Structural arrangement applied to a tray for surgical instruments

Abstract

The present invention relates to the development of a tray used as a support for surgical instruments, said tray (B) being provided with apertures (1, 2 and 3) in which positioners (1a, 2a and 3a) for gripping the surgical instruments are coupled by means of a method for transferring polymeric material by compression.

Description

[0001] DESCRIPTION

[0002] TITLE OF THE INVENTION: CONSTRUCTIONAL ARRANGEMENT IN A TRAY FOR SURGICAL INSTRUMENTS

[0003]

[0001] TECHNICAL FIELD

[0004]

[0002] The following descriptive report for the invention refers to the development of a tray, used as a support for surgical instruments, said tray being manufactured by means of a process of transferring polymeric material by compression.

[0005]

[0003] STATE OF THE ART

[0006]

[0004] A tray or base that serves as a support for medical instruments is a fundamental piece of equipment used in healthcare settings, such as hospitals and clinics, to ensure that medical instruments are positioned correctly and safely during procedures. Some of the main characteristics and functions of this type of base are, respectively:

[0007]

[0005] STABILITY: Provides a firm base for equipment, preventing unwanted movement;

[0008]

[0006] ADJUSTABILITY: Many models allow for height, angle, and orientation adjustments, making the instrument easier to see and access;

[0009]

[0007] MATERIAL: Generally manufactured with durable and easy-to-clean materials, such as stainless steel or engineering plastics;

[0010]

[0008] MOBILITY: Some bases come with wheels or are portable, allowing for easy movement within clinical environments;

[0011]

[0009] PRECISE POSITIONING: Ensures that instruments are in the correct position for use, increasing the efficiency and safety of procedures;

[0012]

[0010] ERGONOMICS: Helps minimize operator fatigue by allowing for more comfortable positions during extended periods of use; and

[0013]

[0011] ORGANIZATION: Facilitates the organization of instruments, ensuring that all necessary items are within reach during a procedure.

[0014]

[0012] In the particular case of the present work, the base is intended to support dental instruments.

[0015]

[0013] An example of a support base for medical instruments is disclosed in BR112015025362-8, comprising a support layer having a relative visible front surface and a relative back surface opposite the visible surface. The support layer also has a series of holes extending from the front surface towards the back surface. More specifically, the support layer has a clamping portion positioned on the back surface and irreversibly joined to the support layer to form a single body with said support layer. The support base has at least one opening for insertion, during use, of a medical instrument, positioned in each hole and extending from the front surface towards the back surface and through the clamping portion.

[0016]

[0014] PROBLEMS WITH THE TECHNIQUE

[0017]

[0015] As is known, in dental treatments, it is common for the instruments used to be contaminated with the patient's saliva and blood. Since these instruments are inserted and removed several times from the support base, contamination of this base with these fluids is certain, making its perfect sterilization after use somewhat complex.

[0018]

[0016] Because of this, the manufacturing processes of these bases, plates or supports for dental instruments seek to eliminate as much as possible areas susceptible to contamination.

[0017] These bases have holes through which the dental instruments pass. To ensure that these instruments are properly positioned, the holes are complemented with sealing rings, made of materials different from the base. These rings can be made of silicone or another type of rubber. However, since there are differences in materials between the support and the fixing rings, areas prone to the proliferation of pathogenic microorganisms are created.

[0019]

[0018] In the process described in BR112015025362-8, the silicone parts are individually assembled into the holes of the polymer base (tray or box) used for the storage and sterilization of dental, medical, and veterinary instruments. This need for individual assembly makes the process expensive.

[0020]

[0019] PROPOSED SOLUTION

[0021]

[0020] Thus, due to the considerations pertinent to the problems of the technique previously described, it is one of the objectives of the present invention to develop a tray intended as a support for surgical instruments, for example, dental instruments.

[0022]

[0021] Because of this, the tray was developed through the process of transferring composite material by compression onto polymeric surfaces, for the tray or base for surgical instruments.

[0023]

[0022] Other objectives achieved with this tray are:

[0024]

[0023] Minimize areas where bacteria and dirt may accumulate; and

[0024] Ensure better cleaning and sterilization.

[0025]

[0025] DESCRIPTION OF THE FIGURES

[0026]

[0026] The additional features and advantages of the present invention are further revealed from the detailed description that follows of a preferred, but not limiting, embodiment of a support base as illustrated in the following figures, where:

[0027]

[0027] [Fig. í] shows the top view of the polymer base (tray or box);

[0028]

[0028] [Fig. 2] shows section AA of the polymer base (tray or box);

[0029]

[0029] [Fig.3] shows the bottom view of the polymer base (tray or box);

[0030]

[0030] [Fig.4] shows the top view of the finished polymer base (tray or box) after the composite material transfer process;

[0031]

[0031] [Fig.5] shows section BB of the polymer base (tray or box);

[0032]

[0032] [Fig.6] shows the bottom view of the finished polymer base (tray or box) after the transfer process;

[0033]

[0033] [Fig.7] shows the top view of the finished polymer base (tray or box) after the composite material transfer process, illustrating the variation in the clamping positioners for surgical instruments, and also the colors;

[0034]

[0034] [Fig.8] shows the bottom view of the finished polymer base (tray or box) after the composite material transfer process, illustrating the variation in the clamping positioners for surgical instruments, and also the colors.

[0035]

[0035] Figure 01 of the polymer base / tray / box reveals the holes (1, 2 and 3) positioned according to the technical requirements of each project, each hole (1, 2 and 3) extends transversely to the extent of the polymer base / tray / box layer, resulting from the polymer injection process.

[0036]

[0036] Figure 02 reveals that the interior of the orifice extends transversely (4) to the extent of the polymer base / tray / box layer.

[0037] Figure 03 shows the flatness (5) and the absence of pre-determined connecting channels between the positioned holes, according to the technical requirements of each project.

[0037]

[0038] Figure 4 shows substantially the shape of the finished base / tray / box with the holes, where each of the holes (1, 2 and 3) is complemented with its respective clamping positioners (1a, 2a and 3a) for the surgical instrument. Each hole extends transversely (4) to the extent of the finished base / tray / box layer, resulting from the compression transfer process. This process allows medical instruments to be inserted into the lined holes, with these instruments remaining suspended from the base, in such a way that there is a pre-determined containment for the insertion of a medical instrument. The containment shape refers to the defined shapes of the edges of the hole, without preventing the circulation of the sterilizing medium.

[0038]

[0039] Figure 05 identifies that the holes (1) are completed with the geometry of the clamping positioner components (1a) of the surgical instrument extending transversely to the extent of the finished base / tray / box layer. Evidencing the way of forming a lining (1a) inside the hole (1) with the composite material, comprising the absence of protrusions along the lower (6) and upper (7) surfaces of the finished base / tray / box.

[0039]

[0040] Figure 06 shows the flatness (5) and the absence of predetermined connecting channels between the holes positioned according to the technical requirements of each project. Showing the absence of protrusions along the upper and lower surface of the finished base / tray / box.

[0041] Figures 07 and 08 exemplify the possibilities of varying the positions of the holes in the surgical instrument clamping positioners, as well as the variation in colors of the surgical instrument clamping positioners, and also show a possible positioning of the feet (8 and 9) of the base.

[0040]

[0042] TRANSFER PROCESS

[0041]

[0043] Several steps were developed to implement this project.

[0042]

[0044] Stage 1 involves the development of the polymer injection mold. This stage includes the conception, design, and manufacture of a high-precision mold for polymer injection, according to the individualized design / layout for each surgical kit model. The mold is manufactured with tight tolerances, with the orifices positioned according to the technical requirements of each project. The upper and lower faces of the mold are polished to a high-gloss finish (roughness < Ra 0.05 µm), thus ensuring a smooth surface and preventing the possible retention of particles and other contaminants during post-use product asepsis.

[0043]

[0045] Step 2 involves the injection of the polymer and the manufacture of the base / tray / box, which involves the injection of a technical polymer, selected for its properties of thermal resistance, compatibility with sterilization processes (e.g., autoclavable), and dimensional stability. The polymer formulation is optimized to withstand exposure to sterilizing agents, ensuring safety in a hospital environment.

[0044]

[0046] The injection molding process is performed in molds with controlled temperature and pressure, aiming to minimize shrinkage and ensure the dimensional integrity of the orifices for the correct positioning of surgical instruments. Surface polishing is essential to eliminate microtextures, ensuring a low-friction surface that is easy to clean.

[0045]

[0047] Step 3 involves the production of the transfer molding tool. This phase includes the conception, design, and manufacture of a transfer molding tool. This tool is specifically designed for each surgical kit model, with cavities adapted to the geometry of the components of the surgical instrument clamping positioners to be produced.

[0046]

[0048] The transfer mold consists of three main components: a compression plate, responsible for pushing the composite material; a transfer plate, which houses the composite material and carries it to the base / tray / box; and a cavity plate, where the base / tray / box is housed and where the geometry of the components of the surgical instrument clamping positioners will be formed.

[0047]

[0049] The tool's flow transfer cavity and chamber are designed with material flow analysis (CAE) to ensure uniform distribution of the composite material during the transfer process in each clamping positioner of the surgical instrument.

[0048]

[0050] Step 4 involves molding and vulcanizing the geometries of the components for the clamping positioners of surgical instruments.

[0049]

[0051] This stage 4 requires four steps:

[0050]

[0052] Step 1 involves preparing the composite material feed. This includes converting the chosen resin into powder, paste, small pellets, or granules. Meanwhile, colorants, plasticizers, stabilizers, or other additives are mixed in to help achieve the desired aesthetic properties.

[0051]

[0053] In step 2, the polymer base / tray / box is inserted into the cavity plate as specifically designed for each surgical kit model;

[0052]

[0054] In step 3, the composite material is loaded onto the transfer plate. Then, a pre-measured load of composite material goes into the transfer chamber on the plate; and,

[0053]

[0055] In step 4, the mold is closed, where the compression plate pushes the composite material into the cavities with the help of a press (usually hydraulic). In this step, the material from the chamber enters the cavities through the transfer holes, followed by the closing of the mold.

[0054]

[0056] Step 5 involves the application of heat and pressure, where the hydraulic press keeps the mold closed, generating continuous heat and pressure for vulcanization of the loaded composite material. This heating is uniform throughout the mold to result in consistent vulcanization. The heat and pressure in the mold force the composite material to flow through transfer orifices, bonding the composite material with the polymer base / tray / box inserted within the cavity plate. Simultaneously, the goal is to achieve a uniform distribution of the composite material for consistent wall thickness and strength.

[0055]

[0057] In step 6, the already heated and pressurized composite material undergoes a chemical transformation (crosslinking and polymerization) to assume the shape of the cavity plate. The essential parameters for vulcanization are: cycle time, pressure, and temperature.

[0056]

[0058] Step 7 describes the mold opening process, where, after vulcanization, the press returns to its initial position, releasing the compression plate, relieving the mold pressure, and allowing the other mold plates to open.

[0057]

[0059] Step 8 refers to the ejection of the finished product.

[0058]

[0060] Finally, with the opening of the cavity plate and the transfer plate, the finished Base / Tray / Box product is removed from the mold. The parts then go for inspection and quality verification.

[0059]

[0061] The polymer base / tray / box, already a finished product, is completely flat, reducing areas where bacteria and dirt could accumulate, thus facilitating cleaning, disinfection, and sterilization processes.

Claims

MODIFIED CLAIMS Received by the International Secretariat on April 22, 2026 (22.04.2026) 1- MANUFACTURING PROCESS FOR SURGICAL INSTRUMENT TRAYS, characterized by comprising: a) Development and manufacture of a high-precision polymer injection mold with tight tolerances and a polished surface roughness < Ra 0.05 pm; b) Injection of autoclavable technical polymer into molds with controlled temperature and pressure, to obtain the tray; c) design and manufacture of a transfer molding tool composed of a compression plate, a transfer plate and a cavity plate; d) molding and vulcanization of positioning components for clamping surgical instruments, by inserting the tray into the cavity plate, loading composite material onto the transfer plate and hydraulic compression; (e) application of continuous heat and pressure for uniform vulcanization and bonding of the composite material to the tray; and f) Opening the mold and ejecting the finished product. 2- PROCESS according to claim 1, wherein the technical polymer is selected for its thermal resistance and compatibility with autoclave sterilization. 3- PROCESS according to claim 1, wherein the upper and lower faces of the injection mold have a high-gloss polished finish with a roughness < Ra 0.05 pm. 4- PROCESS according to claim 1, wherein the transfer molding tool is designed with material flow analysis (CAE) to ensure uniform distribution of the compound. 5- PROCESS according to claim 1, wherein vulcanization is carried out under controlled parameters of cycle time, pressure and temperature. 6- PROCESS according to claim 1, wherein the composite material is previously prepared in the form of powder, paste, pellets or granules, MODIFIED SHEET (ARTICLE 19) containing additives such as colorants, plasticizers or stabilizers. 7- TRAY obtained by the process according to any of the preceding claims, characterized by having: a) polished surface with roughness < Ra 0.05 pm; b) holes positioned with restricted tolerances for housing surgical instruments; and c) integral bonding between autoclavable technical polymer and vulcanized composite material, resulting in mechanical strength and dimensional stability after repeated cycles of hospital sterilization. MODIFIED SHEET (ARTICLE 19)

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