Molded Suture Package with Breakaway Access
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Solution Overview
Problem
Current surgical suture packaging solutions are not universal, as they fail to accommodate both U.S. and European dispensing preferences without additional spacers and are inefficient due to paperboard material limitations, leading to waste, damage, and security issues.
Innovation Solution
A molded plastic package assembly with a removable breakaway portion and a secure lid system that can be adapted for both U.S. and European rack configurations, incorporating anti-counterfeiting features and improved manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a two-piece dispensing box with drawer and sleeve is used to satisfy both U.S. and European preferences, then adaptability to different rack configurations is improved, but device complexity increases due to additional spacers and multiple moving parts
Solution Approach 1:
The molded package is designed with universal dimensions and features that allow it to function in both U.S. and European rack configurations without requiring additional spacers or adapters. The package depth of approximately 6 inches and the breakaway portion design enable it to be dispensed from either horizontal or vertical rack configurations, making a single design suitable for multiple market preferences.
Solution Approach 2:
The invention combines the dispensing functions for both U.S. and European preferences into a single integrated package design, eliminating the need for separate drawer mechanisms and spacers. The breakaway portion serves multiple purposes: it enables U.S.-style horizontal dispensing while also allowing European-style vertical access when the package is positioned vertically in the rack.
2Ease of manufacture
If paperboard boxes are used for packaging, then ease of manufacture is improved, but productivity decreases due to separate folding machinery requirements and 7-10% waste from crushed or damaged boxes
Solution Approach 1:
The invention replaces the mechanical folding and assembly process with injection molding, a single-step manufacturing process that forms the three-dimensional package directly. This substitution eliminates the need for separate folding machinery and the associated waste from damaged boxes during assembly, significantly improving productivity while maintaining ease of manufacture through a streamlined process.
Solution Approach 2:
The manufacturing process transitions from two-dimensional paperboard stamping and folding to three-dimensional injection molding. This parameter change in the manufacturing approach allows the package to be formed in its final three-dimensional shape in a single process step, eliminating waste from crushed or damaged boxes and improving overall productivity.
3Ease of manufacture
If paperboard boxes are used, then ease of manufacture is improved, but reliability decreases due to dust and particulate contamination requiring cellophane wrappers
Solution Approach 1:
The invention uses molded plastic as a composite material that inherently provides a smooth, non-porous surface that does not generate dust or particulates. This material choice eliminates the need for additional protective cellophane wrappers while maintaining ease of manufacture, as the plastic molding process directly produces a clean, protective package surface.
4Reliability
If molded plastic packages are used, then reliability is improved by reducing dust and damage, but device complexity increases due to multiple moving parts required for dispensing
Solution Approach 1:
The invention extracts the complex drawer mechanism from the package design and replaces it with a simple breakaway portion. This extracted simplification maintains the protective benefits of molded plastic while eliminating unnecessary moving parts, allowing the package to be dispensed through a simple breakaway action rather than requiring complex mechanical drawer systems.
5Adaptability or versatility
If additional spacers are added to the two-piece box to ensure proper fit in both U.S. and European racks, then adaptability is improved, but loss of substance increases due to unnecessary material usage
Solution Approach 1:
The molded package is designed with universal dimensions that eliminate the need for additional spacers. The package depth of approximately 6 inches and the breakaway portion design enable it to be dispensed from either horizontal or vertical rack configurations, making a single design suitable for multiple market preferences without requiring extra materials.
Data Source
AI summary
A package assembly and method for packaging sutures is provided. The package includes a substantially rectangular casing defining an internal area therein and including a container portion having a substantially flat bottom side defined by first, second, third and fourth edges, and first, second, third and fourth sides extending upwardly from the first, second, third and fourth edges respectively, and a lid portion removably secured to a top side of the container portion to thereby form an integral casing. The package further includes a plurality of suture packages each having a substantially planar shape, wherein the plurality of packages are positioned within the internal area of the rectangular casing substantially parallel to one another and substantially perpendicular to the bottom side of the container portion. The third side of the container portion, in a region substantially adjacent to the first side of the container portion, includes a removable breakaway portion wherein removal thereof leaves an opening through which the suture packages can be removed.