Surgical Prep Applicator with Flow Distributor
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Solution Overview
Problem
Conventional surgical prep applicators lack control over liquid flow and are not cost-effective, making them inefficient and inconvenient for applying surgical prep solutions to the skin, especially under time pressure and varying surgical procedures.
Innovation Solution
The design incorporates a deformable sponge applicator pad with a flow distributor element featuring an annular slit and recessed channels to regulate liquid flow, ensuring controlled distribution and application, including a mechanism for opening a sterile reservoir to maintain consistent solution delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional swab or sponge is dipped into a dish of liquid and wiped over the skin, then the application can be done with simple tools, but the liquid flow is difficult to control and excess liquid may flow to unintended areas or form pools
Solution Approach 1:
The patent introduces an applicator device as an intermediary between the liquid reservoir and the skin. This device includes a controlled delivery mechanism (such as a sponge or pad with specific porosity and structure) that mediates the liquid flow, allowing precise control over the amount and distribution of liquid applied to the skin, preventing both excess flow and pooling.
Solution Approach 2:
The applicator employs porous materials (sponges or pads with controlled porosity) that regulate liquid flow through their pore structure. The porous nature allows the material to absorb and release liquid at a controlled rate, providing consistent liquid delivery while preventing overflow and pooling on the skin surface.
2Productivity
If surgical prep is done under severe time pressure, then the procedure must be completed quickly, but control over liquid application becomes more difficult
Solution Approach 1:
The applicator device is designed to be self-regulating in its liquid delivery. The controlled porosity and structure of the applicator material enable it to automatically regulate liquid flow without requiring constant manual adjustment by the surgeon, maintaining control even during rapid application under time pressure.
Solution Approach 2:
The patent utilizes parameter changes in the applicator material (such as porosity, density, and compressibility) to optimize liquid delivery speed. By carefully selecting and tuning these parameters, the applicator can deliver liquid rapidly yet controllably, enabling fast surgical prep while maintaining precision in liquid application.
3Reliability
If alcohol-based disinfectant with irritating ingredients is applied, then effective disinfection is achieved, but the liquid may burn or irritate the patient's skin if it pools or flows to unintended areas
Solution Approach 1:
The applicator acts as a controlled intermediary that precisely delivers the disinfectant liquid only to the intended skin areas. The controlled porosity and structured design prevent liquid from pooling or flowing to unintended areas, ensuring that the effective disinfectant ingredients contact only the target surfaces and do not cause irritation or burning from excessive accumulation.
4Reliability
If a sealed sterile reservoir is used to contain the surgical prep solution, then sterility is maintained, but the device complexity increases
Solution Approach 1:
The patent employs a nested structure where the sterile reservoir is integrated within the applicator device housing. The reservoir can be a cartridge or container that fits inside the main device body, allowing the sterile solution to be stored in a sealed compartment while maintaining overall device compactness. This nesting approach preserves sterility without excessively increasing device complexity.
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
This design enhances the control and efficiency of surgical prep solution application, preventing mess and irritation while being adaptable to different surgical needs and preferences, ensuring consistent and controlled liquid distribution to the skin.
Implementation Method 1
a deformable sponge applicator pad with a flow distributor element featuring an annular slit and recessed channels to regulate liquid flow
Data Source
AI summary
Applicators are described suitable for the application of liquid to patient's skin. An applicator pad (3) is supported on a support flange (23) of an applicator housing (2), which receives a liquid cartridge (5). To moderate the rush of liquid on to the back of the applicator pad a flow distributor plate (6) is positioned on the rear position of the pad (3), restricting flow onto the pad to an annular slit opening around the plate (6). The front surface of the plate (6), opposing the pad (3), may have one or more grooves so that liquid can flow from the edge towards the center. Also disclosed, as an alternative, is the use of a projecting cantilevered tongue structure to distribute liquid across the rear surface of the sponge pad. The pad may have a hooked lobe shape for a front end of the applicator pad.