Modular Surgical Screw Carrier for Sterilization
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Solution Overview
Problem
Current methods for packaging, handling, sterilizing, and tracking small surgical screws are inefficient due to bulky packaging, difficulty in precise manipulation, and inadequate identification marking, leading to contamination and increased costs.
Innovation Solution
A modular system comprising cylindrical cells and complementary caps for secure handling and sterilization, with a tray design allowing steam access and durable identification marking, facilitating autoclaving and tracking of small components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If surgical screws are sterilized by autoclaving in sealed plastic pouches, then sterilization is achieved, but the packaging becomes bulky and complicates selection and manipulation of screws
Solution Approach 1:
The invention divides the packaging system into modular cells, each containing a single screw or small group of screws. Each cell is a self-contained sterilizable unit that can be individually selected and manipulated, eliminating the need to handle bulky sealed pouches while maintaining sterilization integrity.
Solution Approach 2:
The cell acts as an intermediary between the sterilization process and the surgical application. The cell can be sterilized autonomously and then serves as a controlled interface for screw delivery, allowing surgeons to access individual screws without compromising the sterilization of the entire package.
2Reliability
If each screw is stored in separate sealed packaging, then sterilization is maintained, but a large number of packages must be ripped open during surgery and surplus screws become contaminated
Solution Approach 1:
The cell is pre-configured with the screw in a sterile state and designed to remain closed until the moment of use. The cap provides a secure seal that maintains sterility, and the cell can be opened only when the specific screw is needed, preventing premature exposure and contamination of unused screws.
Solution Approach 2:
The invention enables recovery and reuse of the cell packaging. After the screw is removed, the empty cell can be sterilized and reused for subsequent screws, reducing waste compared to single-use sealed pouches. The durable cell design allows multiple cycles of use and sterilization.
3Ease of operation
If very small screws are handled with tweezers or similar tools, then manipulation is attempted, but the tools are clumsy and unreliable
Solution Approach 1:
The cell provides a larger, more manageable proxy for handling the tiny screw. Instead of directly manipulating the small screw with difficult-to-control tweezers, the surgeon manipulates the larger cell which contains the screw. The cell serves as a handling interface that translates coarse finger movements into precise screw delivery.
4Loss of information
If identification markings are placed on small surgical screws, then tracking is enabled, but the small size prevents legible markings to the naked eye
Solution Approach 1:
The invention moves the identification markings from the two-dimensional surface of the tiny screw to the larger three-dimensional surface of the cell. The cell provides ample space for legible markings including lot numbers, part numbers, and tracking information that can be easily read by the naked eye, while the screw itself remains too small for effective marking.
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
The modular system enhances handling precision, reduces contamination, and allows for efficient sterilization and tracking of small surgical screws, improving surgical efficiency and reducing waste by enabling reusable packaging and easy identification.
Implementation Method 1
the component can be sterilized by autoclaving (exposure to steam at high pressure and temperature)
Implementation Method 2
exposure to steam at high pressure and temperature
Implementation Method 3
A snap-on coupling between the cell and the cap allows the cap to be snapped securely on the cell under manual pressure; the coupling is further adapted to release upon application of sufficient bending moment across the co-axis of the cell and cap
Data Source
AI summary
A modular system facilitates packaging, marking, handling, sterilizing, tracking, tagging and storing small components such as surgical screws. A small, suitably cylindrical or similar cell receives a screw or other component and seats the component in a predetermined orientation. A complementary cap is adapted to engage the cell from above, closing the top and retaining the component in the cell. The cap is also adapted for use as a tool for handling the cell and the component contained therein. A coupling between the cell and the cap allows the cap to be snapped securely on the cell under manual pressure; the coupling is further adapted to release on application of sufficient bending moment across the co-axis of the cell and cap.