Surgical Stapler Buttress Packaging Hermetic Seal Design
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Solution Overview
Problem
Existing surgical stapling instruments lack effective packaging solutions that preserve the integrity of buttress materials, which are susceptible to degradation from environmental factors such as moisture, compromising their functionality and integrity before use.
Innovation Solution
A packaging assembly comprising an outer tray and inner tray with a foil pouch that forms a hermetic seal, protecting the buttress applicator from moisture and damage, and includes a desiccant material to absorb any remaining moisture, ensuring the buttress assemblies remain intact until deployment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If buttress materials are packaged in conventional non-hermetic containers, then packaging simplicity is maintained, but moisture and environmental factors degrade the buttress material integrity
Solution Approach 1:
The packaging is divided into multiple components: an outer tray providing structural support, an inner tray holding the buttress material, and a hermetic seal layer. This segmentation allows each component to perform its specific function while collectively providing comprehensive protection against moisture and environmental degradation.
Solution Approach 2:
The inner tray containing the buttress material is nested within the outer tray, creating a hierarchical packaging structure. This nesting arrangement maximizes space utilization, provides multiple layers of protection, and maintains structural integrity while protecting the sensitive buttress material from environmental factors.
2Reliability
If hermetic sealing is used to protect buttress material from moisture, then material integrity is preserved, but packaging manufacturing complexity increases
Solution Approach 1:
A flexible hermetic seal layer is used to create an impermeable barrier between the inner and outer trays. This thin film approach provides effective moisture protection while being relatively simple to manufacture and assemble compared to rigid hermetic containers, reducing overall manufacturing complexity.
3Reliability
If desiccant material is added to absorb moisture, then buttress material protection is enhanced, but packaging volume increases
Solution Approach 1:
A desiccant material is placed within the hermetic seal between the inner and outer trays to actively absorb any residual moisture. This intermediary moisture-absorbing layer enhances protection effectiveness while utilizing the existing packaging space efficiently, minimizing volume increase.
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 packaging assembly maintains the integrity and functionality of the buttress materials by preventing exposure to moisture and environmental factors, ensuring reliable performance during surgical procedures.
Implementation Method 1
A packaging assembly comprises an outer tray and inner tray with a foil pouch that forms a hermetic seal
Implementation Method 2
includes a desiccant material to absorb any remaining moisture
Data Source
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AI summary
A packaging assembly is designed for an applicator that contains a buttress assembly that is used with a surgical stapler to reinforce a cut and stapled tissue site. The packaging assembly protects the buttress assembly from damage due to physical contact as well as exposure to adverse environmental factors like excess moisture, etc. In one example the packaging assembly includes a dual tray design with an inner tray that holds the applicator. The combined inner tray and applicator are hermetically sealed within a foil assembly or foil pouch. The foil pouch with the inner tray and applicator within is placed within the outer tray to protect the foil from damage.