Medical Container Packaging With Aperture-Based Gas Sterilization
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Solution Overview
Problem
Conventional medical container packaging faces challenges in efficiently sterilizing and transporting sterile medical products due to difficulties in removing sealing layers without generating particles that can infect the contents, and high material costs associated with using porous materials to cover entire openings.
Innovation Solution
A packaging design featuring apertures in the bottom wall sealed with porous material and a transparent sealing layer that allows for sterilization gas injection through the apertures, reducing the amount of porous material needed and facilitating easy removal of the sealing layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If porous material is used to cover the entire top opening for sterilization, then sterilization effectiveness is improved, but material cost increases
Solution Approach 1:
The packaging design segments the sealing structure into two distinct parts: a peripheral flange that provides structural support and a separate porous insert that provides sterilization functionality. This segmentation allows the porous material to be used only where needed (in the insert) rather than covering the entire opening, reducing material cost while maintaining sterilization effectiveness.
Solution Approach 2:
The porous material is applied locally in the insert rather than uniformly across the entire opening. The insert is positioned within the tub to provide sterilization functionality only in the specific area where gas flow is needed, rather than covering the entire top opening, thus reducing the quantity of porous material required.
2Reliability
If a sealing layer is applied over the entire opening, then sealing effectiveness is improved, but difficulty in removal without particle generation increases
Solution Approach 1:
The sealing system is segmented into a peripheral flange that remains attached to the tub and a removable porous insert. The seal is formed at the interface between the flange and the tub opening, allowing the insert to be removed without compromising the seal integrity. This segmentation enables easy removal of the porous material without generating particles that could contaminate the contents.
Solution Approach 2:
The porous insert is extracted as a separate, removable component from the sealing system. The sealing function is maintained by the peripheral flange that remains attached to the tub, while the porous insert can be easily removed without affecting the seal, thus facilitating easy handling and transportation.
3Reliability
If porous material is used to cover the entire opening, then sterilization coverage is improved, but material cost increases
Solution Approach 1:
The porous material is applied locally in the insert rather than uniformly across the entire opening. The insert is positioned within the tub to provide sterilization functionality only in the specific area where gas flow is needed, rather than covering the entire top opening, thus reducing the quantity of porous material required while maintaining adequate sterilization coverage.
Solution Approach 2:
The sterilization function is moved from a two-dimensional surface coverage (covering the entire top opening) to a three-dimensional configuration where the porous insert extends vertically within the tub. This dimensional change allows sterilization gas to flow through the porous material from above and below, achieving adequate sterilization coverage with less material.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design ensures effective sterilization while minimizing material costs and particle generation, allowing for efficient handling and transportation of sterile medical products with reduced material usage and improved sealing layer application/removal.
Implementation Method 1
The packaging includes an insert of porous material sealed to the bottom wall of the tub over the at least one aperture, the porous material configured to seal the at least one aperture from liquid penetration
Implementation Method 2
sterilization of the contents of the packaging occurs through the injection of a disinfectant through a gas-porous and liquid-resistant material layer
Data Source
AI summary
A packaging for medical containers includes a tub having a bottom wall with at least one aperture through the bottom wall, and peripheral sidewalls extending from a periphery of the bottom wall. The peripheral sidewalls include a peripheral flange along top edges of the peripheral sidewalls, and the peripheral sidewalls form an opening at a top of the tub opposite to the bottom wall. The packaging includes an insert of porous material connected to the tub a disposed over the at least one aperture through the bottom wall, a nest to support a plurality of medical containers, and a sealing layer connected to the peripheral flange to seal the opening at the top of the tub.