Abstract:
An instrument organizer for at least partially supporting one or more surgical instruments includes a base structure having opposed terminal ends and at least one first end post fixedly positioned at one terminal end of the base structure. The instrument organizer also includes at least one movable stabilizing structure that is mountable on the base structure at a location spaced from the first end post, to thereby stabilize and at least partially support one or more instruments. At least one of the base structure and the movable stabilizing structure may include a radiopaque material. Also, the end post base may include a generally triangular shape in cross section and a coupling device for coupling multiple instrument organizers may be provided. Further, a method of applying a radiopaque substance to an instrument organizer is also presented.

Description:
CROSS REFERENCE TO RELATED APPLICATION  
       [0001]    This application is a continuation-in-part application of U.S. patent application Ser. No. 09/515,284, entitled “Instrument Organizer With Movable Stabilizing Post”, filed Feb. 29, 2000 and assigned to the present assignee hereof. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    1. Field of the Invention  
           [0003]    The present invention relates generally to organizers for organizing instruments and, more particularly, the present invention relates to organizers including a stabilizing post for separating and securing surgical instruments, e.g., before and during surgery, and in preparation for sterilization.  
           [0004]    2. Related Art  
           [0005]    Surgical instruments, such as hemostats, scissors, forceps, etc., are normally separated and organized during surgical procedures and also before sterilization by being laid on their side in a vertical or upright position on rolled-up cotton towels. The rolled-up cotton towels, which may have their outside edges taped, support the instruments such that the instruments can be more easily counted, selected and handled by a doctor or nurse during a surgical procedure, or while the instruments are assembled prior to sterilization.  
           [0006]    Foam organizers have also been provided to support and group surgical instruments before and during actual use of the instruments. Such organizers can have an elongated base with fixed posts extending upwardly from ends of the base. The foam organizers support the instruments, with the instruments resting on the base and leaning against the posts, such that the instruments can be more easily counted, selected and handled by a doctor or nurse during a surgical procedure, or while the instruments are assembled prior to sterilization.  
           [0007]    Such rolled cotton towels or foam organizers, with the surgical instruments supported thereon, are usually laid out on a tray or a table. Sometimes, however, before and during use of the surgical instruments, the instruments supported on the rolled towel or the organizer can topple over from their upright positions and become mixed and disorganized and, accordingly, more difficult to count, select and handle prior to actual use of the instruments, or while the instruments are assembled prior to sterilization. In addition, it is not uncommon for the cotton towels to produce lint, which can transmit microorganisms and result in contamination of the surgical instruments.  
           [0008]    Accordingly, it is an object of the present invention to provide means for retaining surgical instruments in an organized and/or upright position.  
           [0009]    It is another object to provide an instrument organizer, wherein, instruments supported thereon are less likely to topple over from an upright position prior to actual use or sterilization of the instruments and are, therefore, easier to count, select and handle.  
           [0010]    It is a further object to provide an instrument organizer that is securable on a surface, such as on a tray or a table top, so that the organizer will not move while supporting instruments.  
           [0011]    It is another object to provide an instrument organizer that is lint-free.  
           [0012]    It is still another object to provide an instrument organizer that is detectable through radiographic techniques or the like.  
           [0013]    It is a further object to provide an instrument organizer that reduces the required set up time such as the time associated with rolling up numerous towels.  
           [0014]    It is still a further object to provide a couple for coupling multiple instrument organizers together in order to increase the space available for instruments and to insure that a particular order of the instruments and/or instrument organizers is retained.  
         SUMMARY OF THE INVENTION  
         [0015]    An instrument organizer that overcomes the above-discussed disadvantages of the prior art, and which at least partially supports surgical instruments, comprises an elongated base that has a uniform, predetermined width. The base defines a continuous surface extending from a first side surface to an opposing second side surface thereof and includes two terminal ends. The instrument organizer may comprise at least one fixed end post that extends from a terminal end of the base and at least one movable stabilizing structure that includes two gripping legs extending from a central body. The gripping legs have opposing, inwardly facing surfaces spaced apart a distance substantially equal to the predetermined width of the base of the instrument organizer. The opposing, inwardly facing surfaces of the two gripping legs being dimensioned and configured to grip the first and second side surfaces of the base of the instrument organizer, respectively, so that the movable stabilizing structure can be attached to the base of the instrument organizer at any point between the terminal ends of the organizer and the central body is held in place by the gripping legs for retaining the surgical instruments in an organized and upright state at least partially on the organizer. In one particular embodiment of the present invention the at least one fixed end post comprises a generally triangular configuration in cross section. In another particular embodiment of the present invention, the continuous surface of the base comprises a contact portion having a non-linear shape in cross section.  
           [0016]    In another embodiment of the present invention a couple for coupling a pair of instrument organizers is presented. The instrument organizers each may comprise an elongated base structure that includes a top surface and a front surface and a rear surface extending from the top surface and the front surface and the rear surface being disposed on opposing sides of the base structure. The elongated base structure may comprise a predetermined width as measured from the front surface to the rear surface and the elongated base structure may include opposed terminal ends. At least one first end post may be fixedly positioned at one terminal end of the base structure and at least one movable stabilizing structure may be provided that is mountable at any axially spaced location along a length of the base structure relative to the first end post. The movable stabilizing structure includes a body portion and opposed, spaced apart legs depending therefrom, the legs may be spaced apart a distance approximately equal to the predetermined width of the base structure to facilitate frictional engagement with the base structure to thereby stabilize and at least partially support one or more surgical instruments. The couple may comprise a coupling device for connecting at least one instrument organizer with another instrument organizer.  
           [0017]    In a particular embodiment of the present invention, the coupling device comprises a wall portion that defines an aperture that is dimensioned and configured to receive adjoining end posts of each instrument organizer when the instrument organizers are disposed in juxtaposition.  
           [0018]    In another embodiment of the present invention, an instrument organizer, for at least partially supporting one or more surgical instruments, includes a base structure having opposed terminal ends and at least one first end post fixedly positioned at one terminal end of the base structure. The instrument organizer also includes at least one movable stabilizing structure that is mountable on the base structure at a location spaced from the first end post, to thereby stabilize and at least partially support one or more instruments. At least one of the base structure and the movable stabilizing structure includes a radiopaque material.  
           [0019]    In a particular embodiment of the present invention, the radiopaque material comprises at least one radiopaque string that, in turn, comprises at least one of a flexible polymer and a copolymer along with a radiopaque substance embedded therein. More particularly, the at least one of a flexible polymer and a copolymer may comprise polyvinyl chloride and the radiopaque substance may comprise a USP barium sulfate additive.  
           [0020]    In a further particular embodiment, the radiopaque material may comprise at least one strand of material composed of a metallic substance. More specifically, the at least one strand may comprise multiple strands embedded within the base structure and/or in the movable stabilizing structure and the metallic substance may consist of at least one metal from the group consisting of platinum, gold and tungsten.  
           [0021]    In a further embodiment, a method of applying a radiopaque material to an instrument organizer that comprises a base structure and a movable stabilizing structure is presented. The method comprises the steps of: providing a thermoplastic polymer; dispersing a sufficient quantity of radiopaque substance into the thermoplastic polymer to render the thermoplastic polymer identifiable on an X-ray image; and compressing the thermoplastic polymer into a polyurethane foam forming the base structure and/or the movable stabilizing structure. 
       
    
    
       [0022]    Other features and advantages of the present invention will become apparent upon reading the following detailed description in conjunction with the accompanying drawings.  
       BRIEF DESCRIPTION OF THE DRAWINGS  
       [0023]    [0023]FIG. 1 is a perspective view of a prior art instrument organizer for supporting surgical instruments within a surgical tray;  
         [0024]    [0024]FIG. 2 is an exploded view, in perspective, of an instrument organizer, including a movable stabilizing post and a self-adhesive strip according to a first embodiment of the present invention;  
         [0025]    [0025]FIG. 3 is a perspective view of the instrument organizer of FIG. 2 including surgical instruments disposed thereon;  
         [0026]    [0026]FIG. 4 is an exploded view, in perspective, illustrating a coupling device for coupling multiple instrument organizers in accordance with another embodiment of the present invention;  
         [0027]    [0027]FIG. 5 is a perspective view of an instrument organizer having triangularly configured end posts in accordance with another embodiment of the present invention;  
         [0028]    [0028]FIG. 6 is a perspective view of a portion of a base of an instrument organizer that has chamfered edges and of a movable stabilizing post in accordance with still another embodiment of the present invention;  
         [0029]    [0029]FIG. 6A is a sectional view of the base taken along lines  6 A of FIG. 6;  
         [0030]    [0030]FIG. 6B is a view similar to that of FIG. 6A of a base of an instrument organizer that has a rounded surface in accordance with yet another embodiment of the present invention;  
         [0031]    [0031]FIG. 7 is a perspective view of an instrument organizer optionally having radiopaque string mounted to a base in accordance with another embodiment of the present invention;  
         [0032]    [0032]FIG. 7A is a sectional view of the base taken along lines  7 A of FIG. 7 optionally having strands of radiopaque material embedded therewithin;  
         [0033]    [0033]FIG. 8 is a perspective view of a radiopaque material mounted on an adhesive strip in accordance with another embodiment of the present invention;  
         [0034]    [0034]FIG. 9 is a perspective view of a base structure having a coil spring embedded therein in accordance with a further embodiment of the present invention; and  
         [0035]    [0035]FIG. 10 is a schematic view of a blank disposed on a conveyer, a radiopaque material and roller for compressing the radiopaque material into the blank. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0036]    Referring to FIG. 1, an existing surgical instrument organizer is shown generally at  10 . The organizer is used for supporting and helping to organize surgical instruments, e.g., before and during actual use of the instruments and/or in preparation for sterilization of such instruments. The organizer  10  includes an elongated base  12  having front and rear surfaces  11 ,  13  spaced a uniform predetermined width “w” and fixed end posts  14 ,  16  extending upwardly from ends of the base.  
         [0037]    Although not shown, surgical instruments, such as hemostats, scissors, forceps, etc., can be supported by the organizer  10  such that the instruments can be organized into separate groups and more easily selected and handled by a doctor or nurse during a surgical procedure and when assembling instruments prior to sterilization. The instrument organizer  10  replaces the rolled-up cotton towel described above.  
         [0038]    Referring to FIGS. 2 and 3, a movable stabilizing structure or post  100  according to one embodiment of the present invention is shown being used with an instrument organizer  110  similar to the instrument organizer  10  of FIG. 1. The movable stabilizing post  100  provides the benefit of maintaining instruments supported by the organizer in an organized and upright manner to ensure that the instruments can be more easily organized, counted, selected and handled by a doctor or nurse during a surgical procedure, or when assembling instruments prior to sterilization, and assures the operating team that the surgical instruments will be lint-free.  
         [0039]    The movable stabilizing post  100  includes two gripping legs  102 ,  104  extending downwardly from a central body that defines a post  103 , and having spaced apart, opposing, inwardly facing surfaces  106 ,  108 . The opposing, inwardly facing surfaces  106 ,  108  of the gripping legs  102 ,  104  of the movable stabilizing post  100  are spaced apart a distance “d” substantially equal to the predetermined width “w” of the base  112  of the organizer  110 .  
         [0040]    The movable stabilizing post  100 , therefore, is fit on the base  112  of the organizer  110  so that the opposing, inwardly facing surfaces  106 ,  108  of the gripping legs  102 ,  104  of the movable stabilizing post  100  grip the front and rear surfaces  111 ,  113  of the base, whereby the movable stabilizing post can be attached to the base of the organizer at any point between the fixed end posts  114 ,  116  and be retained in place at that point by the gripping legs. Preferably, a length “I” of the gripping legs  102 ,  104  is not greater than a height “h” of the base  112  of the organizer  110  so that a bottom surface  105  of the post  103  of the moveable stabilizing post  100  contacts a top surface  115  of the base  112  to provide additional stability.  
         [0041]    As shown in FIG. 3, the movable stabilizing post  100  can be positioned on the base  112  of the organizer  110  to retain surgical instruments  200 ,  201 ,  202  in an upright position against one of the fixed end posts  116  of the organizer. The movable stabilizing post  100  prevents instruments supported on the organizer  110  from toppling over from their upright positions and becoming mixed and disorganized. The improved organization and accessibility provided by the organizer/stabilizing post find particular utility before and during a surgical procedure, and/or in preparation for sterilization.  
         [0042]    Preferably, the organizer  110  and the movable stabilizing post  100  are both made of a non-woven, non-absorbent, lint-free material. The organizer  110  and the movable stabilizing post  100  are preferably made of a lint-free foam plastic. In addition, it is envisioned that the organizer  110  and the movable stabilizing post  100  can be provided in a sterile state. Preferably the organizer  110  and the movable stabilizing post  100  are composed of a non-reticulated polyurethane foam having the physical properties provided in TABLE 1. 
                               TABLE 1                                   Physical Property (Tested                   According to ASTM           D3574/86)   Minimum   Average                           Density   2.0 ± 10%   2.0 ± 10%               lbs./cu. ft.   lbs./cu. ft.           Tensile Strength   22 psi.   27 psi.           Ultimate Elongation   58%   85%           Tear Resistance   1.1 ppi.   1.6 ppi.           Compression set, C t , %   Max. 10%   Max. 10%           50% Deflection           Compression Force   2.4 psi.   2.9 psi.           Deflection, 70% Deflection           Indentation Force   92 lbs.   112 lbs.           Deflection, lbs. 25%           Deflection, 4 inches thick           Cell Count (visual) pores   50 ± 5/in.   50 ± 5/in.           per inch           Retention of Tensile   Min. 70%   Min. 70%           Strength after 5 hours           steam Autoclave @ 120° C.                      
 
         [0043]    Referring in particular to FIG. 2, the organizer  110  can also be provided with a double-sided adhesive strip  118  on a bottom surface of the base  112  of the organizer. The adhesive strip  118  allows the organizer  110  to be secured to a surface, such as a tray or table top, to hold the organizer in place and prevent surgical instruments from toppling over and becoming disorganized.  
         [0044]    As illustrated in FIG. 4, multiple bases may be coupled together in order to increase the space available for supporting and organizing work pieces such as surgical instruments  200 ,  201 ,  202  (FIG. 3). In particular, during a given open-heart procedure a very large number of surgical instruments may be employed and those instruments may be used in a particular order. Accordingly, in order to provide additional space for instruments, eliminate the need for rolling up numerous towels and to ensure that, once placed in a particular order on multiple instrument organizers, the order of the instrument organizers will not change, a coupling device such as a collar  120  may be used to facilitate the connecting of multiple instrument organizers  110 . More specifically, the collar  120  is disposed over and thereby connects end posts  114 ,  116  of adjacent bases  112 . The bases  112  are preferably connected, as shown, with each longitudinal axis disposed perpendicular to the other, although, it will be understood that non-perpendicular angles are contemplated by the present invention. Optionally, the coupling device may be formed integrally with the bases  112 , e.g., the end posts  114 ,  116  may each be configured to interlock with each other (not shown).  
         [0045]    The collar  120 , may be composed of the same material as the instrument organizer  110  discussed above and, may comprise a generally rectangular outer configuration. The collar  120  comprises a wall portion, in turn, comprising walls  121 A,  121 B,  121 C,  121 D and defining an aperture  122 . The height (h) of the coupling device is preferably approximately equal to the height (h′) of the posts  114 ,  116 , e.g., to increase the area of contact and, in turn, the friction therebetween. The configuration of the aperture  122  is preferably generally rectangular in cross section and is preferably appropriately sized to receive the two end posts  114  and  116  with a frictional fit. While each of the end posts  114 ,  116  is illustrated as generally cubical in configuration, it will be understood that, any suitable configuration of the end posts and corresponding configuration of the aperture  122  may be employed.  
         [0046]    A thickness (t) of each of the walls  121 A,  121 B,  121 C and  121 D may be approximately equal and each is preferably 0.5 inch for a coupling device that measures 3 inches in length (L) by 2 inches in width (W). However, it will be understood that thickness (t) may range from approximately 0.25 inch to approximately 0.75 inch.  
         [0047]    Referring to FIG. 5, a base, in accordance with another embodiment of the present invention, is illustrated generally at  312 . In particular, the base  312  comprises a pair of end posts  314 ,  316  that are generally triangular in cross section. The end posts  314  and  316  may be formed integrally with the base  312 , although, less preferably, may be formed separately then adhered to an opposing end of the base. The end posts  314 ,  316  comprise an engagement surface  324 ,  326 , e.g., for supporting the surgical instruments  200 ,  201 ,  202  (FIG. 3). It will be recognized that the triangular outer configuration of the end posts enhances the stability of the base  312 . It will also be recognized that a movable stabilizing post, such as that described above, may be used in conjunction with the present embodiment.  
         [0048]    Referring now to FIGS. 6 and 6A, a portion of a base in accordance with still another embodiment of the present invention is shown generally at  412 . The base  412  includes a contact portion  427  comprising a non-linear shape in cross section. In a particular embodiment, the contact portion comprises at least one chamfered surface  428 ,  428 ′ and a top surface  430 . Also, a movable stabilizing post  400  may be provided that comprises surfaces  431 ,  431 ′ and  433  that may be correspondingly configured to engage the chamfered portions  428 ,  428 ′ and the top surface  430 . The chamfered portions  428 ,  428 ′ assist in better stabilizing instruments  200 ,  201 ,  202  (see FIG. 3), when they are disposed on the base and increases friction with the movable stabilizing post  400  when it is mounted thereon. Optionally, in another embodiment, a base  512  includes a rounded contact portion  527  as shown in FIG. 6B. It will be understood that a movable stabilizing post  400  (FIG. 6), similar to that described above, may be correspondingly configured with a rounded portion to engage the base  512 .  
         [0049]    A further embodiment of an instrument organizer in accordance with the present invention is illustrated generally at  610  in FIG. 7. In this embodiment, the instrument organizer  610  comprises, or is composed of, a material that may be imaged by, for example, an X-ray machine. In particular, a radiopaque material such as a polymer or copolymer including a radiopaque substance embedded therein or, optionally, a metallic substance comprising platinum, gold or tungsten may be employed.  
         [0050]    Another embodiment of the present invention is shown generally at  610  in FIG. 7. The instrument organizer  610  may be similar to that described above in connection with FIGS. 2 and 3, although, in the present embodiment the instrument organizer comprises a radiopaque material. In one particular embodiment, the radiopaque material comprises a radiopaque string  632 ,  634 ,  636  that is composed of a flexible polymer or copolymer with a radiopaque substance embedded therein. The radiopaque string  632 ,  634  may be inserted into a bore  638  in a post  614 ,  616  and then affixed by, e.g., an adhesive such as a silicone adhesive sold under the trademark RTV by the General Electric Company, Pittsfield, Mass. Also, the radiopaque string  636  may be located on an adhesive strip  618 , which may be double sided, and which may be, in turn, adhered to the underside of the instrument organizer  610 . Of course, rather than mounting the radiopaque strings to the instrument organizer, one or more of the radiopaque strings may be embedded within the base  612  and/or within a movable stabilizing post  100  (FIG. 2). Further in accordance with the present embodiment, the radiopaque strings  632 ,  634  or  636  may be used singularly or in any combination thereof. Also, radiopaque string  632 ,  634  or  636  may also be mounted to a movable stabilizing post  100  (FIG. 2) via an adhesive strip or a silicone adhesive as discussed above.  
         [0051]    Suitable polymers for practice of this embodiment of the present invention include polyvinyl chloride and polyethylene. A suitable radiopaque substance is USP barium sulfate dispersed in the polymer in a sufficient quantity to render the polymer detectable by an operator on a x-ray image.  
         [0052]    The radiopaque string may have a length which is in the range of approximately three inches to approximately 24 inches and may have a diameter that is within the range of between approximately 0.093 inch and approximately 0.125 inch, more preferably approximately 0.11 inch.  
         [0053]    In a second optional embodiment, as illustrated in FIG. 7A, a plurality of strands  638  of radiopaque material may be embedded within the base  612  of the instrument organizer and/or embedded within a movable stabilizing post  100  (FIG. 2). The strands  638  may each be composed of a metallic substance such as platinum, gold or tungsten. A suitable diametrical size of the strands for imaging is within the range of approximately 0.0007 inch to approximately 0.0015 inch. Although not shown, it will be understood that, optionally, the strands  638  may be located, e.g., on the adhesive strip  618  rather than embedded within the base  612  and/or movable stabilizing post  100  (FIG. 2).  
         [0054]    In another optional embodiment illustrated in FIG. 8, a thin strip or layer  740  may be employed, for example, adjacent an adhesive strip  718 . The layer  740  may be composed of an acetal homopolymer or nylon that is radiopaque. The adhesive strip  718  and layer  740  may be applied to a base structure (FIG. 7) and may be applied to a movable stabilizing post  100  (FIG. 2).  
         [0055]    A further optional embodiment is illustrated in FIG. 9. In particular, a metallic coil spring  842  may be embedded within a base  812  and may be embedded within a movable stabilizing post  100  (FIG. 2).  
         [0056]    In a further optional embodiment and rather than utilizing radiopaque strings or strands as discussed above, radiopaque materials may be applied to, e.g., a base and a movable stabilizing post. Optionally, the radiopaque material may be affixed during the texturing or embossing steps of forming a base and a movable stabilizing post. This may be accomplished by using, as a carrying means, a piece or section of a suitable thermoplastic polymer which becomes slightly tacky or moldable at the temperatures of these steps and is compressed into the polyurethane foam of the base and/or movable stabilizing structure due to the pressure imparted by the rollers. Suitable materials comprise vinyl plastics and polyvinyl chloride containing X-ray grade barium sulfate dispersed therein.  
         [0057]    As shown schematically in FIG. 10, a blank  944  of polyurethane foam, having the properties described above in Table 1, may be conveyed by a conveyer  946  to a pair of rollers  948 . The rollers  948  function to compress the radiopaque into the polyurethane foam blank  944  thereby causing the blank to be detectable on an X-ray image.  
         [0058]    While the present invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it is to be understood that the present invention is not limited to the disclosed embodiments. Rather, it is intended to cover all of the various modifications and equivalent arrangements included within the spirit and scope of the appended claims.