External Nasal Dilator and Methods of Manufacture

Abstract

The present invention relates to external devices for dilating nasal passageways and to the manufacture thereof. More specifically, the external nasal dilator of the present invention usually comprises a resilient sheet, an adhesive layer, and an adhesive-protecting sheet. In some embodiments of the external nasal dilator, the resilient sheet defines a groove for reducing the peel force that results from bending the dilator over the bridge of the nose. In addition to the groove or in lieu thereof, some embodiments of the external nasal dilator comprise a nasal passage region having a reduced width to reduce the peel force. Finally, the dilator can comprise a sheet of adhesive tape, which in some embodiments can provide an instant tack surface to facilitate application of the dilator.

1 . An external nasal dilator comprising:
 an adhesive layer, said adhesive layer defining a first major surface and a second major surface;   a resilient sheet, said resilient sheet consisting substantially of a resilient material, said resilient sheet defining a third major surface and a fourth major surface, said resilient sheet superposed on said adhesive layer such that said fourth major surface contacts said first major surface; and   an adhesive-protecting sheet, said adhesive-protecting sheet consisting substantially of a first material suitable for protecting said adhesive layer and for being removably adhered to said adhesive layer, said adhesive-protecting sheet defining a fifth major surface and a sixth major surface, said adhesive-protecting sheet superposed on said adhesive layer such that said fifth major surface contacts said second major surface.   
   
   
       2 . The external nasal dilator of  claim 1  wherein said third major surface defines at least one groove, said at least one groove for reducing a peel force exerted by said resilient sheet following application of said external nasal dilator to a nose. 
   
   
       3 . The external nasal dilator of  claim 1  wherein said fourth major surface defines at least one groove, said at least one groove for reducing a peel force exerted by said resilient sheet following application of said external nasal dilator to a nose. 
   
   
       4 . The external nasal dilator of  claim 1  wherein said adhesive layer consists substantially of a hydrocolloid. 
   
   
       5 . The external nasal dilator of  claim 1  wherein said resilient material is selected from the group consisting of PET, boPET, PETG, HDPE, and polyester. 
   
   
       6 . The external nasal dilator of  claim 1  wherein said first material is selected from the group consisting of polypropylene, a similar thermoplastic resin, and a paper-based material. 
   
   
       7 . An external nasal dilator comprising:
 a bridge region for primarily contacting a bridge of a nose;   a first nasal passage region adjacent to said bridge region, said first nasal passage region for primarily contacting a first side of the nose;   a second nasal passage region adjacent to said bridge region and distal to said first nasal passage region, said second nasal passage region for primarily contacting a second side of the nose;   a first end region adjacent to said first nasal passage region and distal to said bridge region; and   a second end region adjacent to said second nasal passage region and distal to said bridge region.   
   
   
       8 . The external nasal dilator of  claim 7  wherein said first nasal passage region has a relatively short average width that is substantially less than the average width of said bridge region, said relatively short average width for reducing a peel force caused by application of said external nasal dilator to the nose. 
   
   
       9 . The external nasal dilator of  claim 7  wherein said second nasal passage region has a relatively short average width that is substantially less than the average width of said bridge region, said relatively short average width for reducing a peel force caused by application of said external nasal dilator to the nose. 
   
   
       10 . The external nasal dilator of  claim 7  wherein said first nasal passage region has a relatively short average width that is substantially less than the average width of said first end region, said relatively short average width for reducing a peel force caused by application of said external nasal dilator to the nose. 
   
   
       11 . The external nasal dilator of  claim 7  wherein said second nasal passage region has a relatively short average width that is substantially less than the average width of said second end region, said relatively short average width for reducing a peel force caused by application of said external nasal dilator to the nose. 
   
   
       12 . An external nasal dilator comprising:
 an adhesive layer, said adhesive layer defining a first major surface and a second major surface;   a resilient sheet, said resilient sheet consisting substantially of a resilient material, said resilient sheet defining a third major surface and a fourth major surface, said resilient sheet superposed on said adhesive layer such that said fourth major surface contacts said first major surface;   an adhesive-protecting sheet, said adhesive-protecting sheet consisting substantially of a first material suitable for protecting said adhesive layer and for being removably adhered to said adhesive layer, said adhesive-protecting sheet defining a fifth major surface and a sixth major surface, said adhesive-protecting sheet superposed on said first adhesive layer such that said fifth major surface contacts said second major surface; and   a sheet of adhesive tape, said sheet of adhesive tape superposed on said resilient sheet such that said sheet of adhesive tape adheres to said third major surface.   
   
   
       13 . The external nasal dilator of  claim 12  wherein said third major surface defines at least one groove, said at least one groove for reducing a peel force exerted by said resilient sheet following application of said external nasal dilator to a nose. 
   
   
       14 . The external nasal dilator of  claim 12  wherein said fourth major surface defines at least one groove, said at least one groove for reducing a peel force exerted by said resilient sheet following application of said external nasal dilator to a nose. 
   
   
       15 . The external nasal dilator of  claim 12  wherein said adhesive layer comprises a hydrocolloid. 
   
   
       16 . The external nasal dilator of  claim 12  wherein said resilient material is selected from the group consisting of PET, boPET, PETG, HDPE, and polyester. 
   
   
       17 . The external nasal dilator of  claim 12  wherein said first material is selected from the group consisting of polypropylene, a similar thermoplastic resin, or a paper-based material. 
   
   
       18 . The external nasal dilator of  claim 12  wherein said sheet of adhesive tape comprises an acrylic adhesive. 
   
   
       19 . The external nasal dilator of  claim 12  wherein said sheet of adhesive tape has a greater area than said resilient sheet, and said sheet of adhesive tape has a greater area than said adhesive layer, thereby defining an instant tack surface on said sheet of adhesive tape, said instant tack surface for facilitating application of said external nasal dilator to a nose. 
   
   
       20 . The external nasal dilator of  claim 12  wherein said resilient sheet is discontinuous. 
   
   
       21 . The external nasal dilator of  claim 12  wherein said adhesive layer is discontinuous. 
   
   
       22 . 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, thereby yielding a grooved three-layered material;   drawing said grooved three-layered material into a second set of rollers; and   cutting said grooved three-layered material, using said second set of rollers, into pieces having the perimeter shape of said external nasal dilator.   
   
   
       23 . The method of  claim 22  further including the step of kiss-cutting said third layer of said grooved three-layered material, using said second set of rollers. 
   
   
       24 . 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.   
   
   
       25 . The method of  claim 24  further including the step of kiss-cutting said unperforated layer of said second grooved three-layered material, using said fourth set of rollers. 
   
   
       26 . A method of making an external nasal dilator, said method comprising the steps of:
 providing a roll of a resilient material, said resilient material defining a first surface and a second surface;   drawing said resilient material into a first set of rollers;   impressing at least one groove into said second surface using said first set of rollers, yielding a grooved resilient material;   drawing said grooved resilient material into a second set of rollers;   providing a roll of a two-layered material, said two-layered material having a first layer and a second layer, said first layer consisting substantially of an adhesive substance, and said second layer consisting substantially of an adhesive-protecting material;   drawing said two-layered material into said second set of rollers;   merging said grooved resilient material and said two-layered material using said second set of rollers, thereby yielding a three-layered material wherein said adhesive substance is adhered to said grooved resilient material and to said adhesive-protecting material and wherein said second surface of said grooved resilient material is contacting said adhesive substance;   drawing said three-layered material into a third set of rollers;   heating said three-layered material using said third set of rollers to encourage bonding between said adhesive substance and said second surface of said grooved resilient material, thereby yielding a bonded three-layered material;   drawing said bonded three-layered material into a fourth set of rollers; and   cutting said bonded three-layered material, using said fourth set of rollers, into pieces having the perimeter shape of said external nasal dilator.   
   
   
       27 . The method of  claim 26  further including the step of kiss-cutting said adhesive-protecting material of said bonded three-layered material, using said fourth set of rollers.