Sterilization Tray With Undulating Foam Sheet
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Solution Overview
Problem
Conventional sterilization trays are complex, costly, and not compatible with both steam and chemical sterilization processes due to their material limitations, making them unsuitable for diverse medical sterilization needs.
Innovation Solution
A sterilization tray with a sheet featuring an undulating profile of peaks and troughs, perforations, and a handle, made from non-corrosive materials like stainless steel or aluminum, which allows for versatile instrument arrangement and easy stacking, and is compatible with both steam and chemical sterilization methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional trays use metal brackets riveted to metal panels to secure instruments, then instrument securing and separation is achieved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent combines multiple functions (instrument support, separation, and securing) into a single integrated foam sheet structure. The foam sheet contains recesses that simultaneously support instruments, separate them from each other, and secure them in place, eliminating the need for separate metal brackets and rivets.
Solution Approach 2:
The foam sheet is designed as a universal component that can accommodate various types of surgical instruments through its array of recesses. The same foam sheet structure serves multiple purposes: supporting instruments, separating them to prevent contact, and securing them during sterilization, making it applicable to different surgical kits.
2Reliability
If conventional trays use multiple brackets and rivets for each instrument, then instrument separation is maintained, but manufacturing time and assembly complexity increase
Solution Approach 1:
The patent integrates instrument separation and securing functions into a single foam sheet component with pre-formed recesses. This eliminates the need for separate brackets and rivets that would require time-consuming assembly, allowing for faster manufacturing and production.
Solution Approach 2:
The foam sheet is pre-formed with recesses during manufacturing, so that instrument separation and positioning features are already in place before use. This preliminary formation of structural features eliminates the need for on-site assembly of multiple components, significantly reducing manufacturing time.
3Weight of moving object
If polymer-based trays are used to reduce cost and weight, then manufacturing cost and weight decrease, but compatibility with chemical sterilization is lost
Solution Approach 1:
The patent uses foam, which is a composite material structure (gas-filled cells within a solid matrix), to create a tray that is both lightweight and chemically resistant. The foam material provides the necessary durability and chemical stability for both steam and chemical sterilization processes while maintaining reduced weight compared to solid metal trays.
4Reliability
If custom bracket arrangements are designed for each surgical kit type, then instrument-specific securing is achieved, but manufacturing cost and complexity increase
Solution Approach 1:
The foam sheet is designed as a universal platform with an array of recesses that can accommodate various surgical instruments. The standardized recess pattern allows the same foam sheet design to be used across different surgical kits, providing instrument-specific support without requiring custom bracket designs for each kit type.
Solution Approach 2:
The foam sheet is divided into multiple discrete recesses, each capable of holding a specific instrument. This segmentation allows for flexible arrangement of different instrument types within a standardized foam sheet structure, providing custom-fit support without requiring custom-designed brackets for each instrument.
Data Source
AI summary
A system for storing instruments is provided. The system includes a tray including at least one tray end. At least one slot is formed in the at least one tray end. The system also includes a cover constructed and arranged to be positioned on the tray. The cover includes at least one cover end. The system also includes a latch positioned within the at least one cover end. The latch includes an actuating member and a locking member. The locking member includes at least one locking flange constructed and arranged to be received in the at least one slot. The at least one locking flange includes an angled lower edge constructed and arranged to engage the at least one tray end when the cover is positioned on the tray so that the latch is actuated into an open position to enable the at least one locking flange to be received within the at least one slot.