least in part, in situ on a human nose, and further comprising:
engaging the first and second end region components to a skin surface adjacent first and second nasal passages, respectively, of the human nose.
15. The method of claim 14 wherein an order of assembling the dilator in situ on the nose is:
the first and second end region components followed by the resilient member first and second end portions bonded thereto.
16. The method of claim 14 wherein an order of assembling the dilator in situ on the nose is:
the first end region component, followed by the resilient member first end portion bonded thereto, followed by the second end region component, followed by the resilient member second end portion bonded thereto.
17. The method of claim 14 wherein an order of assembling the dilator in situ on the nose is:
the first and a second resilient member end portions followed by the first and second end region components bonded thereto.
18. The method of claim 14 wherein an order of assembling the dilator in situ on the nose is:
the resilient member first end portion, followed by the first end region component bonded thereto, followed by the resilient member second end portion, followed by the second end region component bonded thereto.