Abstract:
The system contains a molded plastic reticulated tray composed of a continuous rib that forms a tray rim and a plurality of intersecting ribs defining relatively large openings therebetween. The intersecting ribs are dished and having opposite ends connected to the continuous rib at spaced apart locations therealong. The plurality of intersecting ribs have rounded surfaces so that a fluid sterilant directed at the plurality of intersecting ribs from the outside, upon flowing through said openings, will follow and intimately contact said rounded surfaces to the tray interior so that those surfaces are cleaned thoroughly.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority to copending U.S. Application entitled, “Medical Instrument Container System,” having Ser. No. 11/369,428 filed Mar. 7, 2006, which is entirely incorporated herein by reference. 
     FIELD OF THE INVENTION 
     The present invention is generally related to a system for holding selected medical instruments and devices during sterilization and storage prior to use and to facilitate their cleaning and storage following such use. 
     BACKGROUND OF THE INVENTION 
     Different surgical procedures require the use of different sets of instruments or devices, the number of tools in the set depending upon the complexity of the procedure. Thus, prior to a particular procedure, a surgeon determines or knows from experience which instruments will be required. Those instruments are gathered together as a set, placed in a container, which is packaged in a plastic package and sterilized in an autoclave. The packed instruments are then stored in that sterile condition until ready for use. When the surgeon is ready to perform the procedure, the container is brought to the operating room and opened, exposing the still sterile instruments therein. Following use, the instruments are usually returned to the container and sent to a cleaning facility where the containers and instruments therein are placed in a washing machine which directs jets of water/detergent cleaning fluid at the containers and their contents to clean them prior to another sterilization. 
     To improve the circulation of cleaning fluid throughout the container, the container walls may be formed with a multiplicity of vent holes which may be used to anchor the various brackets which support and fixate the various instruments within the container. Examples of such containers are disclosed in U.S. Pat. Nos. 5,424,048; 5,681,539; 6,193,932 and 6,331,280. 
     Heretofore, the various containers and trays used for the above purposes have structures whose walls are more closed than open. In other words, the containers have planar walls with a multiplicity of vent holes therein leaving relatively wide webs of plastic extending between the vent holes, the total area of the webs invariably being much larger than the total area of the vent holes in order to maintain the structural integrity and rigidity of the container. As a result, when water/detergent or other cleaning fluid impinges upon the container during the cleaning process, the fluid may not come into intimate contact with all the inside surfaces of the webs with the result that those surfaces will not be cleaned to the extent that they should be. That is, as the cleaning fluid is directed into the container through the vent holes, turbulent flow occurs causing the fluid to flow past portions of the flat interior surfaces between the holes resulting in a shadow effect thereon and insufficient cleaning of the flat surface portions within those shadows. 
     In order to obtain a better circulation of cleaning fluid through the container during washing, it has been contemplated to use a more open structure for the container, i.e. one composed of intersecting ribs wherein the total area of the openings into the container between the ribs totals much more than that of the ribs bounding the openings. Thus it has been contemplated to form a tray or container of metal wire coated with a plastic material, i.e. similar to a dishwasher rack. Although such an open structure composed of intersecting ribs allows maximum circulation of fluid through the container with minimal shadow effect, it is not particularly suitable for medical applications. During normal usage over time, a plastic coating can be scratched or otherwise damaged by medical instruments, exposing the underlying metal wire, which will oxidize and provide sites for the buildup of bacteria. Also when such a wire structure is deformed, it will tend to remain so with the result that it may not inter-fit properly with other components of the container system. For example, if a wire tray is deformed, its cover may not fit properly on the tray. 
     Of course, the above problems can be avoided by molding the container or tray entirely of plastic as has been done for clothes baskets, soap dishes and the like. However, such molded plastic open structures are constituted of intersecting webs or ribs, which are thin and have a rectangular cross section. The containers of this type are not rigid enough to protect sensitive medical instruments. Also, since the inner and outer surfaces of those ribs are flat, they suffer the same shadow effect discussed above in connection with perforated plastic trays, albeit to a lesser extent. While the former problem can perhaps be alleviated by thickening the ribs, the latter problem cannot. 
     Thus it would be very advantageous if there existed a container for holding medical instruments during washing and cleaning processes which has the advantages of plastic coated metal wire baskets in terms of strength and rigidity and none of the aforesaid disadvantages thereof. 
     SUMMARY OF THE INVENTION 
     Embodiments of the present invention provide a system and method for retaining medical instruments for sterilization. Briefly described, in architecture, one embodiment of the system, among others, can be implemented as follows. The system contains a molded plastic reticulated tray composed of a continuous rib that forms a tray rim and a plurality of intersecting ribs defining relatively large openings therebetween. The intersecting ribs are dished and having opposite ends connected to the continuous rib at spaced apart locations therealong. The plurality of intersecting ribs have rounded surfaces so that a fluid sterilant directed at the plurality of intersecting ribs from the outside, upon flowing through said openings, will follow and intimately contact said rounded surfaces to the tray interior so that those surfaces are cleaned thoroughly. 
     Other systems, methods, features, and advantages of the present invention will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present invention, and be protected by the accompanying claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Many aspects of the invention can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present invention. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views. 
         FIG. 1  is perspective view of a medical instrument container system, in accordance with a first exemplary embodiment of the present invention. 
         FIG. 2  is a fragmentary perspective view of the medical instrument container system of  FIG. 1 , in accordance with the first exemplary embodiment of the present invention. 
         FIG. 3  is an end view of the medical instrument container system of  FIG. 1 , in accordance with the first exemplary embodiment of the present invention. 
         FIGS. 4A to 4E  are perspective views of various instrument holders that may be part of the medical instrument container system of  FIG. 1 , in accordance with the first exemplary embodiment of the present invention. 
         FIG. 5A  is perspective view of a medical instrument container system, in accordance with a second exemplary embodiment of the present invention. 
         FIG. 5B  is a perspective view of a cover of the medical instrument container system shown in  FIG. 5A , in accordance with the second exemplary embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  is perspective view of a medical instrument container system, in accordance with a first exemplary embodiment of the present invention. The medical instrument container system comprises a tray  10  which may contain one or more medical instruments or devices I. While the illustrated tray  10  is rectangular, it could just as well have some other shape (e.g., round or oval). Preferably, each medical instrument I is supported within the tray  10  by one or more holders  12  which fix the position of the medical instrument I within the tray  10 . 
     As shown in  FIGS. 1 and 2 , the tray  10  is a reticulated structure molded entirely of a rigid plastic that is able to withstand cleaning and sterilization processes (e.g., polyphenylsulphone, PTFE, etc.). Thus, the tray  10  is composed of a plurality of spaced-apart ribs  14   a ,  14   b ,  14   c . The ribs  14   a ,  14   b ,  14   c  include at least one rectangular rib  14   a  which forms a hoop at the rim of the tray  10 , a plurality of spaced-apart, parallel, longitudinal ribs  14   b  which form a bottom wall of the tray  10  and a multiplicity of spaced-apart, parallel, transverse ribs  14   c  which intersect the longitudinal ribs  14   b  at the bottom of the tray  10 . The opposite end segments of the longitudinal ribs  14   b  and the transverse ribs  14   c  are bent up and connect to the rectangular rib  14   a  at the inboard face of the rectangular rib  14   a  at spaced-apart locations therealong. These bent up segments form the sides and ends of the tray  10 . Preferably, the longitudinal ribs  14   b  and the transverse ribs  14   c  are spaced an appreciable distance from their neighboring parallel ribs  14   b ,  14   c  (e.g., 0.75 inch or more), so that the openings between the parallel ribs  14   b ,  14   c  are quite large compared to the parallel ribs  14   b ,  14   c  themselves. The total area of the tray openings O may be at least twice the total longitudinal sectional area of the longitudinal ribs  14   b  and the transverse ribs  14   c . Also, the ribs  14   a ,  14   b ,  14   c  may be rounded or, more precisely, may have circular cross-sections. 
     The rectangular rib  14   a  may be formed with a plurality of outward bends or loops  16  which are spaced along a length of the rectangular rib  14   a  at the sides of the tray  10 . Also, short locating pins  18  may extend up from rectangular rib  14   a  between the loops  16 . 
       FIG. 2  is a fragmentary perspective view of the medical instrument container system of  FIG. 1 , in accordance with the first exemplary embodiment of the present invention. Attached to the ribs  14   a ,  14   b ,  14   c  at the opposite ends of container  10  is a pair of fixtures  22 . Each of the fixtures  22  may be molded integrally with the rectangular rib  14   a  and perhaps also the longitudinal ribs  14   b  and the transverse ribs  14   c . However, the fixture  22  may also be designed as a separate part, which can snap onto one or more of those ribs  14   a ,  14   b ,  14   c . Each fixture  22  may include a pair of laterally spaced-apart ears  22   a  formed with holes  24  that provide journal bearings for loosely receiving laterally extending axles  26   a  of a latch member  26 . 
       FIG. 3  is an end view of the medical instrument container system of  FIG. 1 , in accordance with the first exemplary embodiment of the present invention. Each of the latch members  26  may have a slit  26   b  between, and extending perpendicular to, its axles  26   a  so that the sides of the latch member  26  may be pressed together to permit the insertion of the axles  26   a  into the holes  24  of the corresponding fixture  22  to facilitate the assembly of the latch members  26  to the fixtures  22 . When assembled, each latch member  26  may be manipulated between an open or unlatched position, shown in  FIGS. 1 and 2  wherein a latching surface  26   c  of the latch member  26  is spaced away from the rectangular rib  14   a  of the tray  10 , and a closed or latched position wherein the latching surface  26   c  is spaced above the rectangular rib  14   a  a distance slightly less than a diameter of the rectangular rib  14   a.    
     As shown in  FIGS. 2 and 3 , the container system may also includes a mating molded plastic reticulated cover or lid  30 . While the cover  30  and tray  10  may have different depths to minimize molding costs, the illustrated cover  30  is shaped comparably to tray  10 . The cover  30  includes a rectangular rib  42   a , similar to the rectangular rib  14   a  of the tray  10 , which overlies the rectangular rib  14   a  of the tray  10  when the cover  30  is positioned on the tray  10  as shown in  FIG. 3 . The cover  30  also includes a plurality of longitudinal ribs  42   b , similar to the longitudinal ribs  14   b  of the tray  10 , as well as a multiplicity of transverse ribs  42   c , comparable to the transverse ribs  14   c  of the tray, which intersect the longitudinal ribs  42   b  of the cover  30 , thereby forming a top wall of the cover  30 . The longitudinal ribs  42   b  and the transverse ribs  42   c  of the cover  30  are turned down at their ends so that they connect to the rectangular rib  42   a  of the cover  30  at spaced-apart locations along that rim at the inboard side thereof. 
     As is the case with the tray  10 , the rectangular rib  42   a  of the cover  30 , which forms a rim of the cover  30 , is formed with a series of outward bends or loops  44  at spaced-apart locations at the sides of cover  30 , as well as a series of locating pins  46  comparable to the pins  18  of tray  10 . The respective locating pins  18 ,  46  and loops  16 ,  44  on the tray  10  and the cover  30  are positioned so that when the cover  30  is inverted and positioned on the tray  10 , the locating pins  18  of the tray  10  project up into the loops  44  of the cover  30  and the locating pins  46  of the cover  30  extend down into the loops  16  of the tray  10  thereby maintaining the tray  10  and the cover  30  in register. 
     As seen in  FIGS. 2 and 3 , cover  30  also includes integrally molded fixtures  48  at the opposite ends of the cover  30 , which are comparable to the fixtures  22  of tray  10 . However, the fixtures  48  of the cover  30  do not form hinges. Rather, the fixtures  48  of the cover  30  function as keepers for the latch members  26  when the cover  30  is positioned on the tray  10  and secured thereto by latch members  26 . More particularly, each of the fixtures  48  of the cover  30  (as well as each of the fixtures  22  of the tray  10 ) is formed with a raised keeper surface  48   a . When the corresponding latch member  26  is moved to its latching position, shown in  FIG. 3 , the latching surface  26   c  of each latch member  26  resiliently engages and snaps over the keeper surface  48   a  of the corresponding fixture  48  thereby clamping the cover  30  to the tray  10 . When so clamped together, the cover  30  and the tray  10  make line contact along the rectangular ribs  14   a ,  42   a , minimizing the likelihood of bacterial build up where the cover  30  meets the tray  10 . 
     It may be observed from the figures, before assembly of the latch members  26  to the tray  10 , the cover  30  is identical to the tray  10  in the first exemplary embodiment. Therefore, the cover  30  and the tray  10 , according the first exemplary embodiment, can be made using the same mold. The locating loops  16 ,  44  and the locating pins  18 ,  46  may be positioned so that when the cover  30  is inverted and its rectangular rib  42   a  is brought into register with the rectangular rib  14   a  of the tray  10 , the pins  18  of the tray  10  will project up into the loops  44  of the cover  30  and the pins  46  of the cover  30  will project down through the loops  16  of the tray  10 . Furthermore, this applies for both end-to-end registrations of the cover  30  with the tray  10 . In other words, if the cover  30  is turned 180° relative to the tray  10 , the various locating loops  18 ,  46  and pins  16 ,  44  will still inter-fit to bring the cover  30  and tray  10  into register, according to the first exemplary embodiment of the present invention. 
     As seen in  FIG. 3 , to enable one to grasp a top of latch member  26  to pull is the latch member  26  away from the end of the cover  30  and to release the latch member  26  from the fixture  48  of the cover  30 , the fixture  48  of the cover  30  is formed with a finger notch  48   b . A comparable notch may be present in the fixture  22  of the tray  10  to allow the fixtures  22 ,  48  to remain substantially identical. Also, to provide clearance for each latch member  26  when that latch member  26  is moved to its latching position, the rectangular ribs  14   a ,  42   a  may be provided with flats  52 ,  54 , respectively, which face the corresponding latch member  26  as seen in  FIG. 2 . 
     It may be a feature of this invention that the molded plastic reticulated tray  10  and cover  30  construction described herein provides a container system which is strong and rigid and able to protect the instruments in the tray  10 . Yet, the container system is still very open in that the total longitudinal sectional area of the ribs  14   a ,  14   b ,  14   c ,  42   a ,  42   b ,  42   c  is a relatively small percentage of the total area of the openings in the tray  10  and the cover  30 . That coupled with the fact that the surfaces of the ribs  14   a ,  14   b ,  14   c ,  42   a ,  42   b ,  42   c  are rounded, assures that a cleaning fluid directed toward the tray  10  or cover  30  will pass easily into and through those container components, following the streamlined contours of the ribs  14   a ,  14   b ,  14   c ,  42   a ,  42   b ,  42   c  so that there is limited shadow effect at interior surfaces of the container. This construction provides that the entire container system and its contents will be more thoroughly washed or otherwise cleaned in an efficient amount of time. 
       FIGS. 4A to 4E  are perspective views of various instrument holders  12 ,  70 ,  72 ,  76 ,  78  that may be part of the medical instrument container system of  FIG. 1 , in accordance with the first exemplary embodiment of the present invention. The first instrument holder  12 , shown in  FIG. 4A , is a molded plastic part including a generally U-shaped base  62 . Opposing ends of the U-shaped base  62  are turned outward and downward to form a pair of spaced-apart vertical legs  64 , which extend down below the U-shaped base  62  and are terminated at a pair of quasi-hemispherical clips  66 . Each quasi-hemispherical clip  66  has one or more interior clamping surfaces  66   a  which are dimensioned to frictionally clamp to one or another of the longitudinal ribs  14   b  and the transverse ribs  14   c  of the tray  10 . 
     Molded integrally to the U-shaped base  62  is a flexible resilient instrument holding portion  68  formed with a slot  68   a  for resiliently receiving a medical instrument I, as shown in  FIG. 1 . The holding portion  68  may be molded integrally with the U-shaped base  62  in the manner described in U.S. patent application Ser. No. 11/299,505, the entire contents of which are hereby incorporated by reference herein. As described in that application, the holding portion  68  is molded integrally with the base  62  so that interstices or crevices or openings between the molded members, which could be possible sites for bacterial infestation, are at least substantially avoided. 
     As shown in  FIG. 1 , two of the first instrument holders  12  are clamped to the longitudinal ribs  14   b  of the tray  10  at opposite sides of tray  10 . Accordingly, the first instrument holder  12  may extend substantially the width of the tray  10  to secure the first instrument holders  12  to the outer longitudinal ribs  14   b . To anchor the first instrument holders  12  to the tray  10 , the quasi-hemispherical clips  66  at the end of one of the vertical legs  64  are engaged to one of the longitudinal ribs  14   b  of the tray  10  and the vertical legs  64  are spread apart sufficiently so that the quasi-hemispherical clips  66  on the other vertical leg  64  can engage the longitudinal rib  14   b  at the other side of the tray  10 . 
     The pair of quasi-hemispherical clips  66  on each of the vertical legs  64  face opposing directions. The flexibility of the molded U-shaped base  62  and the vertical legs  64  allow the first instrument holder  12  to be manually twisted such that both quasi-hemispherical clips  66  of the pair can grip the longitudinal ribs  14   b  and/or the transverse ribs  14   c . This arrangement maintains the first instrument holder  12  rigidly in place within the tray  10  more effectively than previously known designs. The vertical legs  64  are sufficiently resilient that, when released, the vertical legs  64  return to unstressed positions, which secure the first instrument holder  12  to the tray  10  and maintain the transverse position of the first instrument holder  12  in the tray  10 . The interior clamping surfaces  66   a  may be molded plastic or flat metal parts, they may have circular cross-sections where they contact the longitudinal ribs  14   b  and/or the transverse ribs  14   c  to minimize the contact areas therewith. 
     Also, the quasi-hemispherical clips  66  may be almost as wide as the distance between the transverse ribs  14   c  of the tray  10  so that, when secured as aforesaid, the first instrument holder  12  is also longitudinally fixed in the tray  10 . Since the openings between the longitudinal ribs  14   b  and/or the transverse ribs is  14   c  at the bottom of the tray  10  are substantially square, each first instrument holder  12  could also be turned 90° and clamped to the transverse ribs  14   c  of tray  10 , if that were necessary to retain a particular medical instrument I within the tray  10 . 
     The first instrument holder  12  need not extend the full width of tray  10 , as provided in accordance with the first exemplary embodiment.  FIG. 4B  is perspective view of a second instrument holder  70 , which is similar to the first instrument holder  12 . The second instrument holder  70  is designed more narrowly than the first instrument holder  12 , such that the second instrument holder  70  spans only two openings in the bottom of the tray  10 . 
       FIG. 4C  is perspective view of a third instrument holder  72  which is similar to the second instrument holder  70  except that the U-shaped base is formed with a pair of integral depending posts  74  which are spaced apart a distance substantially equal to the diameter of the longitudinal ribs  14   b  and/or the transverse ribs  14   c  at the bottom of the tray  10 . When the third instrument holder  72  is clipped to the tray  10  in a manner similar to that of the first instrument holder  12 , the integral depending posts  74  will straddle one of the longitudinal ribs  14   b  or the transverse ribs  14   c  at the bottom of the tray  10 , thereby positively fixing a lateral or transverse position of the third instrument holder  72  within the tray  10 . 
       FIG. 4D  is a perspective view of a fourth instrument holder  76 . The fourth instrument holder  76  has a pair of spaced-apart upstanding loops  76   a  for fixating a relatively wide instrument or device.  FIG. 4E  is a perspective view of a fifth instrument holder  78 . The fifth instrument holder  78  has a single upstanding loop  78   a  which may be suitable, for example, to secure a scissor handle or other such instrument having an eye, wherein the eye would be pierced by the single upstanding loop  78   a.    
       FIG. 5A  is perspective view of a medical instrument container system, in accordance with a second exemplary embodiment of the present invention. More precisely, a molded plastic reticulated tray  80  is shown in  FIG. 5A .  FIG. 5B  is a perspective view of a cover  82  of the medical instrument container system shown in  FIG. 5A , in accordance with the second exemplary embodiment of the present invention. It should be noted, in accordance with the second exemplary embodiment, that the molded plastic reticulated tray  80  and the cover  82  are much wider than the tray  10  and the cover  30  of the first exemplary embodiment. The larger space afforded by the wide tray  80  and cover  82 , in combination with a variety of the instrument holders shown in  FIGS. 4A to 4E , allows a whole set of instruments or devices to be protectively enclosed for sterilization and handling. Being larger, the tray  80  and cover  82  may be formed with two sets of fixtures  22 ,  48  and latch members  26 . Here also, the tray  80  and the cover  82  may be identically molded plastic parts. However, the cover  82  may be somewhat different from the tray in that the cover  82  may include solid side straps  82   a , shown in  FIG. 5B , to prevent loose instrument I from sliding out of the tray  80 . The latch members  26  are attached to the tray fixtures  22  but not to the cover fixtures  48 , with the latter functioning as keepers for the latch members  26 . Of course in both the first and second exemplary embodiments, the latch members  26  could just as well be hinged to the cover fixtures  48  with the tray fixtures  22  functioning as keepers for those latch members  26 . 
     It is apparent from the foregoing that the container system of the present invention has definite advantages in terms of protecting the instruments contained therein as well as facilitating efficient washing and sterilization of those instruments as well as the inside surfaces of the container. Yet being molded entirely of plastic, the system can be made in quantity relatively inexpensively. Therefore, it should prove to be very useful in hospital, clinics and other settings where medical instruments and devices have to be cleaned on a routine basis. 
     It should be emphasized that the above-described embodiments of the present invention, particularly, any “preferred” embodiments, are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the invention. Many variations and modifications may be made to the above-described embodiment(s) of the invention without departing substantially from the spirit and principles of the invention. All such modifications and variations are intended to be included herein within the scope of this disclosure and the present invention and protected by the following claims.