Orthopedic instrument system including instrument sterilization tray with masking layer

Abstract

An orthopedic instrument system is disclosed, including a sterile tray for storing orthopedic instruments during sterilization and transport. The sterile tray has a masking layer positioned on the upper surface of its bottom wall.

Description

Technical Field

[0001] (Cross - Reference to Related Applications) This application claims cross - reference to U.S. Design Patent Application No. 29 / 893245, entitled "ORTHOPAEDIC SURGICAL INSTRUMENT WITH SURFACE ORNAMENTATION", filed on the same date as this application and assigned to the same assignee as this application (Attorney Docket No. 265280 - 381493, DEP7154USDP1).

[0002] (Field of the Invention) The present disclosure generally relates to orthopaedic instruments for use in performing orthopaedic procedures, and more particularly to a sterilization tray for use in storing and transporting orthopaedic instruments.

Background Art

[0003] During orthopaedic surgeries such as orthopaedic trauma procedures or joint replacement surgeries, orthopaedic surgeons typically use various different orthopaedic instruments, such as, for example, handles, drills, reamers, drill guides, cutting blocks, prosthesis trials, and other surgical instruments, to prepare the patient's bone to receive an orthopaedic implant such as a fracture plate or joint prosthesis. Such surgical instruments can be constructed from either a metal or polymer material and are generally designed to be reusable. After use, reusable surgical instruments are kit - ed in a sterilization tray, sterilized, and then returned to the operating room for use in subsequent procedures.

[0004] Some sterilization trays rely on highly visible color markers to indicate specific aspects of the instruments contained within the tray, such as their size and functionality. Typically, this is done by single-color printing on the bottom wall and instrument holders within the tray. During the washing and sterilization process, even if the instruments are completely and safely sterilized, water stains and water marks may appear on the bottom wall of the tray. These water stains and water marks occur on most, if not all, sterilization trays, but they are far more noticeable on painted sterilization trays. [Overview of the Initiative] [Means for solving the problem]

[0005] According to one aspect of the present disclosure, a surgical instrument sterilization tray includes a bottom wall having an upper and lower surface, and a plurality of side walls extending upward from the bottom wall to cooperate with the bottom wall in defining an instrument storage surface area. A plurality of instrument holders are fixed to the bottom wall and configured to hold orthopedic instruments during their sterilization and transport. A masking layer is positioned on the upper surface of the bottom wall within the instrument storage area. The masking layer defines a destructive pattern comprising a plurality of interconnected common geometric shapes. The masking layer has a pattern coverage ratio of at least 50:50.

[0006] In one embodiment, the masking layer is printed on the upper surface of the bottom wall. In another embodiment, the masking layer is etched onto the upper surface of the bottom wall.

[0007] In one embodiment, the masking layer has a pattern coverage ratio of at least 60:40.

[0008] The bottom wall may have multiple fluid pores formed within it.

[0009] In one embodiment, the common geometric shape is a circle. In another embodiment, the common geometric shape is a hexagon.

[0010] The bottom wall and multiple side walls may be made of anodized aluminum.

[0011] In another embodiment, an orthopedic instrument system includes a surgical instrument sterilization tray made of anodized aluminum. The sterilization tray includes a bottom wall having an upper and lower surface, and a plurality of side walls extending upward from the bottom wall to cooperate with the bottom wall to define an instrument storage surface area. The orthopedic instrument system also includes a plurality of instrument holders fixed to the bottom wall of the sterilization tray and configured to hold orthopedic instruments during their sterilization and transport. A masking layer is positioned on the upper surface of the bottom wall of the sterilization tray within the instrument storage area. The masking layer defines a destructive pattern comprising a plurality of interconnected common geometric shapes. The masking layer has a pattern coverage ratio of at least 50:50.

[0012] In one embodiment, the masking layer is printed on the upper surface of the bottom wall. In another embodiment, the masking layer is etched onto the upper surface of the bottom wall.

[0013] In one embodiment, the masking layer has a pattern coverage ratio of at least 60:40.

[0014] The bottom wall may have multiple fluid pores formed within it.

[0015] In one embodiment, the common geometric shape is a circle. In another embodiment, the common geometric shape is a hexagon.

[0016] In another embodiment, the orthopedic instrument system includes a surgical instrument sterilization tray made of anodized aluminum. The sterilization tray includes a top surface, a bottom surface, and a bottom wall having a plurality of fluid holes formed in the middle. Each of the plurality of fluid holes extends from the top surface to the bottom surface. The sterilization tray also includes a plurality of side walls extending upward from the bottom wall to cooperate with the bottom wall in defining an instrument storage surface area. The orthopedic instrument system also includes a plurality of instrument holders fixed to the bottom wall of the sterilization tray and configured to hold orthopedic instruments during their sterilization and transport. A masking layer is positioned on the upper surface of the bottom wall of the sterilization tray within the instrument storage area. The masking layer defines a destructive pattern comprising a plurality of interconnected common geometric shapes. The masking layer has a pattern coverage ratio of at least 60:40.

[0017] In one embodiment, the masking layer is printed on the upper surface of the bottom wall. In another embodiment, the masking layer is etched onto the upper surface of the bottom wall.

[0018] In one embodiment, the common geometric shape is a circle. In another embodiment, the common geometric shape is a hexagon. [Brief explanation of the drawing]

[0019] For a detailed explanation, please refer in particular to the following drawings. [Figure 1] This is a front view of an exemplary embodiment of an orthopedic instrument system. [Figure 2] As indicated by the rectangular area, this is an enlarged front view showing a more detailed view of the masking layer of the sterilization tray, cut out from Figure 1. [Figure 3] This figure is similar to Figure 2, but shows another embodiment of the masking layer. [Modes for carrying out the invention]

[0020] While the concepts of this disclosure are open to various modifications and alternative forms, specific exemplary embodiments are shown in the drawings as examples and described in detail herein. However, it should be understood that the concepts of this disclosure are not intended to be limited to the specific forms disclosed, but rather to encompass all modifications, equivalents, and alternatives that are included in the spirit and scope of the invention as defined by the appended claims.

[0021] Terms such as anterior, posterior, medial, lateral, superior, and inferior, which represent anatomical reference points, may be used throughout this specification in relation to orthopedic implants and orthopedic instruments described herein, as well as in relation to the vivisection of the patient. Such terms have well-understood meanings in both the study of anatomy and the field of orthopedic surgery. The use of such anatomical reference terms in the descriptions and claims described herein is intended to be consistent with their well-understood meanings unless otherwise specified.

[0022] Referring now to Figure 1, an orthopedic instrument system 10 is shown. The orthopedic instrument system 10 includes a sterile tray 12 used for storing several orthopedic instruments (not shown) during sterilization, storage, and transport. The terms “orthopedic instrument” or “orthopedic instrument system” refer to surgical tools used by a surgeon when performing orthopedic surgical procedures. Therefore, it should be understood that, as used herein, the terms “orthopedic instrument” and “orthopedic instrument system” are distinct from orthopedic implants or prostheses that are surgically implanted in a patient’s body.

[0023] As shown in FIG. 1, the sterilization tray 12 includes a base or bottom wall 14 that includes an upper surface 16 and an opposite lower surface. The sterilization tray 12 has a generally rectangular shape with rounded corners. A plurality of side walls 18 extend upward from the bottom wall 14 of the tray. By doing so, the side walls 18 cooperate with the bottom wall 14 to define an instrument storage surface area 20. A pair of handles 22 are disposed on opposite sides of the sterilization tray 12 for use by surgical staff when carrying the tray 12.

[0024] As can be seen in FIG. 1, the bottom wall 14 of the sterilization tray 12 has a plurality of fluid holes 24 formed therein. The fluid holes 24 extend through the bottom wall 14 (i.e., from the upper surface 16 of the bottom wall to the opposite lower surface). In this way, the fluid holes 24 allow the entry and exit of sterilizing fluid (e.g., water) into and from the instrument storage surface area 20, and thus enable the sterilization of orthopedic instruments positioned therein. It should be understood that fluid holes may also be formed in the side walls 18 of the sterilization tray 12.

[0025] The sterilization tray 12 has a number of instrument holders 30 fixed to its bottom wall 14. The instrument holders 30 are configured to hold orthopedic instruments of various different shapes during sterilization, storage, and transportation of the surgical instrument system 10. The instrument holders 30 may be configured as brackets, connectors, cradles, or any other type of mechanism for holding an orthopedic instrument in a desired position and orientation. It should also be understood that the instrument holders 30 may take the form of specific shaped recesses or cavities formed in the instrument sterilization tray 12 into which an orthopedic instrument can be inserted and held.

[0026] In exemplary embodiments, the sterilization tray 12 is formed from a metallic material, such as anodized aluminum. In particular, the bottom wall 14 and side walls 18 form a metal assembly assembled from two or more separate components. Alternatively, the bottom wall 14 and side walls 18 may take the form of a single monolithic metal component. The sterilization tray 12 may be formed by conventional machining techniques, or alternatively, by using 3D printing techniques. In the case of 3D printing, the sterilization tray 12 is formed layer by layer.

[0027] As shown in Figure 1, the upper surface 16 of the bottom wall 14 within the instrument storage area 20 has a masking layer 40 placed thereon. The masking layer 40 masks the presence of any water traces and / or water stains that may occasionally accumulate on the upper surface 16 of the bottom wall 14 during the sterilization process. To this end, the masking layer 40 is structured as a destructive pattern containing a plurality of interconnected common geometric shapes. As used herein, the term “destructive pattern” is defined as a form of camouflage that functions by breaking the contour of the structure to be camouflaged by using a pattern that makes up a high contrast. In this case, the destructive pattern is used to break the contour of water traces or water stains. As shown in Figures 1 to 3, in the exemplary embodiments described herein, the destructive pattern of the masking layer is sufficiently irregular to cause visual destruction (by being embodied as an offset array of four slightly different geometric shapes).

[0028] As described above, the destructive patterns of the masking layer are embodied in a common geometric shape. In this specification, the term “common geometric shape” means that all geometric shapes of the destructive patterns are of the same type. For example, as shown in Figures 1 and 2, all geometric shapes of the destructive patterns of the masking layer are circular. It should be understood that the destructive patterns of the masking layer may be embodied in other common geometric shapes. For example, as shown in Figure 3, all geometric shapes of the destructive patterns of the masking layer may be embodied as hexagons. Further examples of geometric shapes that can be used for the destructive patterns of the masking layer include triangles, squares, and other regular polygons.

[0029] As described above, the common geometric shapes of the destructive patterns in the masking layer are connected. In this specification, the term “connected” in relation to the common geometric shapes of the destructive patterns in the masking layer means that the outer edges of adjacent geometric shapes are in contact with each other. This results in uniform connectivity within the destructive pattern. In the Gestalt principle, “uniform connectivity” refers to the “grouping effect” in which similar connected objects are perceived as visually connected.

[0030] In the exemplary embodiments described herein, each of the connected geometric shapes of the destructive pattern of the masking layer has a perimeter or "footprint" of the same size. For example, even if the configuration of the unconnected circles of a given connected circle (i.e., circles within a connected circle) differs from the configuration of adjacent connected circles (e.g., line thickness and shading), the perimeter of each connected circle has the same circumference.

[0031] As seen in Figures 2 and 3, the destructive pattern of the masking layer is relatively dense and therefore covers most of the upper surface 16 of the bottom wall 14. In particular, the destructive pattern of the masking layer has a relatively high pattern coverage ratio. As used herein, the term “pattern coverage ratio” refers to the ratio of the total surface area of ​​the applied pattern to the total surface area of ​​the background. In other words, within a given surface area of ​​the bottom wall 14 of the tray on which the masking layer 40 is placed, a portion of the surface area is covered by the applied pattern (i.e., the portion shown as a dark line in Figures 2 and 3, as referenced by reference no. 42), and a portion of the surface area is not covered (i.e., the portion shown as a white space in Figures 2 and 3, as referenced by reference no. 44). The uncovered portion of the surface area is the background (the base metal is visible). Within a given surface area of ​​the tray bottom wall 14 on which the masking layer 40 is placed, the "pattern coverage ratio" refers to the ratio of the total surface area of ​​the tray bottom wall 14 to which the pattern is applied (e.g., printed) to the total surface area of ​​the tray bottom wall 14 that is uncovered, i.e., the background. In an exemplary embodiment, the pattern coverage ratio of the destructive pattern of the masking layer is 50:50. In another embodiment, the covered surface area is larger than the uncovered surface area, and the pattern coverage ratio of the destructive pattern of the masking layer is 60:40.

[0032] The masking layer 40 can be placed on the upper surface 16 of the bottom wall 14 in many different ways. For example, the masking layer 40 may be printed on the bottom wall 14 by means of sublimation printing, for example. The masking layer 40 may be painted on the bottom wall 14. In another embodiment, the masking layer 40 may be etched into the bottom wall 14. It should also be understood that the masking layer 40 may be embodied in any given color that suits the requirements of a given design of the sterilization tray 12.

[0033] While the drawings and the above description have illustrated and illustrated the present disclosure in detail, such illustrations and descriptions are by their nature illustrative and should not be considered limiting, and merely illustrate illustrative embodiments. It is understood that all changes and modifications that fall within the spirit of the present disclosure should be protected.

[0034] This disclosure offers several advantages based on various features of the methods, apparatus, and systems described herein. It should be noted that alternative embodiments of the methods, apparatus, and systems of this disclosure do not include all of the features described, but still benefit from at least some of the advantages of such features. Those skilled in the art can easily independently implement methods, apparatus, and systems encompassing the spirit and scope of this disclosure as defined by the appended claims, incorporating one or more features of the present invention.

[0035] [Implementation Method] (1) A surgical instrument sterilization tray, A bottom wall having an upper surface and a lower surface, Multiple side walls extending upward from the bottom wall in cooperation with the bottom wall to define the surface area for storing the equipment, A plurality of instrument holders fixed to the bottom wall and configured to hold orthopedic instruments during sterilization and transport, A surgical instrument sterilization tray comprising: a masking layer disposed on the upper surface of the bottom wall within the instrument storage area, the masking layer having (i) defined a destructive pattern including a plurality of connected common geometric shapes, and (ii) having a pattern coverage ratio of at least 50:50. (2) The surgical instrument sterilization tray according to Embodiment 1, wherein the masking layer is printed on the upper surface of the bottom wall. (3) The surgical instrument sterilization tray according to Embodiment 1, wherein the masking layer is etched onto the upper surface of the bottom wall. (4) The surgical instrument sterilization tray according to Embodiment 1, wherein the masking layer has a pattern coverage ratio of at least 60:40. (5) The surgical instrument sterilization tray according to Embodiment 1, wherein the bottom wall has a plurality of fluid holes formed therein.

[0036] (6) The surgical instrument sterilization tray according to Embodiment 1, wherein the common geometric shape is circular. (7) The surgical instrument sterilization tray according to Embodiment 1, wherein the common geometric shape is a hexagon. (8) The surgical instrument sterilization tray according to Embodiment 1, wherein the bottom wall and the plurality of side walls are made of anodized aluminum. (9) Orthopedic instrument system, A surgical instrument sterilization tray made of anodized aluminum, comprising: (i) a bottom wall having an upper surface and a lower surface; and (ii) a plurality of side walls extending upward from the bottom wall so as to cooperate with the bottom wall to define an instrument storage surface area; A plurality of instrument holders fixed to the bottom wall of the sterilization tray and configured to hold orthopedic instruments during sterilization and transport, An orthopedic instrument system comprising: a masking layer disposed on the upper surface of the bottom wall within the instrument storage area, the masking layer having (i) defined a destructive pattern including a plurality of connected common geometric shapes, and (ii) having a pattern coverage ratio of at least 50:50. (10) The surgical instrument system according to Embodiment 9, wherein the masking layer is printed on the upper surface of the bottom wall of the sterilization tray.

[0037] (11) The surgical instrument system according to Embodiment 9, wherein the masking layer is etched onto the upper surface of the bottom wall of the sterilization tray. (12) The surgical instrument system according to Embodiment 9, wherein the masking layer has a pattern coverage ratio of at least 60:40. (13) The surgical instrument system according to Embodiment 9, wherein the bottom wall of the sterilization tray has a plurality of fluid holes formed therein. (14) The surgical instrument system according to embodiment 9, wherein the common geometric shape is circular. (15) The surgical instrument system according to Embodiment 9, wherein the common geometric shape is a hexagon.

[0038] (16) Orthopedic instrument system, A surgical instrument sterilization tray made of anodized aluminum, comprising: (i) a bottom wall having a top surface, a bottom surface, and a plurality of fluid holes formed therein, each of which extends from the top surface to the bottom surface; and (ii) a plurality of side walls extending upward from the bottom wall so as to cooperate with the bottom wall to define an instrument storage surface area; A plurality of instrument holders fixed to the bottom wall of the sterilization tray and configured to hold orthopedic instruments during sterilization and transport, An orthopedic instrument system comprising: a masking layer disposed on the upper surface of the bottom wall within the instrument storage area, the masking layer having (i) defined a destructive pattern including a plurality of connected common geometric shapes, and (ii) having a pattern coverage ratio of at least 60:40. (17) The surgical instrument system according to embodiment 16, wherein the masking layer is printed on the upper surface of the bottom wall of the sterilization tray. (18) The surgical instrument system according to embodiment 16, wherein the masking layer is etched onto the upper surface of the bottom wall of the sterilization tray. (19) The surgical instrument system according to embodiment 16, wherein the common geometric shape is circular. (20) The surgical instrument system according to embodiment 16, wherein the common geometric shape is a hexagon.

Claims

1. A surgical instrument sterilization tray, A bottom wall having an upper surface and a lower surface, Multiple side walls extending upward from the bottom wall in cooperation with the bottom wall to define the surface area for storing the equipment, A plurality of instrument holders fixed to the bottom wall and configured to hold orthopedic instruments during sterilization and transport, A surgical instrument sterilization tray comprising: a masking layer disposed on the upper surface of the bottom wall within the instrument storage area, the masking layer having (i) defined a destructive pattern comprising a plurality of connected common geometric shapes, and (ii) having a pattern coverage ratio of at least 50:

50.

2. The surgical instrument sterilization tray according to claim 1, wherein the masking layer is printed on the upper surface of the bottom wall.

3. The surgical instrument sterilization tray according to claim 1, wherein the masking layer is etched onto the upper surface of the bottom wall.

4. The surgical instrument sterilization tray according to claim 1, wherein the masking layer has a pattern coverage ratio of at least 60:

40.

5. The surgical instrument sterilization tray according to claim 1, wherein the bottom wall has a plurality of fluid holes formed therein.

6. The surgical instrument sterilization tray according to claim 1, wherein the common geometric shape is circular.

7. The surgical instrument sterilization tray according to claim 1, wherein the common geometric shape is a hexagon.

8. The surgical instrument sterilization tray according to claim 1, wherein the bottom wall and the plurality of side walls are made of anodized aluminum.

9. An orthopedic instrument system, A surgical instrument sterilization tray made of anodized aluminum, comprising: (i) a bottom wall having an upper surface and a lower surface; and (ii) a plurality of side walls extending upward from the bottom wall so as to cooperate with the bottom wall to define an instrument storage surface area; A plurality of instrument holders fixed to the bottom wall of the sterilization tray and configured to hold orthopedic instruments during sterilization and transport, An orthopedic instrument system comprising: a masking layer disposed on the upper surface of the bottom wall within the instrument storage area, the masking layer having (i) defined a destructive pattern including a plurality of connected common geometric shapes, and (ii) having a pattern coverage ratio of at least 50:

50.

10. The surgical instrument system according to claim 9, wherein the masking layer is printed on the upper surface of the bottom wall of the sterilization tray.

11. The surgical instrument system according to claim 9, wherein the masking layer is etched onto the upper surface of the bottom wall of the sterilization tray.

12. The surgical instrument system according to claim 9, wherein the masking layer has a pattern coverage ratio of at least 60:

40.

13. The surgical instrument system according to claim 9, wherein the bottom wall of the sterilization tray has a plurality of fluid holes formed therein.

14. The surgical instrument system according to claim 9, wherein the common geometric shape is circular.

15. The surgical instrument system according to claim 9, wherein the common geometric shape is a hexagon.

16. An orthopedic instrument system, A surgical instrument sterilization tray made of anodized aluminum, comprising: (i) a bottom wall having a top surface, a bottom surface, and a plurality of fluid holes formed therein, each of which extends from the top surface to the bottom surface; and (ii) a plurality of side walls extending upward from the bottom wall so as to cooperate with the bottom wall to define an instrument storage surface area; A plurality of instrument holders fixed to the bottom wall of the sterilization tray and configured to hold orthopedic instruments during sterilization and transport, An orthopedic instrument system comprising: a masking layer disposed on the upper surface of the bottom wall within the instrument storage area, the masking layer having (i) defined a destructive pattern including a plurality of connected common geometric shapes, and (ii) having a pattern coverage ratio of at least 60:

40.

17. The surgical instrument system according to claim 16, wherein the masking layer is printed on the upper surface of the bottom wall of the sterilization tray.

18. The surgical instrument system according to claim 16, wherein the masking layer is etched onto the upper surface of the bottom wall of the sterilization tray.

19. The surgical instrument system according to claim 16, wherein the common geometric shape is circular.

20. The surgical instrument system according to claim 16, wherein the common geometric shape is a hexagon.

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