Sterile Surgical Tool Packaging with Segmented Blister Protection
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Solution Overview
Problem
Current packaging methods for sterile surgical tools with cutting or sawing edges are inadequate as they allow the tools to slip and potentially come into contact with polybag surfaces, risking contamination and damage during shipping and handling.
Innovation Solution
A two-part packaging system comprising a protective package that holds the tool's sensitive edges and a blister pack that secures the protective package in a fixed position, preventing contact with plastic surfaces and ensuring the tool remains sterile and undamaged.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single polybag is used to package surgical tools, then the packaging is simple and easy to manufacture, but the tools can slip around and come into contact with the polybag interior surfaces, causing contamination and damage
Solution Approach 1:
The packaging system is divided into two distinct parts: an inner protective package that directly holds the surgical tool and an outer blister pack that contains the inner package. This segmentation allows each layer to perform its specific function - the inner package protects the tool from contamination and damage, while the outer package provides additional protection and secure positioning during shipping and handling.
2Reliability
If the protective package volume is increased to prevent tool contact with surfaces, then the tool is better protected, but the packaging size and material usage increase
Solution Approach 1:
The inner protective package is nested within the outer blister pack, creating a compact hierarchical structure. This nesting approach allows the protective elements to be tightly integrated without requiring excessive space, as each layer fits within the contours of the outer package, minimizing overall volume while maintaining protection.
3Reliability
If the tool is secured in a fixed position in the blister pack, then the tool cannot slide and pick up microparticles, but the positioning mechanism adds complexity to the packaging
Solution Approach 1:
The inner protective package serves as an intermediary between the surgical tool and the outer blister pack environment. By securing the inner package in a fixed position within the blister pack rather than directly securing the tool, the system prevents the tool from contacting the blister pack walls and picking up microparticles, while the intermediary nature of the inner package simplifies the positioning mechanism.
Data Source
AI summary
Packaging and methods for packaging tools having a sharp or cutting edge, such as surgical tools, in which the tool is packaged under sterile conditions. The tool may be packaged first—at least partially—and in particular with its sensitive cutting edges and working surfaces packaged in a protective package. The protective package containing at least the cutting or working surfaces of the tool may then be secured in a fixed position in an outer blister pack, which may be sealed with a sealing film.