Modular Surgical Tray Inserts for Custom Instrument Sets
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Solution Overview
Problem
Existing surgical apparatus trays are inefficient and cumbersome due to the need for multiple trays to accommodate varying surgical procedures, leading to redundant items, difficulty in locating equipment, and challenges in inventory control.
Innovation Solution
A modular approach using inserts with male and female attachment features that allow for customizable surgical apparatus trays, enabling efficient assembly and connection of inserts with a friction fit and locking mechanism, allowing for flexible tray configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple fixed trays are provided to accommodate different surgical procedures, then all necessary apparatus can be available, but the number of trays increases and redundancy occurs
Solution Approach 1:
The surgical tray is divided into multiple detachable inserts that can be independently selected and combined. Each insert can hold specific surgical apparatus, and the inserts can be attached or detached from the tray base to create custom configurations for different surgical procedures, eliminating the need for multiple complete trays
Solution Approach 2:
The tray configuration is made dynamic through the ability to reattach and reconfigure inserts during storage and use. Rather than fixed layouts, the inserts can be moved between different tray bases or stored separately, allowing the system to adapt to varying surgical needs without requiring a large inventory of static trays
2Loss of substance
If customised trays with selected apparatus are provided, then redundancy is reduced, but the ease of locating and controlling inventory is reduced
Solution Approach 1:
The tray base is designed as a universal platform that can accommodate multiple different insert types through standardized attachment features. This allows the same tray base to be used across different surgical procedures by simply changing the inserts, maintaining inventory control and ease of location while reducing redundancy
Solution Approach 2:
Indicia such as colors, symbols, or labels are provided on the inserts and tray base to facilitate quick identification and matching of compatible components. This visual coding system helps staff quickly locate the correct inserts and understand their compatibility with specific tray bases, maintaining ease of operation despite customization
3Adaptability or versatility
If a large number of items are provided in each tray, then all possible apparatus is available, but the weight and volume of the tray increases
Solution Approach 1:
By segmenting the tray into a base and separate inserts, only the necessary inserts for a specific procedure are attached and transported. The empty tray base weighs less than a fully loaded custom tray, and unused inserts remain in storage rather than adding weight to each individual tray configuration
Data Source
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AI summary
An insert for a surgical apparatus tray and method of preparing a surgical apparatus tray are described. The insert may include an upper part defining at least one support configured to receive an item of surgical equipment, and defining a first plane and having a plurality of edges defining a polygonal shape. A first side wall may extend downwardly from a first edge of the upper part and define a second plane. The first side wall may have a first, male attachment feature. A second side wall may extend downwardly from a second edge of the upper part and have a second, female attachment feature. The first attachment feature may be configured to mate with the form of the female attachment feature when the first side wall is moved in a direction parallel to the first plane and the second plane to connect the insert to a further insert having a similar construction.