Foley Catheter Tray Packaging Segmentation
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Solution Overview
Problem
Conventional packaging systems for Foley catheters and their associated components, such as coiled tubing and fluid drain bags, often result in damage during shipping and use due to bending or kinking, compromising their sterility and functionality.
Innovation Solution
A tray-based packaging system with compartments designed to securely hold Foley catheters, coiled tubing, and fluid drain bags, along with syringes and lubricating jelly, which includes features like clamps, clips, and a peninsular barrier to prevent snagging and contamination, while allowing for easy access and use of the components without compromising the sterile field.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Foley catheters and coiled tubing are shipped in conventional sterile packaging, then sterility is maintained, but the tubing is susceptible to bending, kinking, and damage during shipping and use
Solution Approach 1:
The packaging system is divided into multiple compartments: a first compartment for the Foley catheter and a second compartment for the coiled tubing and fluid drain bag. This segmentation allows each component to be protected independently, preventing damage to the tubing while maintaining sterility of both components through separate sterile barriers.
Solution Approach 2:
A sterile barrier acts as an intermediary between the external environment and the medical components. The barrier can be selectively opened to access either the catheter or tubing compartment, allowing sterile access without exposing the entire assembly to contamination risk, thereby maintaining sterility while enabling safe handling.
2Ease of manufacture
If coiled tubing is placed in conventional packaging, then shipping is simplified, but the tubing is prone to snagging and damage during unwrapping and use
Solution Approach 1:
The tubing is isolated in a separate compartment with dedicated access through the sterile barrier. This segmentation prevents the tubing from snagging on other components during unwrapping, as each compartment can be opened and accessed independently without disturbing the other components.
Solution Approach 2:
The packaging design anticipates potential damage during handling by providing a protected compartment structure. The sterile barrier and compartment walls act as protective elements that cushion and protect the coiled tubing from mechanical damage during shipping, unwrapping, and initial setup procedures.
3Reliability
If all components are packaged together in a single sterile package, then sterility is maintained, but access and use of components becomes difficult without compromising the sterile field
Solution Approach 1:
The single sterile package is segmented into multiple compartments that can be accessed independently. The sterile barrier can be opened at different locations to access the catheter compartment or the tubing compartment separately, maintaining the sterile field while enabling convenient access to specific components as needed during the procedure.
Solution Approach 2:
The sterile barrier serves multiple functions: it maintains overall sterility of the package while also allowing selective access to different compartments. The barrier can be opened to access either the catheter or the tubing, making the packaging system universally applicable for maintaining sterility regardless of which component needs to be accessed first.
Data Source
AI summary
A medical procedure kit includes a first tray. A second tray situates atop the first tray. The second tray includes preformed compartments configured to receive and house a plurality of medical implements. A Foley catheter positioned within a Foley catheter compartment of the plurality of preformed compartments of the second tray. A drainage system stowed within an interior of the first tray. A third tray can be situated atop the second tray. The second tray can include a plurality of catheter retention devices. A planar substrate can be positioned beneath the first tray. A Foley catheter compartment can define a barrier wall extending across a majority of its length. A cutout in the second tray and another cutout in the first tray can be positioned at opposite ends of the kit. These features can be used alone or in combination, and many can even be applied to a single-layer tray.