Trauma Resistant Suspension Cell Package for Secure Shipping
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Solution Overview
Problem
Conventional packaging for 'fast-acting biological indicators' (FABI) is inadequate in providing low-cost, secure protection against physical trauma during shipping and handling, leading to premature activation due to vibrations and shocks.
Innovation Solution
A new shipping container design featuring a frangible insert with openings that allow the vial and cap assembly to be suspended, preventing accidental activation, combined with a reinforcing divider and absorbent pad for enhanced protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional packaging materials (cardboard, plastic, film) are used for FABI, then cost is reduced, but protection against physical trauma and premature activation is inadequate
Solution Approach 1:
The packaging is divided into multiple functional layers: an outer body, an insert with openings, and a partitioning divider. Each layer serves a specific protective function, with the insert preventing cap-vial contact and the divider providing structural support, thereby achieving reliable protection without excessive cost.
Solution Approach 2:
The insert with openings is positioned beforehand to create a suspended configuration that prevents the cap from contacting the vial during normal handling and shipping. This preemptive design eliminates the risk of premature activation without requiring expensive reinforcement materials.
2Strength
If the vial and cap assembly is suspended in the container, then protection against impact is improved, but device complexity increases
Solution Approach 1:
The insert with openings serves multiple functions simultaneously: it suspends the vial and cap assembly, prevents cap-vial contact during impact, and maintains the assembly in a protected configuration. This multi-functionality achieves impact resistance without adding separate complex protective mechanisms.
Solution Approach 2:
The partitioning divider is nested within the outer body, and the insert with openings is positioned within the cavity formed by the divider. This nested arrangement creates a compact, multi-layer protective structure that achieves enhanced impact resistance while minimizing overall packaging complexity.
3Reliability
If the opening in the insert is sized to suspend the vial and cap assembly, then protection against accidental activation is improved, but ease of extraction deteriorates
Solution Approach 1:
The opening in the insert is sized with specific local dimensions that allow the vial and cap assembly to be suspended securely during shipping, while the overall container design includes features that facilitate easy extraction at the destination. The local opening size balances protection with eventual accessibility.
Data Source
Figure 1(a)~3(b)
Figure 4(a)~4(d)
Figure 5(a)~5(c)
AI summary
AAn impact and crush resistant shipping container for a vial and cap assembly, e.g., a FABI, the container having sides and a bottom defining a cavity and an opening, and a closeable cover; a partitioning divider defining at least one vertical receptacle for receiving a portion of the vial and cap assembly; an insert having at least one opening therethrough for receiving the vial and cap assembly, each opening sized such that the vial and cap assembly can be suspended in the opening, and the partitioning divider positionable with respect to the insert such that the vial and cap assembly can be suspended at least partially within the receptacle, and the partitioning divider and the insert with the at least one vial and cap assembly suspended therein are positionable within the cavity such that the cover can be closed without contacting the at least one vial and cap assembly.