Blow-Molded Polyurethane Packaging for Bone Screws
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Solution Overview
Problem
Current packaging solutions for bone screws are complex to manufacture and handle, pose risks due to sharp edges, and fail to meet hygiene requirements, especially when handling multiple items.
Innovation Solution
A packaging method involving a strip with cavities for bone screws, where a punch line is formed in the cavity wall to facilitate easy opening and closure, using polyurethane materials that are resistant to sharp objects and suitable for sterilization, with optional break webs and fold lines for easy handling and sterilization access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex packaging designs with multiple components are used to protect bone screws, then protection from damage and hygiene requirements are improved, but manufacturing complexity and handling difficulty increase
Solution Approach 1:
The patent combines multiple packaging components (outer sleeve, inner sleeve, sealing closure) into a single integrated blow-molded packaging structure. The blow-molding process creates a unified component that incorporates the cavity, closure, and sealing elements, eliminating the need for separate clamping fits and multiple assembly steps while maintaining protection and hygiene requirements.
Solution Approach 2:
The blow-molded packaging structure serves multiple functions simultaneously: it provides mechanical protection against damage from sharp bone screw threads, maintains sterile hygiene conditions, enables easy opening through the integrated closure, and allows for cost-effective manufacturing. This multi-functional design resolves the contradiction by achieving reliability without complexity.
2Reliability
If individual packaging for each bone screw is implemented to meet hygiene requirements, then hygiene and safety are improved, but manufacturing complexity and handling difficulty increase
Solution Approach 1:
The patent creates individual packaging units (blister packs) for each bone screw through the blow-molding process. Each cavity in the molded structure forms a separate sealed compartment that can be individually filled and sterilized. This segmentation maintains hygiene and safety while the integrated molding process keeps manufacturing simple and cost-effective.
3Reliability
If the cavity remains completely closed to protect the bone screw, then protection from damage is improved, but access for removal of the bone screw becomes difficult
Solution Approach 1:
The blow-molded packaging structure incorporates a pre-formed closure mechanism that maintains complete sealing during storage and transport to protect the bone screw. The closure is designed with predetermined breaking points or opening mechanisms that allow easy access during surgical use, resolving the contradiction between protection and ease of opening.
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 solution simplifies packaging production and handling, ensures safety from sharp edges, and allows for efficient sterilization, while enabling easy access to the bone screws through a punch line mechanism, making it suitable for both individual and blister pack formats.
Implementation Method 1
both sheets being made of polyurethane, which is not damaged even by sharp-toothed objects, such as bone screws
Implementation Method 2
it is particularly suitable for use in an autoclave because it can withstand relatively high temperatures
Data Source
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Figure 5
AI summary
In a method for producing a packaging (P) for at least one object (1), in particular a bone screw, wherein at least one cavity (3) for the at least one object (1) is formed in a strip, the at least one object (1) is inserted into the cavity (3) and the cavity (3) is closed by a cover strip (15), after forming the cavity (3) a punch line (7) is formed into at least a part of the wall of the cavity (3).