Disposable Medical Kit Tray With Foldable Protective Shell
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Solution Overview
Problem
Conventional packaging systems for medical kits fail to adequately protect internal components, such as pump segments and filters, from kinking and pressure marks during storage and shipment, as they primarily focus on external protection.
Innovation Solution
A disposable kit with a customizable tray configuration that encloses internal components, featuring hinged sections and channels to prevent kinking and pressure marks, along with pre-mounted filters and tubing to simplify setup and ensure secure protection during storage and use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional packaging systems are used, then external protection is provided, but internal components (tubes, filters, pump segments) are not protected from kinking and pressure marks
Solution Approach 1:
The packaging structure is divided into multiple sections: an outer shell providing external protection, and an inner tray with specific compartments and channels for each internal component (tubes, filters, pump segments). This segmentation allows each component to be protected individually while maintaining overall structural integrity.
Solution Approach 2:
The inner tray is nested within the outer shell, creating a hierarchical packaging structure. The tray with its compartments and channels is placed inside the larger protective shell, allowing the smaller protective structure to provide specialized protection for internal components while the outer shell provides general protection.
2Volume of stationary object
If components are tightly packed to reduce space, then storage efficiency improves, but tube kinking and pressure marks occur
Solution Approach 1:
The tray design provides different local characteristics for different components: raised compartments for filters, channels for tubes to maintain their natural curvature, and specific positioning areas for pump segments. This localized customization ensures each component is protected according to its specific shape and vulnerability without requiring excessive overall volume.
Solution Approach 2:
The packaging utilizes vertical dimension with raised compartments and channels that extend upward from the tray base. This three-dimensional arrangement allows components to be positioned in multiple levels and orientations, protecting them from deformation while optimizing space utilization through vertical stacking rather than only horizontal expansion.
3Object-affected harmful factors
If custom packaging is designed for each component, then protection improves, but manufacturing complexity and cost increase
Solution Approach 1:
The inner tray is designed as a universal structure that can accommodate multiple types of components (tubes, filters, pump segments) within its standardized compartments and channels. This multi-functional design allows a single tray mold to produce packaging suitable for various component combinations, reducing the need for multiple custom molds while still providing component-specific protection.
Solution Approach 2:
The tray compartments and channels are pre-formed during tray manufacturing, creating ready-made protective structures before components are inserted. This preliminary action of forming the protective geometry in advance simplifies the assembly process and ensures consistent protection without requiring complex post-assembly adjustments or additional manufacturing steps.
Data Source
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AI summary
A disposable kit for a medical apparatus comprises a tray (11) and a subassembly (20) with a plurality of sections (21 to 23) foldably connected to each other. At least one of the sections (21 to 23) can fold itself onto the tray (11) so that the subassembly (20) encloses a region of the tray (11). When the tray (11) is laid on the subassembly (20) in a predetermined position, elevated channel (13) regions formed on a front side of the tray (11) and facing the subassembly (20) can accommodate component installations of the subassembly (20), and a section of the plurality of sections (21 to 23) can be folded to the rear side of the tray (11) so that component installations on that section can be accommodated in elevated channel (13) regions formed on the rear side of the tray (11). In this manner, the subassembly (20) forms a hard-shell that at least partially surrounds the tray (11) and protects pre-installed or packed pressure-sensitive components, parts and or regions of the disposable kit.