Laminate Nasal Dilator with Segmented Resilient Layer
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Solution Overview
Problem
Existing nasal dilator devices face challenges such as limited skin surface area for dilation, adhesive breakdown due to moisture, discomfort from spring biasing forces, and high material waste in manufacturing, leading to inefficiencies in both production and user experience.
Innovation Solution
A laminate nasal dilator with vertically stacked layers, including a base layer, resilient layer, and cover layer, configured as a truss with adjustable length and minimal material waste, featuring divergent extensions and enlarged terminal ends to provide effective dilation with reduced stress on the skin and improved user adjustability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If spring-based resilient means are used to engage and urge outwardly the nasal passage outer walls, then nasal passage dilation is achieved, but peel and tensile forces are created that work to delaminate the end regions of the dilator device from the skin surfaces
Solution Approach 1:
The dilator device is divided into multiple segments including a first end region, an intermediate region, and a second end region. The resilient means is positioned specifically in the intermediate region, separating the force-generating function from the adhesive attachment regions. This segmentation prevents the spring biasing forces from directly acting on the adhesive bonds at the end regions, thereby reducing delamination while maintaining dilation effectiveness.
Solution Approach 2:
The intermediate region acts as an intermediary zone that houses the resilient means and transmits its biasing force to the nasal passage walls without directly involving the adhesive attachment points. This intermediary structure allows the spring force to be applied to the tissue while the end regions maintain stable adhesive contact with the skin, preventing delamination.
2Ease of manufacture
If the resilient member is made flat, substantially rectangular or slightly arcuate, then manufacturing is simplified, but the device creates concentrated peel and tensile forces that delaminate from skin surfaces
Solution Approach 1:
The resilient member is segmented into a first resilient portion and a second resilient portion positioned in the intermediate region, with the force application points separated from the adhesive end regions. This segmentation allows the resilient member to maintain simple flat or rectangular geometry for ease of manufacture while preventing concentrated forces from acting on the adhesive bonds, thereby improving retention.
3Reliability
If adhesive is applied to secure the dilator device to skin surfaces, then device attachment is achieved, but adhesive breaks down in the presence of skin oils, moisture and moisture vapor transmission within hours
Solution Approach 1:
The adhesive is applied only to the end regions (first and second end regions) that are separated from the resilient means by the intermediate region. This segmentation isolates the adhesive from the spring biasing forces, preventing force-induced delamination. Combined with positioning the adhesive away from moisture-prone areas near the nasal passages, this extends adhesive durability beyond the typical few-hour limit.
Solution Approach 2:
The intermediate region serves as a protective intermediary that shields the adhesive-bonded end regions from the harsh environment (moisture, skin oils) and mechanical forces (spring biasing) in the intermediate region. This intermediary positioning allows the adhesive to maintain its bond integrity for extended periods despite exposure to challenging nasal passage conditions.
4Ease of manufacture
If material is used to create peripheral dimensions of nasal strip devices, then device structure is formed, but material usage is substantially in excess of that devoted to the dilator itself with corresponding waste
Solution Approach 1:
The laminate structure is designed so that the same material layers serve multiple functions: providing structural support, housing the resilient means, and enabling adhesive attachment. By integrating these functions into a unified multi-layer construction rather than using separate components, the design reduces overall material usage and minimizes waste while maintaining manufacturability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances nasal passage dilation, reduces material waste, and provides a comfortable, user-adjustable, and cost-effective nasal dilator that can be easily assembled and applied, addressing the limitations of prior devices.
Implementation Method 1
a resilient layer (20) composed of a resilient means (22) having opposite terminal ends (23a, 23b) configured to provide between 15 and 30 grams of spring return
Data Source
AI summary
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.