Abstract:
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&#39;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.

Description:
RELATED APPLICATIONS 
     The present application is a Continuation of, and claims priority benefit to, U.S. Nonprovisional patent application Ser. No. 12/024,763 filed Feb. 1, 2008, incorporated by reference in its entirety herein. U.S. patent application Ser. No. 12/024,763 claims priority benefit to U.S. Provisional Patent Application No. 60/888,543 filed Feb. 6, 2007, also incorporated by reference in its entirety herein. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to apparatus and methods of dilating external tissue. As disclosed and taught in the preferred embodiments, the tissue dilator devices and methods of fabrication of tissue dilators are particularly suitable for use as external nasal dilators for supporting, stabilizing, and dilating nasal tissues adjacent and overlying nasal airway passages, including the nasal valve and/or the vestibule areas thereof. 
     BACKGROUND OF THE INVENTION 
     A portion of the human population has some malformation of the nasal passages which interferes with breathing, including deviated septa and swelling due to allergic reactions. A portion of the interior nasal passage wall may draw in during inhalation to substantially block the flow of air through the nasal passage. Blockage of the nasal passages as a result of malformation, symptoms of the common cold or seasonal allergies are particularly uncomfortable at night, and can lead to sleep disturbances, irregularities and general discomfort. 
     Spring-based devices for dilating tissue of the human nose adjacent the nasal passages, and the concept of utilizing resilient means to engage and urge outwardly the nasal passage outer walls from either the interior mucosa or exterior epidermis sides thereof, have a history spanning over one hundred years. Some examples of present external nasal dilators are disclosed in U.S. Pat. Nos. 6,453,901; D379,513; D429,332; D430,295; D432,652; D434,146; D437,64; U.S. patent application Ser. No. 08/855,103; and Japanese patent Reg. No. 1037944; the entire disclosures of which are incorporated by reference herein. The commercial success of at least one of these inventions, together with that of other modern external nasal dilators, collectively and commonly referred to as nasal strips, has led to the creation and establishment of a nasal dilator product category in the present consumer retail marketplace. Commercial success of prior art devices disclosed before 1990 is assumed to be commensurate with the nature of the consumer product retail environments at the times of those inventions. 
     A long-standing practice in the construction and use of medical devices which engage external bodily tissue (i.e., tissue dilators, nasal splints, ostomy devices, surgical drapes, etc.) is to interpose an interface material between the device and the user&#39;s skin to facilitate engagement of the device to the skin and to aid user comfort. Said material, such as a spunlaced polyester nonwoven fabric, typically has properties which permit limited, primarily plastic and somewhat elastic deformation within the thickness thereof. These properties can spread out peeling, separating or delaminating forces such as may be caused by gravity acting on the weight of the device; the device&#39;s own spring biasing force or rigidity (such as that of a tissue dilator or nasal splint); biasing force that may be present in bodily tissue engaged by the device; surface configuration differences between the device and the skin of the device wearer; displacement of the device relative to the skin or external tissue as a result of shear, tensile, cleavage and/or peel forces imparted thereat via wearer movement (e.g., facial gestures) and/or contact with an object (e.g., clothing, pillow, bedding, etc.); and so on, that may cause partial or premature detachment of the device from the wearer. By spreading out these delaminating forces, said interface material acts as a buffering agent to prevent the transfer of said forces to its adhesive substance, if any, and thereby to the skin. Preventing the transfer of focused delaminating forces substantially eliminates any itching sensation (caused by the separation of the adhesive substance or device from the skin) that a wearer may experience if these delaminating forces were otherwise imparted directly to the skin. 
     The present nasal dilator art addresses, in part, obstacles and design constraints of spring-based dilator devices. Firstly, tissues associated with first and second nasal passages have limited skin surface areas to which dilation may be applied. Said surface areas comprise a range extending vertically from the nostril opening to the cartilage just above the nasal valve, and extending horizontally from each approximate line where the nose meets the cheek to the vertical centerline of the bridge of the nose. Secondly, nasal dilators are, of necessity, releasably secured to said skin surfaces by use of pressure sensitive adhesives. Skin surfaces transmit moisture vapor to the surrounding atmosphere. Said adhesives break down in the presence of skin oils, moisture and the transmission of moisture vapor, usually within hours. Thirdly, the functional element of external spring-based nasal dilator devices is a semi-rigid resilient member flexed across and extending on each side of the bridge of the nose adjacent the nasal passages. In modern nasal dilators the resilient member is flat, substantially rectangular or slightly arcuate, and made of plastic. The resilient member exerts a spring biasing force which tends to substantially return or restore the device to an original, typically planar, state thus dilating the local tissue. Fourthly, said spring biasing force creates peel and tensile forces which work to delaminate the end regions of the dilator device from the skin surfaces so engaged. Less than 15 grams of spring return may not provide suitable stabilization or dilation of the nasal passage tissue, while a restoring force of greater than 35 grams would likely be uncomfortable, and would, in addition, require adherence or engagement means that would be uncomfortable, if not damaging, to the tissue. 
     External nasal dilators are thus subject to the design parameters and dynamics associated with surface area, comfort, dilation efficacy, engagement/adherence means and durational longevity. Accordingly, the vast majority of spring-based nasal dilator devices which engage nasal outer wall tissues are typically within 5.0 to 7.5 cm (2.0″ to 3.0″) in length and 1.2 to 2.5 cm (0.5″ to 1.0″) in width. Their resilient members are typically from 4.2 to 5.8 cm (1.7″ to 2.3″) long, approximately 0.048 to 0.12 cm (0.12″ to 0.30″) wide and typically 0.010″ thick. A resilient member thickness of more or less than 0.010″ is not typically used in the art, but can be incorporated with proportionate adjustments to width and length. 
     The most widely used peripheral dimensions of commercially available nasal strip devices result in material usage (excluding resilient member material) of about 1.7″ squared (from an average 2.63″L×average 0.63″W), and up to about 3.3″ squared if two full dimensional material layers are used. The latter is considered a best practice for commercially available nasal strips. Nasal strips are typically manufactured in a continuous process with their lengths parallel to the machine direction (MD) of the material used. Standard converting techniques space each strip apart by about 0.125″ on all sides to allow waste material therebetween to be removed as a single matrix. To individually package finished dilators in the same operation, said spacing must be further increased to allow a suitable contact perimeter extending around the dilator within which upper and lower packaging material webs may form a seal. Individual packaging is also considered a best practice. In the alternative, nasal strip parts fabricated in closer proximity with correspondingly less waste may be individually packaged in a separate operation, with an additional converting cost associated therewith, in lieu of said additional spacing between nasal strip devices. Regardless, material usage in a spaced-apart relationship, excluding resilient member material, can be substantially in excess of that which is devoted to the dilator itself, and can encompass about 3.9″ squared (3.13″L×1.25″W) per each of one or two layers. Accordingly, 1,000 square inches (MSI) of material could yield as few as about 256 single-layer, substantially rectangular, dilator devices that are narrower in the middle and wider at their ends, or about 128 two-layer devices (dilator material use=256×1.7″ sq., or 128×3.3″ sq. per MSI). This corresponds to material usage of about 43% with a corresponding waste of about 57%, or a usage-to-waste ratio of about 0.75 to 1. 
     A minority of presently known nasal dilator devices are suitable or adaptable for mass commercialization in the present consumer retail markets. A minority of these have had commercial success. Exemplary of the latter include devices disclosed in U.S. Pat. Nos. D379,513; 5,546,929; RE35408; 7,114,495; Spanish Utility Model 289-561 for Orthopaedic Adhesive; and a widely available retail product, Breathe Right Nasal Strips. These devices provide sufficient dilation of nasal passageway tissue and thus provide the claimed benefit to the vast majority of users. However, these devices can be costly to manufacture, either by wasting material in the course of manufacture and packaging, or by greater fabrication (i.e., converting) costs associated with techniques by which to reduce material waste. Furthermore, these devices are not adapted for assembly of their constituent components by the user. 
     In an open market environment, nasal dilator device innovation and competitive value propositions to resellers and consumers contribute to product category viability and longevity. A need in the art thus exists for continued innovation in manufacturing nasal dilator devices at lower costs without sacrificing features that may adversely affect user perception of device benefits or measurable device efficacy. The present invention is directed to discrete embodiments and various forms of external nasal dilators, including techniques and methods for manufacturing nasal dilators and/or fabricating the constituent components thereof. 
     SUMMARY OF THE INVENTION 
     The present invention teaches, depicts, enables, illustrates, describes and claims new, useful and non-obvious apparatus and methods of providing dilation to external tissue. In particular, the present invention provides a wide variety of tissue dilators adapted to engage an exterior tissue region of a nose to dilate interior nasal passages thereof, including the vestibule and/or nasal valve areas. The present invention builds upon the prior art and addresses several still unmet needs in the art. 
     In the specification and claims herein, the term vertical refers to a direction parallel to the thickness of the dilator or truss. The term horizontal refers to a direction parallel to the length, or longitudinal extent, or long axis of the dilator or truss. The term lateral refers to the width or opposite end edges of the dilator or truss, or a direction perpendicular to the length, longitudinal extent, or long axis of the dilator or truss. The term longitudinal centerline refers to a line parallel to the longitudinal extent of the dilator or truss, bisecting the width of the dilator or truss midway between its upper and lower long edges. The term lateral centerline refers to a line perpendicular to the length, longitudinal extent, or long axis of the dilator or truss, bisecting the long axis, or upper and lower long edges, midway along the length thereof. 
     The external nasal dilator of the present invention comprises a laminate of vertically stacked layers, each comprising at least one member which may include components thereof, including a base layer, a resilient layer comprising resilient means, and a cover layer. The combined laminated layers form a unitary, or single body, truss. The truss features horizontal regions including first and second end regions adapted to engage outer wall tissues of first and second nasal passages, respectively, and an intermediate region adapted to traverse a portion of a nose located between the first and second nasal passages and joining the end regions. In use the dilator acts to stabilize and/or expand the nasal outer wall tissues and prevent said tissues from drawing inward during breathing. 
     Dilator members and/or components are fabricated to dimensional criteria suitable to engage and provide effective dilation to nasal passages, as described hereinbefore, that create lateral and longitudinal registration of dilator members or components during manufacture, and that facilitate manufacture with minimal material waste, all as part of a continuous manufacturing process. The dilator of the present invention is configured to maximize the percentage of a given amount of material used in the manufacturing process and to return a greater number of individual dilator units per a given quantity of material. The dilator is further configured to facilitate assembly and application by the user (i.e., fabricated in situ) and to allow user adjustment of the truss length. The truss is configured to be comfortable on the tissue engaged and to be easily removed from the tissue with minimal stress thereto. 
     Methods of manufacture include separate functions, or steps, for the fabrication, assembly and packaging of dilator members and/or components thereof. Said functions or steps are combined into a single continuous process. Embodiments include, without limitation, a truss which features a resilient member with divergent extensions and/or enlarged terminal ends, resilient means comprising a plurality of resilient members joined together at their end portions to form a single member, and a truss adapted for user-adjusted length thereof. 
     It is the principal objective of this invention to provide nasal dilator devices which overcome the aforementioned limitations and disadvantages of prior dilator devices. It is a further objective of this invention to provide nasal dilator devices that are less expensive to manufacture, that utilize a greater percentage of a given quantity of material in the manufacturing process without increasing the converting cost thereof, that are simple and easy to use, that use less material in device construction, that waste less material in manufacturing, that effectively dilate external tissue, that may be assembled by the user, that have a user-adjustable length, that are comfortable and may be removed from the tissue with minimal stress thereto, and which are more affordable to the user than prior art dilator devices. 
     For fabricating and assembling the dilator of the present invention, the skilled man in the art will appreciate the applicability of the continually developing art of medical device converting, including rotary laminating and die cutting, flatbed and class A tool die cutting and punching, fluid or pneumatic modular automation components, and pneumatic feeding and material handling components and systems. 
     The present invention is not limited to the illustrated or described embodiments as these are intended to assist the reader in understanding the subject matter of the invention. The preferred embodiments are examples of forms of the invention comprehended by the devices taught, enabled, described, illustrated and claimed herein. All structures and methods which embody similar functionality are intended to be covered hereby. In certain instances, the devices depicted, taught, enabled and disclosed herein represent families of new, useful and non-obvious tissue dilators having a variety of alternate embodiments. The skilled man will appreciate that features, devices, elements, components, methods, processes or techniques may be applied, interchanged or combined from one embodiment to another. Dilator members, components, materials, layers or regions may be of differing size, area, thickness, length or shape than that illustrated or described while still remaining within the purview and scope of the present invention. The preferred embodiments include, without limitation, the following numbered, discrete forms of the invention, as more fully described below. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING 
       In the drawings which accompany this disclosure, like elements are referred to with common reference numerals. Drawings are not rendered to scale. 
         FIG. 1  is perspective view of a portion of a face with a nasal dilator in accordance with the present invention secured to a nose. 
         FIG. 2  is an exploded perspective view of the nasal dilator of  FIG. 1 . 
         FIG. 3  is a perspective view of the nasal dilator of  FIG. 2 . 
         FIG. 4  is a plan view of a second form of nasal dilator embodying the features of the present invention. 
         FIG. 5  is a fragmentary plan view illustrating lateral registration, within a continuous fabrication process, of components of the nasal dilator of  FIG. 4 . 
         FIG. 6  is a fragmentary plan view illustrating longitudinal registration, within a continuous fabrication process, of components of the nasal dilator of  FIG. 4 . 
         FIG. 7  is a fragmentary plan view illustrating a method of manufacturing and assembling constituent layers of the nasal dilator of  FIG. 4 . 
         FIG. 8  is a plan view of a third form of nasal dilator embodying the features of the present invention. 
         FIG. 9  is a perspective view of an alternative form of nasal dilator embodying the features of the present invention. 
         FIG. 10 a    is a fragmentary perspective view illustrating the initial steps of a method of manufacturing a nasal dilator. 
         FIG. 10 b    is a fragmentary perspective view illustrating subsequent steps of a method of manufacturing the nasal dilator of  FIG. 9 . 
         FIG. 10 c    is a fragmentary perspective view illustrating the final steps of a method of manufacturing the nasal dilator of  FIG. 9 . 
         FIG. 11  is a perspective view of a plurality of continuous resilient members as die cut from a continuous resilient layer material. 
         FIG. 12  is a perspective view illustrating a method of manufacturing and assembling the constituent components of a fourth form of nasal dilator embodying the features of the present invention. 
         FIG. 13  is a perspective view illustrating a method of manufacturing and assembling the constituent components of an alternate form of the nasal dilator of  FIG. 9 . 
         FIG. 14  is a perspective view of a nasal dilator assembled from the components and method illustrated in  FIG. 13 . 
         FIG. 15  is a plan view of a fourth form of nasal dilator embodying the features of the present invention. 
         FIG. 16  is an exploded perspective view of an alternative form of the nasal dilator of  FIG. 15 . 
         FIG. 17  is a perspective view of a variation of the nasal dilator of  FIG. 15 . 
         FIG. 18  is a plan view of an alternative form of the nasal dilator of  FIG. 4 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     An embodiment of nasal dilator,  10 , in accordance with the present invention, is illustrated in  FIG. 1  which shows dilator  10  engaged to a nose,  11 , seen as a portion of a human face,  12 . 
     As illustrated in  FIG. 2 , dilator  10  comprises a laminate of vertically stacked layers, each comprising at least one member which may include components thereof, including: a base layer composed of discrete first and second base layer pads,  14   a , and  14   b , which may be formed as a single member; a resilient layer composed of a pair of spaced apart upper and lower resilient bands,  20   a  and  20   b  joined together at end portions,  21   a , and  21   b , respectively, to form a single resilient member,  22 ; and a cover layer composed of discrete first and second cover layer pads,  18   a  and  18   b , which may be formed as a single member. First and second cover layer pads  18   a  and  18   b  may have like or dissimilar dimensions as first and second base layer pads,  14   a  and  14   b . A protective layer of release paper liner,  15 , removably covers the exposed adhesive of base layer pads  14   a  and  14   b  preliminary to use of dilator  10 . The shape and dimensions of release liner  15  may correspond to the periphery of base layer pads  14   a  and  14   b , the periphery of dilator  10 , or a periphery exceeding one or more dilators  10 . The members, components or layers of dilator  10  are not required to be, but are preferably, aligned along their longitudinal centers. Said longitudinal centers are parallel to the length, or longitudinal extent, of dilator  10 . 
     The preferred material for the base and cover layers is from a group of widely available flexible nonwoven synthetic fabrics that allows the skin on user nose  11  to exchange gases with the atmosphere and to maximize comfort of dilator  10  thereon. Said fabrics have a continuous pressure sensitive adhesive substance disposed on one flat surface side thereof; the adhesive side, opposite the non-adhesive side. The non-adhesive side is opposite the skin facing/engaging side. Said adhesive is preferably of a type that is biocompatible with external human tissue for engaging dilator  10  to the nose  11  of a wearer. A protective layer of release paper liner removably covers said adhesive. Said fabrics are available in continuous rolls wound in a machine direction (MD) or warp, which is perpendicular to the cross direction (XD) or fill, of the fabric. The members, components and layers of dilator  10  may be fabricated parallel to either the warp or the fill of said fabrics. Base layer pads  14   a  and  14   b  and/or cover layer pads  18   a  and  18   b  are configured by their length and width to correspond to at least portions of the skin surfaces of outer wall tissues adjacent and overlying first and second nasal passages, respectively. As described hereinbefore, said surfaces extend vertically from the nostril opening to just above the nasal valve and extend horizontally from the approximate lines where nose  11  meets the cheek of a face  12  to the vertical centerline of the bridge of nose  11 . The width of first and second base layer pads  14   a  and  14   b  and/or the first and second cover layer pads  18   a  and  18   b  define the width of dilator  10 . 
     An interface member,  16 , may be optionally interposed between at least portions of the layers of dilator  10 , but preferably between the base layer and resilient layers. Interface member  16  may comprise an adhesive substance or a suitable material, including flexible or semi-rigid plastic, fabric, foam or the like with an adhesive substance disposed at least in part on either one or both opposite flat surface sides. Interface member  16  may be of any shape, but preferably does not exceed the periphery of dilator  10 . Interface member  16  may optionally extend along the entire length of resilient member  22  or a portion thereof.  FIG. 2  shows interface member  16  joining or laminating the resilient layer to the base layer. It may simultaneously laminate portions of the base layer to the cover layer. 
     The preferred material from which resilient member  22  is fabricated is a biaxially oriented polyester resin (PET) widely available in continuous rolls under trade names such as Mylar® and Melinex®. Said rolls may include a continuous pressure sensitive adhesive substance disposed on one flat surface side thereof protected by a layer of release paper liner which removably covers said adhesive. PET comes in standard thicknesses of 0.005″, 0.007″, and 0.010″. The spring biasing properties of PET are similar both MD and XD. Accordingly, in the preferred embodiments herein, resilient member components are preferably fabricated perpendicular to the continuous roll length (MD) of the PET. Resilient member  22  may have an adhesive substance disposed on at least a portion of at least one of two opposite flat surface sides for engaging or laminating resilient member  22  to other members, components or layers of dilator  10  as well as to the skin of nose  11 . Optionally eliminating adhesive from along those portions or surfaces of resilient member  22  that contact the skin of a nose  11  creates and defines an adhesive void,  19 , along said contacting portions or skin-facing surfaces. With less adhesive surface on dilator  10 , adhesive void  19  allows easier removal from nose  11  with less stress thereto. Resilient member  22  has opposite terminal ends,  23   a  and  23   b , respectively, that may conform to at least portions of the outer lateral end edges of dilator  10 . Terminal ends  23   a  and  23   b  may be variably aligned with said end edges, extending past or short thereof. In this manner the overall length of truss  30  may be increased or decreased to fit a wider range of dimensions of a nose  11  without altering the spring biasing properties of resilient member  22 . As illustrated in  FIGS. 1-3 , terminal ends  23   a  and  23   b  of resilient member  22  are preferably rounded and preferably correspond to at least portions of like rounded outer lateral end edges of dilator  10 . 
     Resilient member  22  includes a discontinuity of material in the form of a material separation which may be contained either wholly within the peripheral edges of resilient member  22 , or may extend inward or outward from at least one peripheral edge thereof. Said material separation may comprise at least one slit, cut, opening, notch, protrusion, indentation or the like, and may be symmetric, asymmetric, straight, curved or gradient. In  FIGS. 1-5 , said material separation comprises an elongated interior opening,  26   a , extending along the length of resilient member  22 . Opening  26   a  defines the parallel, spaced apart relationship of upper and lower resilient bands  20   a  and  20   b , and defines the lengths of first and second end portions,  21   a  and  21   b , of resilient member  22 . First and second end portions  21   a  and  21   b  extend from each terminal end of opening  26   a  to each terminal end  23   a ,  23   b , respectively, of resilient member  22 . End portions  21   a  and  21   b  may be of the same or dissimilar widths as the overall width of resilient member  22 . Resilient bands  20   a  and  20   b  may be of like or dissimilar widths, and are preferably parallel to each other and parallel to a longitudinal extent of dilator  10 . The spaced apart arrangement of resilient bands  20   a  and  20   b , along with the relatively slight thickness of the PET, enhances the axial, torsional flexibility of resilient member  22  along its length. 
     Resilient member  22  is configured by its overall dimensions of width, length, and thickness to provide between 15 and 30 grams of spring return biasing force. In those embodiments where resilient member  22  includes a upper and lower resilient bands,  20   a  and  20   b , each band contributes a portion of that total. Thus the dimensions of resilient member  22 , which may be defined in part by opening  26   a , end portions  21   a  and  21   b , and upper and lower resilient bands  20   a  and  20   b , determine said spring biasing force and further define the lateral and longitudinal dimensional relationships of resilient member  22  to the other components of dilator  10 . 
     As illustrated in  FIG. 3 , the combined laminated layers of dilator  10  create, define and form a unitary, or single body, truss,  30 , having horizontal regions as indicated by broken lines. Truss  30  includes a first end region,  32 , a second end region,  34 , and an intermediate region,  36 , joining first end region  32  to second end region  34 . The members or components of dilator  10  may overlap from the originating region to the adjacent region. End regions  32  and  34  are adapted to engage outer wall tissues of first and second nasal passages, respectively. Discrete base layer pads  14   a  and  14   b  and/or discrete first and second cover layer pads,  18   a  and  18   b , correspond substantially to respective first and second end regions  32  and  34 . Accordingly, said discrete cover or base layer pads may be referred to generally as end region components. 
     End regions  32  and  34  include lateral end edges,  33   a , and  33   b , respectively, which typically define the outer lateral end edges of truss  30  and thus dilator  10 . End edges  33   a  and  33   b  may correspond or conform, at least in part, to terminal ends  23   a  and  23   b  of resilient member  22 . The width of intermediate region  36  is generally less than the width of end regions  32  and  34 , and may be prevented from contacting the skin by use of a centrally located absorbent pad,  38 . Pad  38  creates and defines a contact void,  40 , between the skin facing side of intermediate region  36  and the skin of the nose  11 , and extending from the lateral sides of pad  38  to respective end regions  32  and  34 . As with adhesive void  19 , contact void  40  aids in user comfort due the truss  30  contacting less of the skin surface area of a nose  11  than would otherwise be engaged by dilator  10 . Thus dilator  10  may be more easily removed from the tissue with less stress thereto. 
     When engaged to a nose  11 , dilator  10 , through its resilient means and as a result of its constituent members, components and layers combined to form truss  30 , acts to stabilize and/or expand the nasal outer wall tissues and prevent said tissues from drawing inward during breathing. 
       FIG. 4  illustrates an alternative form of the nasal dilator of  FIGS. 1-3  in which terminal ends  23   a , and  23   b  of resilient member  22  are substantially straight and are angled inward in a direction from bottom to top, corresponding substantially to like angled lateral end edges  33   a  and  33   b  of truss  30 . A cover layer is optional. 
     Dilator members and/or components are fabricated to dimensional criteria including: (a), dimensions suitable for engaging and providing effective dilation to nasal outer wall tissues within design parameters as described hereinbefore; (b), dimensions whereby individual dilator members or components thereof are continuously fabricated in close proximity to one another and/or along common lines that define at least a portion of their peripheral edges; and (c), dimensions that create lateral and longitudinal registration of dilator members or components thereof to their respective layers and to each other as part of a continuous fabrication process. 
     Said registration is achieved during manufacturing by aligning a repeating ratio of a first member, or its components, from a continuous succession thereof, to a repeating ratio of a second member or its components, from a continuous succession thereof, thereby forming at least one layer of the dilator. As more particularly discussed below, successive resilient members are laminated to continuous end region components, optionally via interface member  16 , by registered laterally to successive rows of end region components and registered longitudinally to corresponding pairs of end region components. 
       FIG. 5  illustrates lateral registration of separate dilator components as part of a continuous fabrication process whereby to form at least one layer of dilator  10 . Continuous resilient member components are die cut from, and perpendicular to, the length (MD) of a continuous web of resilient layer material to form continuous resilient members aligned along common long edges. Continuous end region components are similarly die cut from a continuous material web, optionally spaced apart adjacent their respective long edges, to form continuous successive pairs thereof. The combined widths of a greater number of continuous resilient member components correspond to the combined widths of a lesser number of continuous successive pairs of end region components (shown in broken lines and brackets) such that the longitudinal centerline of at least one resilient member  22 , out of consecutive equal numbers thereof, registers to each successive pair of end region components, preferably along the longitudinal centerline,  56   a , thereof. In this case the combined width of two successive resilient members (or any multiple thereof) equals the width of a corresponding end region component, or pair (or any multiple thereof), optionally plus spacing, if any, between successive end region components, a ratio of 2:1. Furthermore, the registration ratio of the continuous resilient member components is 1:2 (one out of each two successive parts is registered), and the registration ratio of the (pairs of) end region components registered thereto is 1:1 (each successive pair is registered to). 
     It will be obvious to the skilled man that a range of registration ratios between any two disparate continuous dilator members (including components thereof) is possible while keeping within the teachings of the present invention. It will be further obvious that while centerline alignment provides a symmetric dilator, it is not a requirement. An asymmetric dilator may be formed using the same technique by aligning members or components off center. 
       FIG. 6  illustrates, in broken lines and brackets, longitudinal registration of separate dilator members to form at least one layer of dilator  10 . The combined lengths of a greater number of end region components within successive rows align with the combined overlapping lengths of a lesser number of successive resilient members such that each overlapping resilient member, within successive rows thereof, aligns horizontally with the lateral centerline,  56   b , of successive pairs of first and second end region components. For the sake of clarity,  FIG. 6  shows resilient members  22  horizontally staggered across said successive rows of end region components. However,  FIG. 7  more particularly illustrates said continuous overlapping resilient members in broken lines. The ratio of said longitudinal registration is 1:1. That is, each resilient member is registered to each pair of end region components. 
       FIGS. 6-7  further illustrate registration of dilator components as part of a continuous fabrication process. Continuous base layer pads  14   a  and  14   b  are die cut in successive rows,  58 , from continuous material web  60  in a cross direction (XD) perpendicular to the machine direction (MD) of said material. Since end region components corresponding to respective first and second nasal passages are typically mirror images of each other, rows  58  contain an equal number of base layer pads  14   a  die cut across from an equal number of base layer pads  14   b , forming a group,  59 , aligned along their longitudinal centerlines  56   a . Group  59  is horizontally centered on a lateral centerline,  56   c , which is perpendicular to centerline  56   a . Accordingly, the first of said equal number of base layer pads  14   a  within group  59  corresponds to the first of said equal number of base layer pads  14   b . Second of, and third of, base layer pads  14   a  further correspond to second of and third of base layer pads  14   b  (and optionally so on). Each row  58  thus has at least one group  59  of corresponding pairs of base layer pads aligned to centerlines  56   a  and  56   c . Each of said pairs substantially defines the length of dilator  10  and first and second end regions  32  and  34  of truss  30 . The number of groups  59  within each row  58  are limited only be the width (XD) of web  60 . 
       FIG. 7  also illustrates that web  60  may optionally include interface members  16  laminated thereto in a spaced apart grid, each member  16  registering with each end region component in groups  59  of rows  58  for laminating end portions  21   a  and  21   b  of resilient member  22 . As further shown in  FIG. 7 , three overlapping sets of continuous resilient members  22  are laminated to groups  59  within rows  58 . Accordingly, successive steps must be used to laminate one set at a time, and the resultant laminates extracted from the material matrix so as to expose the end region components underneath, before proceeding to subsequent overlapping sets of continuous resilient members. Said extraction may be accomplished, for example, by pneumatic suction removal of the finished parts (i.e., a “pick and place” motion control system) from the material web. The extracted parts may be placed on a separate continuous release paper liner, and groups thereof packaged for retail sale. In addition, said grid of interface members  16  may be optionally laminated to the continuous resilient layer material in the course of fabricating resilient members  22 . 
     As further illustrated in  FIGS. 6-7 , the inside lateral edges of said third of base layer pads  14   a  and said first of base layer pads  14   b  lie, at least in part, adjacent to line  56   c . Said edges may also align directly on line  56   c . The number of base layer pads in group(s)  59 , of row(s)  58 , is determined by their shape and dimensions, preferably configured, along with the dimensions of resilient member  22 , to engage and provide effective dilation to a nose  11  within design parameters as discussed hereinbefore; said shape and dimensions being thus limited by said design parameters. Base layer pads  14   a  and  14   b  fabricated from web  60  in close proximity to one another as shown in  FIGS. 6-7  utilize about 70% of the surface area of web  60 . The corresponding material waste is thus about 30%, providing a usage-to-waste ratio of about 2.33:1. In the embodiments of  FIGS. 4-7 , a cover layer for dilator  10  is optional; the adhesive substance on resilient members  22  and/or interface members  16  being sufficiently strong so as to maintain the structural integrity of truss  30  when dilator  10  is in use on a nose  11 . 
       FIG. 8  illustrates an embodiment in accordance with the present invention based upon the peripheral dimensions of the dilator of  FIG. 4 , in which the discontinuity of material of resilient member  22  comprises two openings  26   c , one on each side of the lateral centerline of truss  30 . Openings  26   c  extend from intermediate region  36  into end regions  32  and  34 , respectively, forming upper and lower spring fingers  28  which terminate at end portions  21   a  and  21   b , respectively, of resilient member  22 . At least a portion of resilient member  22  has a continuous gradient width, which may curve arcuately or be straight, and is narrower at intermediate region  36  and wider at end regions  32  and  34 . Openings  26   c  may be used to laterally spread the spring biasing properties of dilator resilient means primarily at the end regions of the truss. Openings  26   c  may also gradiently reduce spring biasing properties in horizontal direction extending from the intermediate region to opposite end edges  33   a  and  33   b , respectively. Interface members  16  may be interposed between end portions  21   a  and  21   b  and base layer pads  14   a  and  14   b , respectively, the inside lateral edges thereof represented by broken lines. 
       FIG. 9  illustrates an alternative nasal dilator  10  in accordance with the present invention in which the material separation of resilient member  22  comprises an elongated interior slit,  26   b , extending along the length thereof. Similar to opening  26   a , slit  26   b  defines, at least in part, the widths of upper and lower resilient bands  20   a  and  20   b , the spaced apart relationship thereof, and the lengths of first and second end portions,  21   a  and  21   b , of resilient member  22 . 
       FIG. 10 a    illustrates the initial steps of a continuous fabrication process (using the dilator of  FIG. 9  as an example) in which continuous strips of interface material,  63 , are laminated onto the non-adhesive side of continuous base layer material web  60  at spaced apart intervals across (XD) web  60 . The width of continuous material strips  63  may be varying or constant, but in either case defines the length of interface member  16 . Said length is parallel to the longitudinal extent of truss  30 . Web  60  is then slit lengthwise (MD) into continuous strands,  64 , with each strand  64  including one continuous strip  63  laminated thereto. The widths of continuous material strands  64  may be varying, constant or gradient, but in any case defining the length of base layer pads  14   a  and  14   b , said length being parallel to the longitudinal extent of truss  30 . In addition, the placement of said slits and resultant width of each strand  64  generally correspond to respective end regions of truss  30 . Said placement of slits and resultant widths, whether varying, gradient or straight, is preferably substantially uniform, but may be optionally non-uniform. 
       FIG. 10 b    continues the fabrication process. Every other strand  64 , while maintaining their relative positions, is grouped as a pair forming the base of a fabrication matrix,  65 . Said pair may be optionally rewound onto a separate continuous release paper liner to releasably secure both strands  64 . This requires separating base layer material  60  from its original protective release paper liner in the course of slitting strands  64 . The width of each strand  64  and the spacing between each strand in a pair corresponds substantially to the lengths of first, second and intermediate regions of truss  30 . The inside edge of each strand  64  within a pair thereof defines the inside lateral edges of base layer pads  14   a  and  14   b.    
     A continuous strand of material from which pad  38  will be formed is preferably laminated to the adhesive side of a continuous resilient layer material web,  66 . Web  66  is then aligned and its speed and machine direction synchronized to the fabrication matrix base so as to allow lateral registration of at least one resilient member  22 , out of consecutive equally numbered groups thereof, to be die cut from resilient material web  66  and laminated onto the fabrication matrix base at equally spaced apart intervals thereon, thus further forming fabrication matrix  65 . Material separation  26   b  is formed at the same time. Said intervals preferably correspond to the longitudinal centerline of dilator  10  plus the width of dilator  10  extending laterally from both sides of said centerline, plus any desired spacing between dilators  10  die cut from fabrication matrix  65 . Said placement further defines the point of contact for end portions  21   a  and  21   b  of resilient member  22  to base layer pads  14   a  and  14   b  via interface member  16 . In this case, the lateral registration ratio of the continuous resilient member components is 1:3 (one out of each three successive parts is registered). It will be apparent to the skilled medical device converter that, as an alternative to dimension-based lateral registration of dilator components or members (where, for example, the combined widths of x like components corresponds to the width or widths of a disparate component), synchronizing separate material webs by using different machine speeds may also be used to align disparate dilator members or components. 
       FIG. 10 b    further illustrates a pair of continuous cover layer material strands,  62 , laminated onto fabrication matrix  65  via their adhesive sides, substantially over the non-adhesive sides of strands  64 . Alternatively, a single strand  62 , preferably not greatly exceeding the width of fabrication matrix  65 , may be laminated thereto. Strand  62  may be of any width, and may be laminated off-center strands  64  or fabrication matrix  65 , and may thus further define the length of truss  30  or may cause end regions  32  and  34  to overlap into intermediate region  36  when dilator  10  is die cut therefrom. 
       FIG. 10 c    illustrates the final steps of the continuous fabrication process. Fabrication matrix  65  is layered onto one of two packaging film webs,  68   a , which provides the surface against which individual dilators  10  will be die cut. Die cuts,  69 , extend around resilient member end portions  21   a  and  21   b , as close as practicable thereto, and extend vertically through strands  62 , strips  63  and strands  64  to the surface of film web  68   a . The waste matrix of fabrication matrix  65  is preferably removed leaving finished dilators  10  spaced at equal intervals upon film web  68   a . In this embodiment, die cuts  69  form end regions  32  and  34  and interface members  16 . Die cuts  69  further define the width of interface members  16  extending between the upper and lower long edges of end regions  32  and  34 . In this manner interface members  16  simultaneously laminate portions of the base layer of dilator  10  to both the cover layer and resilient layers thereof. Finished dilators are sealed between upper and lower packaging film webs  68   a  and  68   b . Said webs may be of any suitable material, but are preferably sealable to each other, such as a cohesive cold seal paper film, compression sealable paper film, or heat sealable plastic film. 
       FIGS. 11-13  illustrate embodiments of nasal dilators  10  in accordance with the present invention in which pre-fabricated components are assembled by the user into finished nasal dilator units.  FIG. 11  shows a continuous plurality of resilient members  22 , die cut from a resilient layer material web  66 . Continuous interface material strips  63  and a continuous strand of material from which absorbent pad  38  is fabricated may be laminated to resilient layer material web  66  prior to die cutting finished resilient members  22 . Strips  63  are laminated to correspond substantially to resilient member end portions  21   a  and  21   b . The resilient members are die cut, preferably along common lines defining their respective upper and lower longitudinal edges. Said edges may be either perpendicular or parallel to the continuous length (MD) extent of material web  66 . Said die cuts are made through resilient material web  66  to the protective paper liner thereof (i.e., kiss cut) to form resilient members  22  including interface members  16  and pads  38 . The waste matrix from web  66  is removed from the area surrounding the resilient members, leaving a continuous plurality thereof on said paper liner. Said resilient members may be packaged in groups for retail sale along with base layer and cover layer components of dilator  10 . 
       FIGS. 12 and 13  illustrate continuous rows of end region components die cut from base layer material web  60  using fabrication techniques similar to that described with regard to  FIGS. 6-7 . The waste matrix from between end region components is preferably removed, leaving said rows on release paper liner. End region components in  FIG. 12  are die cut such that they are nested along common lines defining at least a portion of their peripheral edges, and are preferably aligned along their longitudinal centers. End region components in  FIGS. 12 and 13  are dimensionally configured, including spacing, if any, between at least a portion of their peripheral edges, such that every other component in each row form a pair. Said pairs correspond substantially to first and second end regions of truss  30  and to the length of dilator  10 . The end region components of  FIG. 12  are substantially triangular in shape, with a gradient width increasing along their lengths. They may be packaged in groups for retail sale along with resilient layer and cover layer components of dilator  10 . 
     To assemble end region components and resilient members  22  for use on a nose  11 , a user removes a resilient member from the paper liner exposing the adhesive substance on at least interface members  16 , and affixes end portions  21   a  and  21   b  onto a said pair of every other end region components from the continuous plurality thereof, thus substantially forming truss  30 . The spaced apart relationship of each pair on paper liners provides a guide as to the length of dilator  10 . However, it will be apparent that a slightly greater or lesser length may be selected by the user simply by placing a greater or lesser portion of one end of resilient member  22  onto one component, as desired, lifting said component off the paper liner, and then placing the other end onto another component, as desired. An additional pair of end region components may be peeled by hand from the plurality thereof (i.e., in the same manner one would peel a self-adhesive label from a continuous sheet thereof) and placed on top of each end portion  21   a  and  21   b , aligned with any, all, or none of the peripheral edges of the first pair of end region components underneath resilient member  22 . Thus the user may further adjust the overall length and/or width of dilator  10 . 
     A particularly efficacious technique is to align all end region components substantially along the longitudinal centerline of resilient member  22 , placing the additional end region components so that they overlap the outer lateral end edges of said first pair of end region components as shown in  FIG. 12 . The user then applies dilator  10  to a nose  11  in the same way as a prefabricated nasal strip device. In the alternative, a user may successively apply the components of dilator  10 , as described above, to nose  11  (i.e., assembly in situ). 
       FIG. 13  further illustrates pre-fabricated components of nasal dilator  10  to be assembled by the user. End region components are die cut in a spaced apart grid arrangement, similar to the fabrication techniques described with regard to  FIGS. 6-7 , comprising rows  58  containing groups  59  centered on line  56   c . As similarly described with respect to  FIGS. 5-7  and  FIG. 12 , pairs of components substantially define the length of dilator  10  and/or correspond to the length of resilient member  22 .  FIG. 13  shows opposite terminal end edges  23   a  and  23   b  of resilient member  22  aligning precisely with lateral end edges of end region components. For the sake of clarity,  FIG. 13  shows fragmentary sections of resilient member  22  where the user may align end portions  21   a  and  21   b  thereof to end region components, preferably within a range as defined by directional arrows in between broken lines, to adjust the length of dilator  10 . By example,  FIG. 14  illustrates dilator  10  lengthened. A user may also apply one or more additional end region components on top of the embodiment of truss  30  as described with respect to the embodiment of  FIG. 12 . 
     A user may be further provided with a variety of disparately sized resilient member components with which to combine with a variety of disparately sized end region components whereby to form any number of nasal dilator configurations, preferably within design parameters for engaging nasal outer walls as discussed hereinbefore. For example, resilient member components with varying degrees of spring biasing force, along with various shapes and configurations of resilient member and end region components may be co-packaged for retail sale. Instructions and suggestions for both routine and optional assembly of said components are easily conveyed to the user within the retail packaging of said components of dilator  10  for retail sale. It will be apparent to the skilled man that the fabrication and assembly techniques for dilator components as disclosed in  FIGS. 5-7, 10   a - 10   c , and  11 - 13  may be applied to a wide variety of nasal dilator devices. 
       FIGS. 15-16  illustrate an embodiment of nasal dilator  10  in accordance with the present invention in which the discontinuity of material of resilient member  22  comprises a plurality of spring fingers,  28 , diverging from a common center and terminating at discrete end region components. Said center is preferably aligned with the lateral and longitudinal centerlines of intermediate region  36  of truss  30 . Fingers  28  have gradient widths, and may curve, may be uniform or asymmetric, and may be equidistant from the longitudinal centerline of truss  30  or be of varying distance therefrom. Fingers  28  have enlarged end portions at their terminal ends which engage base layer pads  14   a  and  14   b , respectively, via interface member  16 . Said base layer pads are bifurcated laterally into separate components, each engaging each said terminal end of each finger  28 . Said separate components may be symmetric or asymmetric, of equal or disparate size and/or shape. This divergent end region structure creates additional lateral torsional flexibility primarily at the end regions of truss  30 , and allows dilator  10  to simultaneously engage nasal outer wall tissues adjacent both the nasal valve and nasal vestibule. As further illustrated in  FIG. 16 , dilator  10  may optionally include a cover layer formed as a single member,  18   c , laminated on top of resilient member  22 . 
       FIG. 17  illustrates a variation of the embodiment of  FIG. 15  in which the discontinuity of material of resilient member  22  comprises indentations,  27   a  and  27   b , extending inward from terminal end edges  23   a  and  23   b  thereof forming divergent spring fingers. Said fingers may be confined substantially to the end regions of truss  30 , and may be of uniform or non uniform length and width. Said indentations widen resilient member end portions  21   a  and  21   b  and help spread the spring biasing force of resilient member  22  laterally from the longitudinal centerline thereof. Lateral end edges  33   a  and  33   b  of first and second end regions  32  and  34  are angled inward in a substantially straight line from bottom to top corresponding approximately to the line where nose  11  meets the cheek of a face  12 . However, a portion of said lateral end edges may correspond to indentations  27   a  and  27   b . In this particular embodiment, the base layer of dilator  10  is formed as a single member and extends longitudinally through at least portions of the respective regions of truss  30 . Said member may also be placed on top of the resilient layer and thus comprise the cover layer of dilator  10 , either in addition to or in lieu of said base layer. In the present embodiment, however, interface members  16  adhere the resilient layer to the base layer at the respective end regions of dilator  10 , thus creating a separation void,  41 , of non-adherence in between said layers which extends between the inside lateral edges of interface members  16 . Separation void  41  allows relative independent movement between the base layer and resilient layers of dilator  10  substantially at the intermediate region thereof when dilator  10  is in use on a nose  11 . 
       FIG. 18  illustrates a variation of the embodiment of  FIGS. 12-13  in which the components of dilator  10  may be assembled by the user.  FIG. 18  shows resilient member  22  having enlarged, substantially round end portions  21   a  and  21   b  corresponding to interface members  16  engaging substantially round base layer pads  14   a  and  14   b , respectively. 
     As illustrated and described in examples of the preferred embodiments, the components of dilator  10  are fabricated to design parameters suitable for effective engagement to, and dilation of, a nose  11 . Said components are simultaneously fabricated with minimal material waste and configured for latitudinal and longitudinal registration to each other. Dilator  10  is further configured to maximize the percentage of a given amount of material used in the manufacturing process and to return a greater number of individual dilator devices per a given quantity of material. Dilator  10  is further configured to facilitate assembly and application by the user, and to allow user adjustment of the truss length.