Cuff for use with medical tubing and method and apparatus for making the same

Abstract

A method of manufacturing more than one inflatable cuff per blow molding operation is provided. The method includes using two or more molds arranged in series and/or in parallel to simultaneously form two or more cuffs. The two or more cuffs may then be used in the manufacture of two or more respective endotracheal tubes. Apparatuses and systems for simultaneously forming the two or more cuffs are also provided.

What is claimed is: 
     
         1 . A blow molding system, comprising:
 two or more molds, each comprising a cavity corresponding to a shape of a cuff having a distal end and a proximal end, and wherein the two molds are arranged end to end such that the distal end of one cavity is adjacent to the proximal end of the other cavity, and wherein each cuff is configured to be separated from a forming tube to form an endotracheal tube; and   one or more heating/cooling jackets configured to secure the two or more molds and to actively heat and cool the two or more molds.   
     
     
         2 . The blow molding system of  claim 1 , comprising two or more clamps, wherein the two or more heating/cooling jackets and the two or more molds are positioned between at least two of the clamps that are configured to move toward and away from the one or more heating/cooling jackets and the two or more molds. 
     
     
         3 . The blow molding system of  claim 2 , comprising a control station configured to control operation of the one or more heating/cooling jackets and the two or more clamps. 
     
     
         4 . The blow molding system of  claim 1 , wherein each mold is secured in a respective heating/cooling jacket. 
     
     
         5 . The blow molding system of  claim 1 , wherein at least two molds are secured in each heating/cooling jacket. 
     
     
         6 . The blow molding system of  claim 1 , wherein each cavity is tapered. 
     
     
         7 . The blow molding system of  claim 1 , wherein four or more molds are arranged in series and in parallel in the one or more heating/cooling jackets such that a first subset of the molds are situated end-to-end with respect to one another but side-by-side with respect to a second subset of the molds. 
     
     
         8 . The blow molding system of  claim 1 , wherein the two or more molds comprise beryllium copper. 
     
     
         9 . A method of manufacturing a two or more inflatable cuffs in a single operation, comprising:
 loading one or more tubes into a mold assembly comprising two or more molds, wherein the two or more molds each comprise a cavity corresponding to a shape of a cuff having a distal end and a proximal end, and wherein the two molds are arranged end to end such that the distal end of one cavity is adjacent to the proximal end of the other cavity;   initiating a blow molding program on a blow molding machine, wherein the blow molding program initiates and controls stretching, heating, and pressurizing operations performed by the blow molding machine such that a cuff is formed in a respective portion of tube disposed within each of the two or more molds;   removing the one or more tubes from the mold assembly, wherein each tube comprises at least two cuff regions; and   cutting the cuff regions from the one or more tubes to form two or more cuffs.   
     
     
         10 . The method of  claim 9 , comprising calibrating the blow molding machine. 
     
     
         11 . The method of  claim 9 , wherein the blow molding program initiates and controls cooling operations performed by the blow molding machine. 
     
     
         12 . The method of  claim 9 , wherein four or more molds are arranged in series and in parallel such that a first subset of the molds are situated end-to-end with respect to one another but side-by-side with respect to a second subset of the molds. 
     
     
         13 . The method of  claim 12 , comprising loading a first tube of the one or more tubes into the first subset of the molds and a second tube of the one or more tubes into the second subset of the molds. 
     
     
         14 . The method of  claim 12 , comprising attaching each of the two or more cuffs to a respective endotracheal tube body to form respective endotracheal tubes. 
     
     
         15 . A method of manufacturing two or more inflatable cuffs in a single operation comprising:
 clamping each end of a forming tube, wherein portions of the forming tube are positioned within two or more molds, wherein the two or more molds each comprise a cavity corresponding to a shape of a cuff having a distal end and a proximal end, and wherein the two molds are arranged end to end such that the distal end of one cavity is adjacent to the proximal end of the other cavity;   stretching the forming tube by pulling the ends of the forming tube away from the two or more molds; and   increasing the pressure within the forming tube such that the portions of the forming tube within the two or more molds are blown outward to conform to the shape of the molds to form two or more cuffs, wherein each cuff is configured to be separated from the forming tube and attached to a respective endotracheal tube body to form an endotracheal tube.   
     
     
         16 . The method of  claim 15 , comprising heating the molds for an interval of time. 
     
     
         17 . The method of  claim 16 , comprising cooling the molds. 
     
     
         18 . The method of  claim 15 , comprising decreasing the pressure within the forming tube. 
     
     
         19 . The method of  claim 15 , wherein each cavity is tapered. 
     
     
         20 . The method of  claim 15 , comprising:
 removing the forming tube with the two or more cuffs from the two or more molds;   cutting the two or more cuffs from the forming tube; and   attaching each of the two or more cuffs to a respective endotracheal tube body to form respective endotracheal tubes.