Instrument Tray Folding Automation for Reproducible Sterile Packaging

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Solution Overview

Problem

Manual folding of instrument trays into packaging material is non-reproducible, prone to contamination, physically demanding, and increases the risk of microorganism penetration due to imperfect folding patterns, leading to rejected sets and operational delays.

Innovation Solution

A device comprising a supporting surface, movable folding plates, a folding aid, and clamps to automate the folding process, ensuring precise and sterile packaging by guiding and fixing the packaging material around the instrument tray.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual folding of instrument trays into packaging material is performed, then flexibility and adaptability are maintained, but manufacturing precision and reliability deteriorate due to non-reproducible folding patterns and contamination risks

Engineering Contradiction:

Improvemanual folding flexibilityVSAvoidfolding pattern consistency

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent replaces the manual mechanical folding system with an automated mechanical folding device. The device uses a folding arm with a folding element that automatically performs the folding actions according to a predetermined pattern, eliminating human variability while maintaining the mechanical folding process. The control unit orchestrates the folding arm movements to achieve consistent, reproducible folding patterns for every instrument tray packaged.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The folding device is designed to automatically position and fold the packaging material without requiring continuous human intervention. The folding arm moves autonomously through the folding sequence, and the device self-regulates to ensure consistent folding patterns. The system serves itself by using the packaging material's own properties (flexibility, layers) to achieve the desired folded structure.

Inventive Principle:

Principle #25Self-service

2Adaptability or versatility

If manual folding is performed to accommodate varying instrument tray sizes, then adaptability is improved, but device complexity increases and productivity decreases due to time-consuming manual operations

Engineering Contradiction:

Improveaccommodation of different tray sizesVSAvoidpackaging speed

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The folding device incorporates a movable folding arm that can dynamically adjust its position and movement parameters. The control unit can modify the folding sequence and arm trajectory to accommodate different instrument tray sizes and packaging requirements. This dynamic capability allows the same device to handle various tray dimensions without sacrificing packaging speed, as the automation maintains high productivity while adapting to different configurations.

Inventive Principle:

Principle #15Dynamics

3Ease of operation

If manual folding operations are performed repeatedly, then physical strain on personnel increases, but automation requires higher device complexity and initial investment

Engineering Contradiction:

Improvereduction of physical strainVSAvoidautomation system complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent replaces the human mechanical system with an automated mechanical folding device. The folding arm, driven by appropriate actuators, performs all folding actions that previously required manual effort. This substitution eliminates physical strain on personnel while the device complexity is managed through modular design and programmable control, making the automation achievable with reasonable investment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If imperfect folding patterns occur during manual operation, then contamination risk increases, but strict protocol adherence reduces operational flexibility

Engineering Contradiction:

Improvesterility maintenanceVSAvoidoperational flexibility

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The folding device incorporates feedback mechanisms through its control unit, which monitors and adjusts the folding process in real-time. The control unit receives information about the folding arm position, packaging material state, and tray configuration, and uses this feedback to ensure the folding pattern consistently meets sterility requirements. This automated feedback loop maintains reliability while the programmable nature of the system provides the necessary operational flexibility.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS12364566B2Device and method for folding an instrument set in a package

Publication Date: 2025.07.22 R SOLUTION MEDICAL BV

AI summary

Device for folding an instrument tray into a packaging material, comprising a supporting surface for supporting the instrument tray during folding of the instrument tray into the packaging material, a first folding plate and a second folding plate, a movable folding aid for fixing the packaging material over a predefined line portion before and/or during the making of a fold, at least one movable clamp for gripping and moving the packaging material, a control unit for controlling the movement of the first folding plate between its respective first and second positions, the movement of the second folding plate between its respective first and second positions, the movement of the folding aid, and the movement and clamping and release of the at least one clamp.