Undulating Sterilization Tray with Integrated Instrument Recesses
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Solution Overview
Problem
Conventional surgical instrument sterilization trays are complex, costly, and not compatible with both steam and chemical sterilization processes due to their material limitations, requiring specialized brackets and hardware for each type of instrument set.
Innovation Solution
A sterilization tray with a sheet featuring an undulating profile of peaks and troughs, perforations, and adjustable openings to accommodate various instruments, made from non-corrosive metals like stainless steel or aluminum, allowing for easy stacking, handling, and compatibility 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 instruments are securely held and separated, but the trays become very complex and require considerable time to manufacture and assemble
Solution Approach 1:
The patent combines multiple separate brackets and mounting hardware into a single integrated tray structure. The tray body itself incorporates instrument-retaining features such as recesses, channels, and positioning elements that are formed as part of the tray manufacturing process, eliminating the need for separate brackets and rivets.
Solution Approach 2:
The patent designs a universal tray structure that can accommodate multiple types of surgical instruments through integrated retaining features. The tray includes various recesses and positioning elements that can secure different instrument types without requiring specialized brackets for each instrument, allowing one tray design to serve multiple functions.
2Reliability
If conventional trays use specialized brackets for each type of instrument, then each instrument is properly secured, but the cost and complexity of manufacturing trays for different surgical kits increases
Solution Approach 1:
The patent creates a universal tray design with integrated retaining features that can accommodate multiple instrument types. The tray includes various recesses, channels, and positioning elements that can secure different surgical instruments without requiring specialized brackets for each instrument type, simplifying manufacturing across different surgical kits.
Solution Approach 2:
The patent segments the instrument-retaining function into integrated features distributed throughout the tray body. Rather than using separate brackets for each instrument, the tray incorporates multiple small retaining features (recesses, channels, positioning elements) directly into the tray structure, allowing instruments to be secured at their specific locations without requiring assembly of separate components.
3Ease of manufacture
If polymer-based materials are used for sterilization trays, then some shortcomings of metal trays are addressed, but the trays are not suitable for chemical sterilization processes
Solution Approach 1:
The patent employs metal materials (such as stainless steel or aluminum) that are compatible with both steam and chemical sterilization processes. The tray structure may incorporate different metal components or coatings that provide both the manufacturing advantages of metal (durability, sterilization resistance) and the chemical resistance needed for various sterilization methods.
4Reliability
If multiple brackets and rivets are used for each instrument, then instruments are securely held, but the manufacturing time and assembly time increase considerably
Solution Approach 1:
The patent combines multiple separate brackets and mounting hardware into a single integrated tray structure. The tray body itself incorporates instrument-retaining features such as recesses, channels, and positioning elements that are formed as part of the tray manufacturing process, eliminating the need for separate brackets and rivets and significantly reducing assembly time.
Solution Approach 2:
The patent segments the instrument-retaining function into integrated features distributed throughout the tray body. Rather than using separate brackets for each instrument, the tray incorporates multiple small retaining features (recesses, channels, positioning elements) directly into the tray structure, allowing instruments to be secured at their specific locations without requiring assembly of separate components.
Data Source
AI summary
The disclosure of the present application includes a sterilization tray for instruments. In an exemplary embodiment of a sterilization tray of the present disclosure, the sterilization tray comprises a sheet having a first end, an opposing second end, and a center portion between the first end and second end, in which the center portion having an undulating profile with a plurality of peaks and troughs and having a plurality of openings formed through the sheet. The openings are positioned and formed to receive one or more instruments. In at least one embodiment, the center portion includes a corrugated profile. Alternatively, the center portion includes a triangular or saw-tooth profile. In at least one embodiment, the distance between adjacent peaks of the center portion defines a wave having a length, and the center portion includes a non-uniform profile comprised of one or more waves of varying lengths.