Patent Publication Number: US-2019192268-A1

Title: Adjustable dental cassette system

Description:
FIELD OF THE DISCLOSURE 
     The disclosure relates to the field of dental-instrument cassettes engineered for insertion in ultrasonic and autoclave machines, said cassettes possessing capacity to safely grip, dry and sterilize dental instruments of multiple shapes and sizes. 
     BACKGROUND 
     This invention relates to a universal adjustable dental cassette which grips, stores, displays, holds [for drying] and secures a wide range of dental instruments during the various phases of instrument sanitation while preventing instrument damage, while facilitating superior liquid drainage, while protecting dental hygienists from being poked by loose or protruding instruments. 
     Dental instrument sterilization cassettes hold soiled dental instruments during sterilization processes. Contaminated instruments are stored in cassettes, which are then placed in autoclave and other steam-cleaning sterilization machines, as well as ultrasonic and other solution-and-agitation cleaning machines. These cassettes customarily come in “hygiene” size and “diagnostic” size, infra. 
     Sterilization cassettes customarily have apertures for cleaning-vapor or solutions to pass through and agitate the instruments. Cassettes in ultrasonic machines must endure high frequency sound waves&#39; resultant cavitation bubbles, which release contaminants that are stuck to the instruments (dental debris). The holes also provide for future drainage. The instant invention is an adjustable cassette-and-gripper system specifically tailored for all sterilization processes, usually consisting of holding/solution, ultrasonic and sterilization processes. The instant cassette is preferably embodied in two-sizes of the same adjustable cassette which can secure almost any dental instrument (infra) through the autoclave, sterilization, instrument washing, and ultrasonic (enzyme solution) cleaning processes. 
     Preventing instrument jostling within each cassette is paramount, as instruments can scratch and break within the cassette. In addition, housing and anchoring multi-sized and multi-shaped instruments has heretofore remained an enigma in the industry, as the industry still uses shallow, substantially-fixed, “metal rack style” cassettes which cannot adjust to solve the above issues, and which commonly allow protruding, sharp instruments to stick out of the cassettes and poke dental workers. 
     No dental cassette has heretofore been invented which addresses all these sterilization and drainage needs. Present cassettes are either too shallow to house larger dental instruments like mouth mirrors and hand-pieces, or their gripping rails/ribs are uniform and parallel, and thus cannot accommodate differently-sized instruments. Furthermore, many cassettes offer polymer bases, which trap debris during sterilization (allowing ongoing contamination) and which provide insufficient drainage (pooling). 
     In sum, current raw-boxy steel dental cassettes with fixed internal steel internal ribs offer insufficient sterilization and safety. Current polymer cassettes offer slightly better safety, but they also lack in hygiene and stability. An intelligent “universal adjustable” cassette is needed. 
     SUMMARY 
     A novel dental cassette featuring a ‘pop-in’ securing gripper-rails system to clamp odd-shaped dental instruments, while providing adjustable canting, gripping, and drainage capacity through its materials, design and engineering. The silicon gripping posts and feet, and the shovel-and-groove clamps, and the plurality of hex [preferred] holes, provide superior anchorage for dental instruments through autoclave and sterilization processes. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The drawings described herein are for illustrative purposes only and illustrate only selected embodiments of the present invention. The enclosed drawings are not intended to limit the scope of the present disclosure. 
         FIG. 1  is a perspective view of the [in this embodiment] stainless steel tray component of the dental cassette, showing the ‘fold up stamping’ method of manufacture and hexagonal aperture design, herein shown with a double-grooved rail along the tray&#39;s top walls, and herein showing two sets of pliable gripping strips/posts. 
         FIG. 2  is a worm&#39;s-eye, exploded view of the tray with grippers inserted in double-row perpendicular transverse fashion and [herein embodiment] equal size feet/stoppers (un-canted). 
         FIG. 3  is a perspective, worm&#39;s-eye view of the tray showing tray depth to allow secure gripping of odd shaped items. Anti-slip feet are herein shown, plugged through the hex-drainage apertures. 
         FIG. 4  is a perspective aerial view of the tray with a single gripping strip/post holding a single dental instrument (probe), showing secure “shovel top” gripping posts, securing the dental instrument through the rigor of autoclave processes. Adjustability (movability) of said plug/strips is shown, as additional apertures are available to allow dentists to “re-anchor” said probe in the position they want. 
         FIG. 5  is an aerial side view of the tray with lid cover, as it fits in sterilization machines, showing the gripping strips plugged into the drainage apertures, and showing the unit&#39;s canting from differently-sized plug-feet (for drying, to prevent pooling). 
         FIG. 6  is a worm&#39;s-eye view of the tray, featuring parallel grippers/transversal of the dental instruments) and differently-sized feet for canting. 
         FIG. 7  is a perspective, aerial view of the tray with [herein] same-sized pliable gripper strips (posts) holding multi-shaped dental instruments with its “shovel plug and groove” gripper strip/post tops, said strips anchored (plugged) through the tray&#39;s hexagonal drainage apertures. 
       Optional “grass-like” “bristly” Silicone Clamping-Sheet Insert not herein shown (a pliable pad/sheet that lays atop said dental instruments to further secure them during sterilization). This feature is essentially a rubber sheet inserted between the instruments and the lid. 
       Optional Convex lid not herein shown (for superior drainage). 
       Optional Concave tray base not herein shown (for superior drainage). 
     
    
    
     DETAILED DESCRIPTION 
     In the Summary above and in this Detailed Description, and the claims below, and in the accompanying drawings, reference is made to particular features (including method steps) of the invention. It is to be understood that the disclosure of the invention in this specification includes all possible combinations of such particular features. For example, where a particular feature is disclosed in the context of a particular aspect or embodiment of the invention, or a particular claim, that feature can also be used, to the extent possible, in combination with and/or in the context of other particular aspects and embodiments of the invention. 
     Certain terminology and derivations thereof may be used in the following description for convenience in reference only, and will not be limiting. For example, words such as “upward,” “downward,” “left,” and “right” would refer to directions in the drawings to which reference is made unless otherwise stated. Similarly, words such as “inward” and “outward” would refer to directions toward and away from, respectively, the geometric center of a device or area and designated parts thereof. References in the singular tense include the plural, and vice versa, unless otherwise noted. 
     The term “comprises” and grammatical equivalents thereof are used herein to mean that other components, ingredients, steps, among others, are optionally present. For example, an article “comprising” (or “which comprises”) components A, B and C can consist of (i.e., contain only) components A, B and C, or can contain not only components A, B, and C but also contain one or more other components. 
     Where reference is made herein to a method comprising two or more defined steps, the defined steps can be carried out in any order or simultaneously (except where the context excludes that possibility), and the method can include one or more other steps which are carried out before any of the defined steps, between two of the defined steps, or after all the defined steps (except where the context excludes that possibility). 
     The term “at least” followed by a number is used herein to denote the start of a range beginning with that number (which may be a range having an upper limit or no upper limit, depending on the variable being defined). For example, “at least 1” means 1 or more than 1. The term “at most” followed by a number (which may be a range having 1 or 0 as its lower limit, or a range having no lower limit, depending upon the variable being defined). For example, “at most 4” means 4 or less than 4, and “at most 40%” means 40% or less than 40%. When, in this specification, a range is given as “(a first number) to (a second number)” or “(a first number)−(a second number),” this means a range whose limit is the second number. For example, 25 to 100 mm means a range whose lower limit is 25 mm and upper limit is 100 mm. 
     Aspects of the disclosed invention may be embodied as a system, method or process, or computer program product. Accordingly, aspects of the disclosed invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module,” or “system.” Furthermore, aspects of the disclosed invention may take the form of a computer program product embodied in one or more computer readable media having computer readable program code embodied thereon. 
     Any element in a claim that does not explicitly state “means for” performing a specified function, or “step for” performing a specific function is not to be interpreted as a “means” or “step” clause as specified in 35. U.S.C. § 112 ¶6. Specifically, the use of “step of” in the claims herein is not intended to invoke the provisions of U.S.C. § 112 ¶6. 
     As discussed infra, the instant invention secures the following instruments [and more] in a safe, hygienic secure manner preferred by key opinion leaders: probes, retractors, mouth mirrors, dental pluggers and condensers, dental burnishers, prosthodontics instruments, excavators, torque wrenches, chisels, forceps, pliers, and syringes and needle-recappers, ADD scalers and curvettes, and needed accessories. 
     DETAILED DESCRIPTION OF THE FIGURES 
       FIG. 1  shows an embodiment of the invention, featuring the “fold up” stamped manufacture of the base/tray. The cassette fits inside most autoclaves, including Midmark™ and Ritter™ autoclaves, Tuttnauer and Scican Statim and Hydrim autoclave machines, sterilizers, and more. The invention also fits inside standard baskets for ultrasonic cleaners. The preferred cassettes are the “5 instrument” embodiment at 7½″×2½″×1.5″ (last dimension=height/depth). Another embodiment is for the “medium 8 instrument” cassette at 7½″×4½″×1.5″ (last dimension=height/depth). Other embodiments come in 8″×4.5″×2″, 7″×3″×2,″ and other dimension cassettes are available. 
     Reference number  102  is the tray,  104  is the (optional but preferred) grooved rail to engage the notch-ridge along the inside of the lid-cover (not herein shown);  106  drainage apertures throughout, prevent pooling (preferred embodiment hex hole shape has numerous benefits, especially, herein, they hold the pliable (usually silicon) clamping strips  204  [also called posts  402 , depending on shape of dental instrument held and length and positioning of strip], to prevent the strips/posts  204  from rotating in place (which would allow the dental instruments to jostle, come loose during sterilization, and accidentally poke dental workers). The (optional but preferred) hex holes  106  therefore aid drainage, and also provide proper anchors for the strip  204  plugs  502  to securely (removably) fasten in place. This hex style prevents accidental disengagement or rotation (which would create a mess-o′-dental-instruments inside the cassette, post-sterilization). 
     The [preferred] silicone gripper and rail system reduces instrument contact, allowing for cleaning solutions to agitate-away more debris. [One embodiment] Stainless steel housing construction in the tray/base protects against corrosion. Apertured-edges allow for superior drainage and drying. The [preferred] hexagonally shaped apertures offers multiple advantages, discussed infra and supra. 
       FIG. 2  shows base  202 , which may alternatively (not herein shown) be convex (middle up) to prevent pooling, the pliable gripping strip  204 , herein taking the form of a securing strip affixed (plugged) to the top via aperture plugs (helps to secure the instruments below during the bumpy-and-steamy autoclave-&amp;-sterilization processes), the lid&#39;s notch-ridge  208 , while optional, helps secure the lid, the apertures  106  are shown throughout the lid. The lid  210  should, if [preferred] silicon-pliable material, securely fit over tray  102  ridged rails  104  to hold the unit together for autoclave, sterilization, and storage. 
       FIG. 3  features the anti-slip feet  302 / 304 , being the same size in the embodiment shown in  FIG. 3 , but often differently-sized to create base  202  canting in other embodiments (infra). Feet  302  plug through hex apertures  106  as other gripper plugs, and are preferably rubber or silicon or appropriate similar compound thereof (ideally the same material as all the other the strips  204  and posts  402 ) (Reference numbers  204  and  402  used interchangeably as/where appropriate, as the interchangeability of plug-strip-posts  204 / 402  (and their alternate sizing) is a key component of the instant invention). All  204 / 402  strip/posts feature the same “plug style” removable fasteners  502  and (when posts to grab and secure instruments) the shovel-and-groove style clamp tops  404 . 
       FIG. 4  herein shows differently sized anti-slip feet  302  and  304 , respectively, preferred canting not herein shown, the ‘shovel and groove’ shaped clamp-top  404  to the gripping strip/post  402 , the clamped dental instrument  406  (herein a “pointy” probe, showing the need for stable clamps). 
       FIG. 5  shows the cassette assembled (lid-on) for sterilization and storage, herein showing the gripping strip  502  plugged through the hex holes  106 . 
       FIG. 6  shows the main tray with gripping strips/posts  402  plugged/secured through the hex base holes  106 , herein two strips positioned in parallel to hold elongated dental instruments. As with all the invention&#39;s pliable strips/posts  402 , different dental instruments may receive different strip/post  402  sizes and configurations, therein making the dentist&#39;s “presentation/diagnostic” stage, and latter-sterilization/hygiene processes, easier and “tailor-made” for the instruments s/he is using. Said strips/posts  402  may also be color-coordinated by instrument-type or by patient, or other logical indexing means. 
       FIG. 7  shows multiple probes  406  and a mirror  406  (all dental instruments  406  for reference purposes) securely held by gripping posts/strips  402 / 204  (here said strips are arranged in parallel). Note the tray is sufficiently deep to hold canted-mirrors  406 , which the gripper posts  402  accommodate due to their “pop-in/pop-out” versatility (allowing various posts  402  to be different heights when needed, such as for odd-shaped instruments like mirrors [unlike probes, which are fairly common in size and shape]). 
     PREFERRED EMBODIMENT OF THE INSTANT INVENTION 
     Cassette feet are silicone-rubber [either or compound or mixture] stoppers  302 / 304  feet for support, improving drainage and preventing slippage. Small and large feet are optionally positioned on the distal and proximal ends, effectively creating a drainage chute [canting of base  202 ], as base is then a canted cassette floor for superior drainage. Adjustable color coded “Snap-in/Plug-in” support retainers (“Grippers”)  204 / 402  to anchor and secure [usually] ⅜″ and thinner probes  406 ; also for bigger mirrors  406 ; adjustable walls within the cassette (formed by popping-in-additional-strips  204 , not herein shown), also anchored with the hex plugs. 
     Hexagonal drainage apertures  106  allow proper spillage, prevents pooling and allows instrument debris to flow out of the cassette. Other hole shapes are appropriate for the invention, so long as their width and geometry allows for the secure “pop-in-pop-out” method of securing rails/grippers  204 / 402 . The size, arrangement and shape of [preferred hex] holes (drainage apertures)  106  prevents instruments from sticking/poking out of the cassette and therefore from poking the dental hygienists and other workers. 
     Stainless steel [preferred] housing  102  with silicone (or similar semi-pliable) (antibiotic-treated) lid  210 ; adjustable (including diagonal [alternative embodiment, but “easily adjustable by dentist upon arrival]) gripping rail  204 / 402  design, adjustable for ‘odd shaped’ instruments  406 . 
     [Preferred] Silicone lid cover  210  (rather than steel or metal) (BPA Free), with Triclosan-style (e.g. Microban™) antibiotic added to the lid material (rather than mere stainless steel). The lid  210  pops on and off like Tupperware™ (or similar groove lip and ridge system). The lid also optionally has at least one corner tab for easy-opening (grabbing) (not herein shown). 
     Lid  210  and Cassette Tray/Base  202  may also have convex planes, to further improve drainage and prevent pooling; 
     Hygiene Size and Diagnostic Sizes available (5-instrument and 8-instrument cassette sizes as preferred embodiments). 
     Hexagonally shaped apertures  106  further stabilize the individual-instrument grippers (preventing twisting); 
     Cassette lid  210  has plurality of hex-shaped apertures  106  to allow individual (non-paired) grippers  402  to house and anchor individual ‘odd shaped’ dental instruments  406  like pliers or syringes. 
     Cassette  102  can be loaded into an autoclave or ultrasonic machine either face up or face down while securely anchoring the dental instruments. 
     “Shovel plug and groove shaped clamp” topped  404  adjustable silicone grippers  404  (arranged as colored gripping sets) safely grip almost any dental instrument. 
     Unique color coordination of shaded-borders on hex tray and lid holes  106  (including optional color-coated anodized [optional] stainless steel [optional] itself on lid and tray) for easy insertion of same-colored gripping strips  402 / 204  to house elongated (and individual) instruments  406  (majority of border shading for standard perpendicular). 
     Traversing double-rail grippers  204 , but diagonal and individual color coating for odd-shaped instruments is a [preferred] novel feature of the instant invention. 
     Optional “Grass-like” (“bristly”) Silicone [preferred] Clamping-Sheet Insert (not herein shown) provides additional stability and anchoring for instruments, while allowing the instant invention to maintain its “shovel and groove topped  404  gripping strips  402 ” to still function without impedance. The sheet acts as ballast, and as support, to further buttress the instruments against their rail  402  clamps  404 , to prevent jostling.