Sterilization Backer Card Flap Design for Instrument Protection
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Solution Overview
Problem
Existing medical instrument sterilization methods lack a comprehensive solution that effectively immobilizes instruments, ensures complete sterilization exposure, prevents puncturing of sterilizable envelopes, allows easy identification, and is convenient and cost-effective.
Innovation Solution
A medical instrument sterilization backer card with deployable flaps that immobilize the instrument, provide maximum exposure to sterilizing media, prevent puncturing, facilitate visual identification, and is designed for ease of use and affordability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If tip protectors are placed over the cutting ends or edges of the medical instrument, then protection against puncturing and dulling is improved, but complete sterilization exposure is compromised and cost increases
Solution Approach 1:
The backer card is segmented into multiple functional zones: a base portion for support, a first flap portion that folds over to protect the shaft while leaving the cutting edge exposed, and a second flap portion that forms a shell around the head. This segmentation allows different portions of the instrument to receive appropriate protection or exposure based on sterilization and safety requirements.
Solution Approach 2:
Different portions of the backer card provide different levels of protection: the first flap provides protection along the shaft while leaving the cutting edge exposed for sterilization, the second flap provides comprehensive protection for the head, and windows are provided in specific locations to allow sterilizing medium access. This local differentiation resolves the contradiction between protection and sterilization exposure.
2Object-affected harmful factors
If tip protectors are used to protect cutting edges, then protection is improved, but device complexity and cost increase
Solution Approach 1:
The backer card merges multiple functions into a single integrated structure: it provides immobilization during sterilization, protection of the cutting edge through the first flap configuration, protection of the head through the second flap shell, and visual identification through windows. This consolidation eliminates the need for separate tip protectors and reduces overall device complexity.
Solution Approach 2:
The backer card serves multiple functions simultaneously: it acts as an immobilization device, a protective covering, a sterilization aid, and an identification tool. This multi-functionality replaces the need for multiple separate devices including tip protectors, thereby reducing complexity and cost.
3Object-affected harmful factors
If the backer card structure is designed to protect the instrument, then protection is improved, but ease of operation deteriorates
Solution Approach 1:
The backer card employs dynamic flap portions that can be folded and unfolded as needed. The first flap folds over the base to protect the shaft, the second flap folds to form a protective shell around the head, and these flaps can be easily manipulated during instrument attachment and removal. This dynamic design maintains protection while ensuring ease of operation.
Data Source
AI summary
A medical instrument sterilization backer card includes a flap extending from an end of a base and foldable over the base to form an open-ended pocket that receives an end of a shaft of the medical instrument therein. A second flap extends from the base and is foldable over the base to form a shell defining a compartment configured to receive a head of the medical instrument therein. The assembled backer card holds and protects the medical instrument during and after sterilization.