Sterilization Tray with Elastomeric Lid
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Solution Overview
Problem
Existing sterilization trays for medical and dental instruments are cumbersome, costly to manufacture, and prone to latching mechanism failure due to the need for multiple parts and assembly steps, which complicates the sterilization and storage process, especially in high-volume production.
Innovation Solution
A foraminous sterilization tray with a rigid base and a flexible elastomeric lid that serves as both a retention device and a stackable cover, eliminating the need for hinges or mechanical latching mechanisms by integrating instrument retention members and supports directly into the tray and lid during injection molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a two-part sheet metal sterilization tray with hinge and latching mechanism is used, then the tray can securely enclose instruments, but the manufacturing cost increases and assembly complexity increases
Solution Approach 1:
The patent merges the lid and base into a single integrated component formed from a single sheet of metal. The lid is continuously connected to the base through side connections, eliminating the need for separate parts, hinges, and latching mechanisms. This integration reduces manufacturing cost and assembly complexity while maintaining secure enclosure through the continuous structure and instrument retention features.
2Reliability
If a hinge and latching mechanism are used to secure the lid to the tray, then the enclosure is secure, but the device complexity increases and reliability decreases due to repeated autoclaving
Solution Approach 1:
The lid and base are merged into a single continuous component with side connections that eliminate the need for separate hinges and latches. The secure enclosure is achieved through the integrated structure and instrument retention features rather than mechanical fastening components.
Solution Approach 2:
The patent extracts and eliminates the hinge and latching mechanism from the design. By removing these complex mechanical components, the design achieves secure enclosure through simpler means while reducing device complexity and improving reliability under repeated autoclaving conditions.
3Reliability
If separate instrument support components are used in the tray, then instruments can be held securely, but the assembly time increases and risk of component loss increases
Solution Approach 1:
The instrument support features are merged into the integrated lid and base structure. Retention brackets and finger mats are formed as part of the continuous metal component rather than separate parts, eliminating assembly steps and reducing the risk of component loss while maintaining secure instrument retention.
4Adaptability or versatility
If multiple separate components are used for the sterilization tray, then customization is possible, but the manufacturing cost increases particularly in high volumes
Solution Approach 1:
The tray is merged into a single integrated component that can be manufactured as one piece from a single sheet of metal through forming and cutting operations. This integration reduces manufacturing cost in high volumes while maintaining customization capability through selective formation of retention features and compartment configurations in the continuous structure.
Data Source
AI summary
The invention relates to product, method and system for materials handling apparatus and more particularly to an integrated design of a vessel for combining sterilization, storage, transport and presentment of dental or surgical instruments or implants using a uniquely designed sterilization tray. Fabrication of the tray and the number of parts required can be greatly cost reduced, due to the simplicity of the design.