Abstract:
A color-coded packaging system is provided where a set of different colors are selected with each color designated to signify a varying feature of a product such as a dimensions of a pouch for receiving instruments for sterilization. Printed information or indicia printed on that pouch are printed in a colored ink designating the size of that pouch. Multiple pouches of the same size are packaged in boxes which have information or indicia printed thereon in the same color so that the size of box contents can be readily determined by the color of the printing thereon. The storage area can also include designated color coded areas for placement of like colored boxes. The color coding of the storage area, the boxes and the content of boxes provides for easy selection of a desired product as a means for a quick visual inventory.

Description:
[0001]    The present disclosure is directed to a system for storing multiple samples of various products, all of which have a feature or function which is similar but which each have at least one feature that is different, such as size. The system includes indicia on the product or the product packaging for readily identifying the nature of the product or that different feature or function of each of the stored products from a distance. More particularly, all of the packages having the same feature, and all of the containers holding the multiple packages with the same feature will have, in a readily visible location, a colored or other type of indicia printed thereon that is correlated to the variable feature. More specifically, in one intended use of the system, pouches used for packaging medical instruments are color coded. A user familiar with the color codes, upon viewing a pouch or a storage shelf containing multiple different size pouches, can readily locate a pouch of a specific size, or for a specific use, or fabricated from a specific material and then select the desired pouch for an intended purpose solely by viewing the one or more colors printed on the pouch or boxes of pouches. 
       BACKGROUND 
       [0002]    Numerous medical instruments are sterilized and reused. These instruments are typically cleaned, inserted into a sealable pouch and then sterilized. In dental offices for example, instruments are gathered after use, cleaned, and packaged in sterilizable pouches. The pouches are then sealed and subjected to a sterilizing environment such as an autoclave wherein steam or high temperature water vapor is used to sterilize the instruments. Alternatively, the pouch-enclosed instruments can be subjected to other sterilization techniques such as a sterilizing gas, for example, ethylene oxide, or exposure to radiation or UV light. The instruments are then stored in the sealed pouches for later use. 
         [0003]    Typical sterilizing pouches are formed of two layers of sheet materials printed with identifying brand names and other information on an outward face. These pouches are available in numerous different widths and lengths and may also have different internal volumes by being formed with pleats or gussets. Still further, the pouch may be formed from front and back sheets of a paper or plastic material where at least on sheet or portion thereof is permeable to the sterilant but the sealed pouch is impermeable to bacterial or other contaminants. Examples of suitable materials are cellulosic papers, sheets formed from plastic fibers or fibrillated plastics, such as TYVEK® or clear impervious plastic films. 
         [0004]    In typical embodiments, the pouch comprises first and second sheet material walls, the periphery of the walls being joined to define the pouch. One of the sheet material walls is preferably transparent and water vapor impervious, and one of said walls is preferably cellulosic and water vapor and sterilization gas pervious. The joinder of the walls defines a perimetrical seal about a partially closed volume within which the instruments are placed for sterilization. The pouch can also have a flap on one of the walls arranged to overlie the other of the walls in sealed relation to fully enclose the volume. Typically the two sheets are joined by heat sealing. However, if the pouch includes the flap a medically acceptable adhesive, which is unaffected by the sterilization process, can be applied to the flap so that the pouch seals are provided by both heat sealing and adhesives. 
         [0005]    Multiple pouches (for example  100 ,  200 ,  500  etc.) of the same size are provided in a shelf pack or box. The user will typically order multiple shelf packages of the same size pouch as well as multiple packages of the other available sizes of pouches. For example, the user may purchase several packages of each of the 8-12 different sized pouches that may be available. This means that a working supply of pouches may comprise 50-100 boxes, each box containing 100 or more of a specific size. When these are all stored stacked on shelving it can be difficult to readily locate the desired size pouch for use in packaging the instruments and it may be necessary to handle multiple boxes and read the label on the face of the box to determine its contents. Further, while the identification of the contents of the box may be printed on the end flap, which is visible when stacked, to allow easy access to the contents of the box the end flap is typically removed from the box or at least folded out of view. To further add to the problem of locating the correct pouches, a further set of pouches may have a different use. For example they may be constricted of materials particularly chosen for autoclaving, ethylene oxide sterilization or other sterilization techniques such as radiation or UV exposure. Still further, in a facility with multiple physicians or different departments (i.e., surgery, radiology, pediatrics, etc.) each physician or each department may desire that their supply of pouches is segregated. This requires separate storage arrangements or some means to distinguish the various different pouch inventories. 
         [0006]    Accordingly, there is a need for an easy means to segregate, label, discriminate and select similar products which have at least one feature, characteristic or function which is different when those similar products are all stored in the same storage area. 
       SUMMARY 
       [0007]    A color-coded packaging system is provided where a set of different colors are selected with each color designated to signify a varying feature. For example, pouches for packaging instruments for sterilization are available in different sizes to accommodate different sized contents. A specific color is assigned to each sized pouch and information and indicia printed on that pouch is printed in a colored ink designating the size of that pouch. Multiple pouches of the same size are packaged in boxes which have information or indicia printed thereon in the same color so that the size of box contents can be readily determined by the color of the printing thereon. Both the pouch and the box can also have printing in a second color, selected from a second color coding system, to designate a second feature of the pouch. The storage area can also include designated color coded areas for placement of like colored boxes. The color coding of the storage area, the boxes and the content of boxes provides for easy selection of a desired product as a means for a quick visual inventory. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    The invention will be further described as to an illustrative embodiments in conjunction with the attached drawings in which: 
           [0009]      FIG. 1  is a top view of a representative first embodiment pouch incorporating features of the invention. 
           [0010]      FIG. 2  is a sectional view thereof taken along line  2 - 2  in  FIG. 1 . 
           [0011]      FIG. 3  is a perspective of a representative box containing multiple pouches, as shown in  FIG. 1 , all having the same characteristic or feature. 
           [0012]      FIG. 4  is a front view of multiple boxes, each box containing pouches, on a storage rack incorporating features of the invention. 
           [0013]      FIG. 5  is a view of a first embodiment of a box end flap incorporating features of the invention. 
           [0014]      FIG. 6  is a view of a second embodiment of a box end flap incorporating features of the invention. 
           [0015]      FIG. 7  is a top view of a second embodiment of a pouch incorporating features of the invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0016]      FIGS. 1 and 2  show a typical pouch  10  incorporating features of the invention. In a preferred embodiment the pouch  10  comprises a first or lower sheet  12 , typically a planar sheet material, of a suitable printable barrier material, such as a printable cellulosic medical grade paper which is impermeable to external contaminants, will not decompose under sterilization conditions, and is pervious to steam, water vapor and sterilization gases. A second or upper sheet  14  is a planar sheet, also impermeable to external contaminants and will not decompose under sterilization conditions, but is impervious to water vapor, steam and typical sterilizing gases. It is typically a transparent plastic such as polyester, or a polyester/polyolefin laminate. The second sheet overlies the first sheet and is heat sealed thereto along three sides to form a perimeter seal line  16  created a pouch with an open end  18  to form the pouch  10 . The opposite end, also referred to as the lower end  34  of the pouch  10 , is closed. Following insertion of an instrument into the pouch the open end  18  is closed. One alternative means of sealing is to fold over a flap  20 , which is part of the lower sheet  12  and is coated with an adhesive, and attach the flap to the upper sheet  14 . Attachment may be provided by a contact adhesive  22  which is pre-applied to the flap and is covered by a removable piece of release paper (not shown). An alternative is to use heat sealing techniques, which are known in the art, to seal the upper sheet  14  to the lower sheet  12  thus sealing the instrument within the pouch  10 . 
         [0017]    Printed on the first sheet  12  in various locations  24 ,  26 ,  28 , which may be visible through the transparent second sheet  14  or alternatively printed on the lower surface of the first sheet, are various different pieces of information such as the manufacturer&#39;s name, trademark, various certification marks, a specified use of the pouch or its intended contents and the pouch product code, dimensions and other characteristics. The printing locations identified in  FIGS. 1 ,  3  and  7  are merely representative and are not intended to limit the location of the information or the purpose of the printed information. A feature of the invention is that some or all of the printing on the pouch is in a color, in accordance with an established color code system, that is used to designate the size of the pouch. As an example Table 1 lists 12 different pouch sizes and the colors, referred to as a first color  30 , chosen to represent the various pouch sizes. 
         [0000]    
       
         
               
               
             
           
               
                   
               
               
                 POUCH SIZE 
                 COLOR 
               
               
                 width × length (inches) 
                 (PANTONE COLORS) 
               
               
                   
               
             
             
               
                  3.5 × 5.25 
                 RED (PMS 185) 
               
               
                 2.75 × 9.0  
                 GREEN (PMS 3415) 
               
               
                 3.5 × 9.0 
                 ORANGE (PMS 144) 
               
               
                 2.25 × 4.0  
                 SILVER (PMS 5497) 
               
               
                 5.25 × 6.5  
                 BLUE (PMS 293) 
               
               
                  8.5 × 15.0 
                 PINK (PMS 212) 
               
               
                 3.25 × 12.0 
                 PURPLE (PMS 258 
               
               
                 4.25 × 12.0 
                 GOLD (PMS 118) 
               
               
                  8.0 × 12.0 
                 BLACK 
               
               
                 5.25 × 12.0 
                 BROWN (PMS 469) 
               
               
                 10.5 × 16.0 
                 BABY BLUE (PMS 283) 
               
               
                 13.25 × 20.0  
                 FOREST GREEN (PMS3435) 
               
               
                   
               
             
          
         
       
     
         [0018]    The color coding allows one familiar with the coding system, upon viewing the colored printing on the first or lower sheet  12 , to immediately know the size of the pouch. For example if the first color  30  used for the printing is red the pouch is 3.5″×5.25″. As an added feature, the first color  30  is also applied on the first sheet at the corners  32  of the initially sealed lower end  34  of the pouch so that it can be observed by viewing the initially sealed lower end  34  of the pouch  10 . Colored left and right rectangles  36 ,  38  on the pouch sealed end are merely representative locations and other locations or combinations of locations on the sealed lower end  34 , such as a solid stripe or a series of rectangles across the lower end of the pouch  10  can be utilized. The purpose of this feature is explained below. 
         [0019]      FIG. 3  shows a box  40  with the end flaps  60  removed. The box  40  contains multiple pouches  10  all of the same size and therefore all having the same color print which also matches the color of the left and right rectangular areas  36 ,  38 . The box  40  shown in  FIG. 3  also has at least a first and second area  42 ,  44  printed in the same color as on the pouch  10 . For example, if the box contains 2.75 in×9.0 in pouches the first color  30  is green and the printing on each pouch  10 , the left and right rectangles  36 ,  38 , and the first and second areas  42 ,  44  on the box  40  are all the same color green. Even though the colored printing on the left and right rectangles  36 ,  38  is applied to the top of the lower sheet  12 , it tends to penetrate the material of the first sheet as well as the exposed end of the lower sheet  12  at the initially sealed lower end  34  of the pouch  10 . Therefore, even when the pouches  10  are stacked in the box  40  an individual viewing the open end of the box can see the color of the left and right rectangles  36 ,  38 . In addition, the ends of the pouches tend to curl slightly downward, further allowing the color indicia thereon to be seen. In a preferred embodiment the inner end flaps (not shown) of the box as well as the end flap  60  are also partially or filly colored with the same first color  30 . The first and second areas  42 ,  44  on the box  40  as shown in  FIG. 3  are only representative locations for the location of the first color  30  on the box  40  and other locations or larger or smaller areas on any of the outer surfaces of the box may be colored with the first color  30 . The outer surface of the box can also display a second color  50  which is a color within a second color coding system to designate a further or different feature of the contents of the box. While it is preferred that the second colors  50  from a second coloring system are different from the first color  30  they may be selected from the same set of colors. Confusion is minimized or eliminated because an individual, upon observing the box, recognizes that, because of its specific location on the box, it represents the second feature. In the present example, where the first color  30  identifies the size of the pouch in the box the second color may, for example, represent a characteristic of the packaging material, a physician user within a group of physicians or a department (i.e., radiology, emergency room, pediatrics, etc.) within a medical facility. One skilled in the art will recognize that the outer surface of the box can include many different pieces of information including, but not limited to the manufacturer&#39;s name, address, trademarks, product description, instructions for use, usage warnings, etc. which may be printed in the first color  30 , a complementing color or a second color  50 . In addition, black or white may be used as either a first color  30 , a second color  50 , or limited to use for printing which may have no meaning in the color coding or could designate a still further two color code. 
         [0020]      FIG. 4  shows multiple different sized packages stored in a single storage cabinet  52  and illustrates the utility of the color coding system to aid in selecting individual desired products, for example a particular sized pouch  10 , from multiple boxes  40  of the different sized pouches  10 . Stored and displayed in cabinet  52  are nine different size pouches  10 , the location for a tenth size pouch  10  being empty. In the illustrated example the cabinet  52  contains thirty-one boxes  40  of pouches  10  some of which are open (have the end flap removed) while others are unopened. A first stack  54  of boxes  40  contains three closed boxes  40  with a partially filled open box  40  on the top of the stack  54 . The first color  30 , indicated in this case by the indicia  30   a , signifying the dimensions of the pouches  10  in each box  40 , is the same as shown on the visible end flap  60  of the three closed boxes  40 . The color code  30   a  on the left and right rectangles  36 ,  38  on the pouches  10  in the open box  30  is also visible. Each of the stacks of boxes  40  contains different sized pouches  10  and therefore, to indicate the first color  30  in each instance is different, the indicia for the 9 different stacks of boxes is indicated as  30   a  through  30   j . As an added feature, a label  56  is placed on the front of the shelf  58  below each stack, that label  56  being colored to match the stack of boxes designated for that location (i.e., the label on the shelf  58  below the first stack  54  bears the first color  30 a which matches the first color  30  on the boxes and pouches stacked above. This allows a user to quickly identify, because of the open space on the lower shelf  58 , that all of the pouches  10  of a size designated by the first color  30 h have been used up and it is time to replenish the inventory of that size. 
         [0021]    Further, if the packaging includes a second series of color coding (i.e., the second color  50 ) that color can also appear on the end flap  60 .  FIGS. 5 and 6  show different examples of the end flap  60  which can have one or more colors for the one or more color coding systems. In  FIG. 5  the top of the end flap  60  displays the first color  30  and the lower half can be blank (white) or display a second color  50 . The printed lettering  62  can be a third color, or black or white to designate a third feature or to merely provide information to the user. 
         [0022]      FIG. 7  shows a second embodiment of the pouch  10  also displaying a second color  50  on the visible end of the pouch  10 . 
         [0023]    While the coded packaging system has been illustrated by the use of different colors to designate different sized products packaged in similar types of boxes  40  the system can also utilize other designation systems such as shades of grey or different types of colored or black and white cross hatching. Also, while a specific color, for example green, may be used to designate a specific size product, different shades of that color (light green, forest green, etc.) can be used to designate other features or characteristics of the product. For example, in the coding system set forth above brown designates a 5.25×12.0 pouch. A dark, chocolate brown could designate a flat pouch and a light brown or tan could designate the same size pouch with pleats or gussets and thus expandable to hold a greater volume. Also while the preferred embodiment designates a pouch of a particular length and width, a first color can be used to designate a length and a second color can designate a width. As a still further alternative a set of colors could designate a series of dimensions (a different color for each of 1 inch, 2 inch, 3 inch, etc.) and then the same color code could be used to designate the dimensions for both the length and width. For example if red designates a 3 inch dimension and green designates a 6 inch dimension a red/green combination would designate a 3×6 pouch, a green/red combination would designate a 6×3 pouch and a green/green combination would designate a 6×6 pouch.