One piece stethoscope diaphragm

Abstract

Aspects of the present disclosure relate to a method of making a one piece diaphragm. The method includes providing a tool die, providing a disc formed from a first material, positioning the disc within an injection mold, providing a second material; heating the second material. The method includes melt molding the second material into the tool die and around a peripheral edge of the disc to form the one piece diaphragm comprising a rim, and removing the one piece diaphragm from the injection mold.

What is claimed is: 
     
         1 . A method of making a one piece diaphragm comprising:
 providing a tool die;   providing a disc formed from a first material;   positioning the disc within an injection mold;   providing a second material;   heating the second material;   melt molding the second material into the tool die and around a peripheral edge of the disc to form the one piece diaphragm comprising a rim; and   removing the one piece diaphragm from the injection mold.   
     
     
         2 . The method of  claim 1 , wherein the tool die is an injection mold and wherein melt molding is an injection molding process. 
     
     
         3 . The method of  claim 1 , wherein the disc is further provided with a plurality of apertures positioned around the periphery of the disc. 
     
     
         4 . The method of  claim 3 , wherein melt molding further comprises melt molding the second material into the plurality of apertures and forming a plurality of bonds which connect rim material on one side of the disc to rim material on the opposite side of the disc. 
     
     
         5 . The method of  claim 1 , wherein the first material is selected from a group consisting of: polyester, fiberglass-reinforced plastics, fiberglass, polycarbonates, carbon fiber composites, polystyrene, and metals. 
     
     
         6 . The method of  claim 1 , wherein the rim comprises:
 a wall having a first end and a second end;   a lip extending substantially perpendicularly from the first end of the wall;   a bridge extending substantially perpendicularly from the second end of the wall; and   a fork extending from the bridge.   
     
     
         7 . The method of  claim 6 , wherein portions of the fork are melted through any apertures in the disc to provide secure placement of disc within the rim. 
     
     
         8 . The method of  claim 6 , wherein the wall has a circular or a ring-shaped configuration, the wall having an inner side and an opposite outer side, and a patient facing edge and an opposite chestpiece facing edge;
 wherein the lip extends substantially perpendicularly from the inner side of the wall at the chestpiece facing edge; and   wherein the bridge extends substantially perpendicularly from the inner side of the wall at the patient facing edge of the wall.   
     
     
         9 . The method of  claim 8 , wherein a patient facing surface of the rim of the one piece diaphragm is flat. 
     
     
         10 . The method of  claim 1 , wherein the rim further comprises a step. 
     
     
         11 . The method of  claim 1 , wherein the second material is at least one of polymeric resin, silicone, rubber, flexible plastic and fiberglass 
     
     
         12 . The method of  claim 1 , wherein, upon removing the one piece diaphragm, the disc and the rim are a unitary piece. 
     
     
         13 . The method of  claim 1 , wherein the rim has a Shore A durometer hardness of between about 40 and 110. 
     
     
         14 . The method of  claim 13 , wherein the rim has a Shore A durometer hardness of between about 70 and 90. 
     
     
         15 . The method of  claim 1 , further comprising positioning the one-piece diaphragm on a chestpiece. 
     
     
         16 . The method of  claim 15 , further comprising attaching the chestpiece to a headset.