Stackable Delivery Tray Structure for Low-Particle Medical Packaging

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Solution Overview

Problem

Existing methods for packaging and delivering caps for resealing medical vials are unsuitable as they can generate particulate contamination due to contact and friction, posing serious risks when used with medical solutions intended for injection.

Innovation Solution

A tray and packaging system with compartments and caps designed to minimize contact and friction, using interlocking mechanisms and perforated bases to isolate medical items, combined with a vacuum-sealed tank to maintain sterility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If caps are delivered in bulk and arranged in a tray or vibratory bowl, then delivery efficiency is improved, but particulate contamination is generated due to contact and friction between caps and surfaces

Engineering Contradiction:

Improvedelivery efficiencyVSAvoidparticulate contamination

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The bulk delivery system is segmented into individual compartments, with each cap isolated in its own housing. This segmentation eliminates contact and friction between caps and between caps and tray surfaces, thereby preventing particulate contamination while maintaining organized delivery.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Caps are nested within individual housings that are themselves nested within the tray structure. The caps fit within the housings, which are arranged within the tray, creating a nested configuration that isolates each cap while maintaining compact delivery.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If caps are isolated in individual compartments to prevent contamination, then sterility is improved, but device complexity increases due to multiple compartments and interlocking mechanisms

Engineering Contradiction:

ImprovesterilityVSAvoidtray structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Multiple functional elements are merged into the tray structure: the housings form integral parts of the tray, the caps serve both as containers and as sealing elements, and the interlocking mechanisms are integrated into the basic tray-caps assembly. This merging reduces overall system complexity while maintaining sterility.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The caps serve multiple functions: they contain the medical items, seal the housings, and provide interlocking features for stacking trays. The housings simultaneously provide structural support, isolation, and sealing surfaces. This multi-functionality reduces the need for additional separate components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Object-generated harmful factors

If trays are stacked with interlocking caps to maintain isolation, then contamination prevention is improved, but ease of operation deteriorates due to difficulty in assembly and disassembly

Engineering Contradiction:

Improvecontamination preventionVSAvoidassembly and disassembly ease

Core Design Contradiction:

Object-generated harmful factorsVSEase of operation

Solution Approach 1:

Instead of requiring active engagement mechanisms for interlocking, the design uses passive interference fits where the cap dimensions are slightly larger than the housing openings, allowing automatic engagement during stacking. The interlocking occurs naturally through the inversion of the expected assembly sequence.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The interlocking mechanism is self-servicing through elastic deformation of the housing walls. When caps are placed in the housings, the elastic material automatically deforms to accommodate the cap dimensions and then maintains continuous contact pressure, providing self-locking without requiring additional fastening operations.

Inventive Principle:

Principle #25Self-service

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system effectively reduces particulate contamination by isolating medical items, ensuring sterility and safety during transport and handling.

Implementation Method 1

The upper part of the housings is deformable

Methodology Applied

Scientific EffectVacuum: Vacuum

Implementation Method 2

The upper part of the housings is deformable

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentEP3967624B1Delivery tray and packaging system for medical items

Publication Date: 2026.01.21 A RAYMOND & CO SCS

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Figure 3~4b
Figure 4c~6a

AI summary

The invention relates to a delivery tray (20) for medical devices (50), the tray (20) being equipped with a plurality of compartments (21), each intended to receive a single medical device (50); the underside of the tray (20) having a plurality of caps, the caps being arranged and sized so that when the tray (20) is stacked on a second identical tray, caps (25) of the tray (20) are capable of closing compartments of the second tray. The invention also relates to a packaging system (100) comprising: a container (10) having an opening, a base (10a), and a peripheral wall (10b); a stack formed of a plurality of trays (20); a porous lid (40) sealed on the upper edge of the peripheral wall (10b) of the container (10) for closing it. The invention further relates to a packaging method comprising, in particular, a vacuum sealing step.