Corner protector for instrument sterilization tray

A corner protector for position about a corner of an equipment sterilization tray includes a base portion having a perimeter and a first concave recess. A first wall portion extends from a first portion of the perimeter of the base portion and comprises a second concave recess. A second wall portion extends from a second portion of the perimeter and comprises a third concave recess wherein the first and second wall portions are substantially perpendicular to each other. A connecting portion extends from a third portion of the perimeter wherein the connecting portion connects the first and second wall portions to form a continuous wall.

BACKGROUND

The present disclosure relates to a corner protector for an instrument sterilization tray. More particularly, the present disclosure relates to a corner protector for an instrument sterilization tray that increases radii of edges defining a corner of the instrument sterilization tray.

Equipment sterilization trays are typically utilized to retain surgical instruments through the sterilization process. However, the trays themselves do not maintain a sterile barrier once they exit the autoclave. An uncompromised sterile barrier is of critical importance for hospitals and surgery centers in their fight against infection.

In order to maintain the sterility of the instruments after the sterilization process, a sterile barrier is typically utilized to ensure the sterility of the instruments. One way to maintain a sterile barrier is to utilize a separate sterile container to contain not only the instrument sterilization tray but also the instruments within the instrument sterilization tray.

An alternative to the separate sterile container is to utilize a sterile wrap. A sterile wrap is typically a fabric like material that completely covers or encases the instrument sterilization tray to provide a sterile barrier. The sterile wrap is utilized much in the same way that a paper is used to wrap a present, in that both completely encase an outer surface of the instrument sterilization tray or present.

Because the wrap maintains the sterility of the instruments within the equipment tray, it is important that the wrap is not torn subsequent to being sterilized. If the wrap is torn or punctured after the instruments have being sterilized, the torn wrap must be removed and the tray must be rewrapped and the sterilization process must be performed again.

The most common place where the wrap tears or is punctured is proximate the corner of the instrument sterilization trays. The instrument sterilization trays can have a somewhat sharp corner, and when pressure is improperly applied to the wrap, the corner can tend to tear through or puncture the wrap, and therefore break the sterile barrier.

SUMMARY

In one aspect the present disclosure relates to a combination foot and corner protector configured for use on a corner of an instrument sterilization tray. The foot and corner protector includes a flexible main body that encases a threaded metal insert having a threaded through bore. The threaded insert is positioned within a foot portion of the main body. A first wall portion extends upwardly from a first portion of a perimeter of the foot portion and a second wall portion extends upwardly from a second portion of the perimeter of the foot portion where the first and second side wall portions are substantially orthogonal to each other. An intermediate portion extends upwardly proximate a corner of the foot portion where the intermediate portion connects the first and second side wall portions to form a continuous side wall. A top surface of the foot portion, an inner surface of the first sidewall portion, an inner surface of the second wall portion and an inner surface of the middle corner portion are configured to conform to a portion of a foot and outer corner surfaces of a sterilization tray. The outer bottom surface of the foot portion, the outer side surface of the first side wall portion and the outer side surface of the second side wall portion are substantially flat and smooth. Outer surfaces of the intermediate portion and transitions between the outer bottom surface and the first and second side wall portions are rounded such that there are gradual and smooth transitions in the exterior surfaces between the portions of the main body. The foot and corner protector has no abrupt changes in the configuration of the exterior surface. Therefore, the corner is configured to protect a sterile wrap from tearing or being punctured when placed around an instrument sterilization tray. The foot and corner protector is removably secured to the instrument sterilization tray by inserting a bolt through an aperture in the bottom the sterilization tray and threadably engaging the threaded bore within the threaded insert.

In another aspect, the present disclosure relates to a corner protector configured for use on an instrument sterilization tray. The corner protector is a monolithic structure that includes a substantially continuous inner surface and a substantially continuous outer surface. The substantially continuous inner surface is defined by an inner surface of a base portion and inner surfaces of first and second wall portions extending from a perimeter of the base portion where the first and second wall portions are substantially orthogonal to each other. The corner protector includes first and second transition portions that connect the base portion to the first and second wall portions, respectively, and a third transition portion that connects the first and second wall portions and the base portion. The first, second and third transition portions are configured to engage the three edges of the instrument sterilization tray that defines the corner. The substantially continuous outer wall is defined by outer surfaces of the base portion, the first wall portion, the second wall portion and the first, second and third transition portions. The substantially continuous outer wall includes smooth, rounded transitions between the base and the first and second side portions and between the first and second side portions such there are no abrupt or sharp edges that could potentially tear or puncture a sterile wrap.

In another aspect, the present disclosure relates to a corner protector configured for use on an instrument sterilization tray. The corner protector is a monolithic structure that includes a substantially continuous inner surface and a substantially continuous outer surface where the substantially continuous inner and outer surfaces are defined by a base portion and first and second wall portions extending from the base portion where the first wall portion, the second wall portion and the base portion are connected together with transition portions that are configured to engage the three edges of the instrument sterilization tray that define a corner and outer radii to smoothly transition between the first wall portion, the second wall portion and the base portion to prevent the tearing or puncturing of a sterile wrap when placed about the instrument sterilization tray. The base portion, the first side wall portion and the second side wall portion includes concave areas on the inner surfaces and corresponding convex areas on the outer surface such that the concave portions are configured to be a distance from the walls of the instrument tray when positioned about the corner of the instrument sterilization tray. The convex areas of the base portion, the first side wall portion and the second side wall portion are configured to be movable toward the surfaces of the tray when a force is placed thereon to dissipate the force and further protect a sterile wrap when placed around the instrument sterilization tray.

In another aspect, the present disclosure relates to a corner protector configured for use on an instrument sterilization tray. The corner protector is a monolithic structure that includes a substantially continuous inner surface and a substantially continuous outer surface where the substantially continuous inner and outer surfaces are defined by a base portion and first and second wall portions extending from the base portion where the first wall portion, the second wall portion and the base portion are connected together with transition portions that are configured to engage the three edges of the instrument sterilization tray that define a corner and outer radii to smoothly transition between the first wall portion, the second wall portion and the base portion to prevent the tearing or puncturing of a sterile wrap when placed about the instrument sterilization tray. The corner protector includes a plurality of apertures therein wherein the plurality of apertures are substantially parallel and interrupt the interior and exterior surfaces of the first wall portion, the second wall portion and the base portion.

In another aspect, the present disclosure relates to a corner protector configured for use on an instrument sterilization tray. The corner protector is a monolithic structure that includes a substantially continuous inner surface and a substantially continuous outer surface where the substantially continuous inner and outer surfaces are defined by a base portion and first and second wall portions extending from the base portion where the first wall portion, the second wall portion and the base portion are connected together with transition portions that are configured to engage the three edges of the instrument sterilization tray that define a corner and outer radii to smoothly transition between the first wall portion, the second wall portion and the base portion to prevent the tearing or puncturing of a sterile wrap when placed about the instrument sterilization tray. A length and a mass of the base portion are sufficiently greater than a mass of the first and second wall portions such that a center of gravity of the corner protector is located in the base portion and at a selected distance from both the first and second wall portions such that corner protector is retained on an upper corner of the instrument sterilization tray when positioned thereon.

In all cases, this disclosure presents the disclosed subject matter by way of representation and not limitation. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art which fall within the scope and spirit of the principles of this disclosure.

The figures may not be drawn to scale. In particular, some features may be enlarged relative to other features for clarity. Moreover, where terms such as above, below, over, under, top, bottom, side, right, left, etc., are used, it is to be understood that they are used only for ease of understanding the description. It is contemplated that structures may be oriented otherwise.

DETAILED DESCRIPTION

An equipment sterilization tray having foot and corner protectors is generally illustrated inFIG. 1at10. The equipment sterilization tray10typically includes a box portion11defined by a bottom surface12, a left side wall18extending upwardly from a left side edge of the bottom surface12, a right side wall20extending from an opposing edge, a front wall22and a back wall (not shown) extending from opposing front and back edges of the bottom surface12. The equipment sterilization tray10includes a cover13having four walls14extending from a perimeter15of a top surface16where the four walls14extend over top portions of the four side walls18,20,22and (not shown) to retain the cover13to the box portion11.

The box portion11defined by the four side walls18,20,22and (not shown) along with the bottom surface12defines a volume therein into which surgical instruments can be placed for sterilization. While not illustrated, it is contemplated to attach surgical instrument retaining devices to the bottom surface12that are configured to secure the position of instruments within the tray10prior to sterilization of the tray10and the enclosed instruments.

The box portion11and the cover13are typically made up of a metal, such as stainless steel. Because the box portion11is made of metal, the corners which are defined by the bottom surface12and two adjacent side walls,18,20,22and (not shown) tend to have sharp edges which can lead to a sterile wrap to tear through or puncture a sterile barrier which requires a re-sterilization process which is time consuming and costly. Utilizing a foot and corner protector30of the present disclosure on the all of corners prevents and/or tends to eliminate the issue of the corner of the sterilization tray10tearing through the sterile wrap.

The cover13also has four additional sharp corners. It is contemplated to utilize a corner protector31having a similar construction to the corner protectors30to cover the corners of the cover13, where the corner protector31has shorter side walls than the corner protector30. The corner protectors31can be attached to the four corners of the cover13with a threaded engagement with an insert similar to that disclosed with respect to the corner protector30. It is also contemplated that other securing mechanisms besides a threaded engagement be used to secure the corner protectors31to the corners of the cover13, such as but not limited gravity.

Referring toFIGS. 2,5and7, the foot and corner protector30includes a threaded insert32having a threaded bore34that is molded within a foot portion36of the foot and corner protector30. The threaded bore34is aligned with a through bore (not shown) in the bottom surface12where a bolt (not shown) is inserted and threadably secured thereto to retain the foot and corner protector30to the sterilization tray10.

Referring toFIGS. 5 and 6, it is also contemplated to include a through bore37in the foot portion36wherein the through bore33is configured to accept a securing mechanism, such as but not limited to a bolt or screw. While illustrated as being located in the foot portion36, one or more through bores33can also be located in the foot portion36, the first side wall portion42or the second side wall portion48.

The foot portion36is generally horizontal and includes cut out portion38defined by a shoulder37and a bottom surface39. The cut out portion38is configured to accept a portion of a foot that is attached to the tray10. The foot portion36is substantially horizontal and by accepting the foot of the tray within the cut out portion38, the foot portion36is configured to engage the sterilize wrap and prevents tearing of the sterile wrap. While the cut out portion38is illustrated to accept a foot of a particular tray, such as one marketed under the INSTRU-SAFE® trademark, the cut out portion38can be configured to accept any foot of any instrument sterilization tray.

It is also contemplated that the cut out portion38may be optionally not required if the sterilization tray does not have a foot. In this embodiment, the foot portion36would have a flat bottom surface without a cutout portion38.

Extending upwardly from a first edge portion38of the foot portion36is a first side wall portion42where the first side wall portion42includes an arcuate upper edge44. The first side wall portion42includes a substantially flat inner surface46that is configured to be positioned adjacent to one of the side walls18,20,22and (not shown) of the box portion11.

A second side wall portion48extends upwardly from a second edge portion40of the foot portion36where the second side wall portion48also includes an arced outer edge50and a substantially flat inner surface47that is also configured to be positioned proximate or adjacent the outer surface of one of the side wall18,20,22and (not shown) of the box portion11.

An intermediate corner portion54extends from an intermediate edge portion60located between the first and second edge portions38and40. The intermediate corner portion60connects the first and second side wall portions40and48together to form a continuous inner surface that conforms to a particular sterilization tray10. As illustrated, the sterilization tray10has a gap between the walls18,20,22,24and therefore to insure a snug fit, the intermediate portion60of the foot and corner protector30includes a convex inner surface55configured to be positioned within a gap between two adjacent walls18,20,22,24.

The interior surfaces of the foot and corner protector30is designed to conform to a particular geometry of a sterilization tray10by providing complementary inner surfaces are configured to be positioned proximate the three outer surface of the tray10that define the corner. It is contemplated that the inner surfaces that define the engaging surfaces of the foot and corner protector30can modified to conform to the geometry of any configuration of a corner of a sterilization tray.

The first edge portion38, the second edge portion40and the intermediate edge portion60include a concave curve or radius which are configured to accept edges of the joined walls that define the corner of the box portion11and the cover13.

Referring toFIGS. 3,4,6and8, the outer surface70of the foot and corner protector30is substantially smooth around the entire outer surface70where there are no abrupt edges or transitions. Outer surfaces72,74and76of the left and right wall portions40,48, the intermediate corner portion54have no sharp transitions or edges and gradually transition from one vertical portion72of the left side wall portion42to the vertical portion76of the intermediate corner portion54to the vertical portion74of the right wall portion48.

The outer surface70includes a convex arced transition or radius77on the outer surface70from the vertical portions72,74and76of the outer surface70of the foot and corner protector30to an outer surface78of the foot portion36of the foot and corner protector30. As there are no sharp edges on any portion of the outer surface70of the foot and corner protector30and the foot and corner protector30increases the radius of the corner of the sterilization instrument tray10, the foot and corner protector30prevents the sterilization wrap from being torn or punctured at the corners of the tray10.

As illustrated, the foot and corner protector30is made of a silicone material that is molded around the insert32. However, other materials of construction are also contemplated. Further, other removably attachable securing mechanisms besides a threaded engagement are also contemplated.

Because the foot and corner protectors30and the corner protector31are removably secured to the corners of the box portion11and the cover13, there is no danger of the corner protectors30and the corner protectors13slipping or otherwise dislodging out of place from the corner of the box portion11or the cover13, which can occur with other corner protectors that are not secured to the tray or the cover. Further, because the foot and corner protectors30and the corner protectors31are removably secured, once a foot and corner protector30or a corner protector31requires replacement, an operator can simply reverse the threaded engagement to remove the bolt from the threaded insert32and therefore allow the corner protector30and/or the corner protector31to be easily replaced. As such the present disclosure provides a convenient way of preventing the corners of a sterilization tray10from tearing through the sterile wrap while also retaining the corner protectors30and31in a selected position on the box portion11and the cover31.

Referring toFIG. 9, another corner protector is illustrated at100. The corner protector100is of a monlithic construction and is typically formed through a molding process. A typical material of construction is silicone.

Referring toFIGS. 9,12and14, the corner protector includes a base portion102having a perimeter104and left and right side wall portions106and108extending from the perimeter104wherein the left and right side wall portions106and108are substantially orthogonal to each other.

The left and right side wall portions106and108are connected to the base portion102with left and right transition portions110and112, respectively. The left and right side wall portions106and108are connected with a substantially vertical transition portion114. Outer surfaces111,113,115of the transition portions110,112and114, respectively have concave notches that are configured to accept the three edges of a corner of the equipment sterilization tray and to provide support for retaining the corner protector100to the equipment sterilization tray. A corner engaging surface117is located in the vertical transition portion114at a junction of horizontal lines drawn through the notches113and115and a vertical line drawn through the notch117. The junction of the lines is proximate a contact area of a corner of the box portion11or the cover13with the corner engaging surface117.

An inner surface120of the base portion102includes a substantially flat distal surface122proximate an outer edge124. The inner surface120includes a concave recess126defined by a shoulder128extending from an inner edge of the distal surface122. The left side wall portion106and the right side wall portions108include edge surface130and132proximate a perimeter of each wall, respectively. The edge surfaces130and132have a width and are configured to engage vertical wall of the box portion11or the cover13of the equipment sterilization tray. Extending from the edge surfaces130and132are concave recess134and136defined by shoulders138and140, respectively.

The interior surfaces of the corner protector100are configured such that when the corner protector is positioned about a corner defined by edges in the x, y and z axes, the corner protector100contacts the box portion11or the cover13at the notches111,113and15engage the edges defining the corner and the corner engaging area117contacts the corner. The edge surfaces130and132contact the vertical walls of the corner and the flat distal portion122contacts the horizontal surface of the box portion11or the cover13. The contact areas provide sufficient contact to retain the corner protector100on a corner without significant movement about the corner area.

Edges107and109of the left and right side wall portions106and108, respectively, are arcuate and have lobe shape to provide a sufficient surface to engage the vertical walls of the that define the two surfaces of the corner. The base portion102also has an arcuate outer edge103.

A length of the base portion102to the left or right wall106and108is longer than a height of either the left or right wall portions106and108. A mass of material that defines the distal surface is positioned away from the corner engaging surface115such that a center of gravity of the corner protector100is located a sufficient distance from both the left and right wall portions106and108. With the center of gravity located the sufficient distance from the left and right wall portions106and108, when the corner protector100is positioned on a cover13, the corner protector100is retained on the corner of the cover13and does not fall from the cover13.

The concave recesses126,134and136of the base portion102, the left side wall portion106and the right side walls108, respectively, are configured to extend beyond the surfaces of the three walls defining the corner when the corner protector100is positioned about the corner. The concave recesses126,134and136create spaces between the base portion102, the left side wall portion106and the right side walls108, respectively, and a respective wall when the corner protector100is positioned about the corner.

Referring toFIGS. 10,11,13, and15, an outer surface140of the corner protector100is defined by convex outer surfaces of142,144and146of the base portion102, the left side wall portion106and the right side wall portion108, where the convex surfaces142,144and146extend proximate the edges103,107and109of the base portion102, the left side wall portion106and the right side wall portion108, all respectively. Convex transition portions146and148between the bottom portion102and the left and right side wall portions106and108, respectfully, define substantially continuous outer surface with no sharp edges or abrupt edges that may cause a puncture or tear in a sterile wrap. A convex transition portion150defines a continuous surface between the left and right side wall portions106and108, respectively, such that there are no abrupt or sharp edges between the transition from the left side wall portion106to the right side wall portion108in the outer surface140.

The convex transitions portions for the corner protector depicted inFIGS. 9-15have a radius ranging from about 1/16″ to about ¼″ where the length, height and width of the corner protector is about 1½″. More particularly, the radius of the transition portions is about ⅛″. The corner protector illustrated inFIGS. 2-8has similar dimensions and radii.

When the corner protector100is positioned on a corner of a box portion11or the cover13, the convex surfaces142,144and146opposite the concave recesses126,134and136extend beyond the perimeter of the corner protector100. In the event that contact is made with or a force is placed upon the corner protector100it is likely that the first surface to be engaged is one of the convex surfaces142,144and146opposite the concave recesses26,134and136. As contact is made or a force is placed on one or more of the convex surfaces142,144and146opposite the concave recesses126,134and136, the convex portions142,144or146are flatted along with the concave recess126,134and/or136. The flatting of the surfaces absorbs the contact or force and dissipates the force such that a sterile wrap is less likely to be torn or punctured. The space between the concave recess126,134and/or136and the respective wall acts similar to a cushion because the space allows for the movement of the portions base portion102, the left side wall portion106and/or the right side wall portion108which absorbs and dissipates the forces caused by contact or other forces.

The corner protector100includes a plurality of drain holes160in the base portion102, the left side wall portion106and the right side wall portion108and the transition portions that connect the base portion102to the left and right side wall portions106and108, respectively, and the left and right side wall portions106and108. The plurality of drain holes160is substantially parallel to each other. The configuration of the drain holes140allows the plurality of drain holes160to be formed during the molding process and allows the mold to be separated and remove after the material forming the corner protector100has cured by displacing a portion of the mold from the cured corner protector100. When the mold components are separated, the corner protector100with the plurality of drain holes160is formed without difficulty in removing the molds, which can be an issue when the drain holes are formed substantially perpendicularly through the thickness of the base portion102in surfaces that have surfaces in three dimensions. The configuration and location of the plurality of drain holes160allows for the drainage of moisture from between the box portion11and/or the cover13and the corner protector100that is deposited through the sterilization process.

Referring toFIG. 16another corner protector is illustrated at200. The corner protector200is of a monolithic construction that is formed through a molding process where a typical material of construction is silicone.

The corner protector200has a base portion202with a perimeter204. Extending upwardly from the base portion202at the perimeter204are left and right wall portions206and208. A vertical transition portion210connects the left and right wall portions206and208to form a continuous outer surface212and a continuous inner surface214.

An edge216of the left side wall206is arcuate and raises in elevation from the corner of the left side wall206and the base portion202to the vertical transition portion210. The edge218of the right side wall208is the mirror image of the edge216. The edges210and212form a smooth transition with no abrupt or sudden changes which could cause a puncture or tear in a sterile wrap.

An inner surface220of the vertical transition portion210is concave and is configured to accept an edge proximate a corner of an equipment sterilization tray. Transitions portions222and224along the perimeter204at the junction of the base portion202and the left and right wall portions206and208are configured to accept edges of edges proximate the corner such that the base portion is positionable on a substantially horizontal surface and the left and right wall portions206and208are configured to engage vertical side walls on the equipment sterilization tray.

The inner surfaces of the left and right side wall portions206and208include a plurality of parallel vertical ribs230. The plurality of ribs230are configured to engage vertical walls of the equipment sterilization tray10and minimize the contact between the side wall portions206and208and a wall of the equipment sterilization tray10to decrease the time required for the moisture to be removed therebetween.

The base portion202includes a grid242with ribs defining drain holes244. The drain holes244are configured to allow moisture to pass therethrough. Perpendicular ribs246and248are raised in the grid242to form a raised “V” shaped surface250configured to engage the horizontal surface of the equipment sterilization tray10. As illustrated the corner protector200includes three concentric raised “V” shaped surfaces250. However, the number of raised surfaces250can be more or less than three depending upon the desired application. The raised surfaces250minimize contact between the base portion202and the horizontal surface and thereby decrease the drying time required during the sterilization process.

Referring toFIG. 17, another corner protector is illustrated at300. The corner protector300is of a monolithic construction that is formed through a molding process where a typical material of construction is silicone.

The corner protector300has a similarly configured outer surface as the corner200where the outer surface has smooth transitions and no sharp or abrupt edges.

The corner protector300has a base portion302with a perimeter304. Extending upwardly from the base portion302at the perimeter304are left and right wall portions306and308. A vertical transition portion310connects the left and right wall portions306and308to form a continuous outer surface312and a continuous inner surface314.

An edge316of the left side wall portion306is arcuate and raises in elevation from the corner of the left side wall306and the base portion302to the vertical transition portion310. The edge318of the right side wall portion308is the mirror image of the edge316. The edges310and312form a smooth transition with no abrupt or sudden changes which could cause a puncture or tear in a sterile wrap.

The left wall portion306and the right wall portion308include a plurality of channels320that extend form the base portion302to the edges316and318, respectfully. The plurality of channels320provide for drainage from between the left and right side wall portions306and308and the wall of the tray10that the side wall portion306and308contact.

The base portion302has a substantially flat top surface330. The flat surface is interrupted with a plurality of drain holes332that are configured in a grid pattern. The drain holes332include beveled side walls334that form a top portion336of each drain hole332. A top surface of a bevel334is adjacent a top surface334of a bevel of an adjacent drain hole332such that line or thin rib338is formed. The line or thin ribs336minimize the contact with the surface of the tray and reduces the time required to remove the moisture between the sterilization tray10and the corner protector300.