Method and packaging system for packaging a sterilized item

[0002] This is a continuation of application Ser. No. 09/616,100, filed Jul. 14, 2000, now U.S. Pat. No. 6,578,348.

[0003] The present invention relates to a packaging system, a method for packaging a sterilizable item for aseptic presentation onto a sterile field, and a packaging element having instructional information printed thereon.

[0004] In my U.S. Pat. No. 5,638,661, I teach a method and packaging system for packaging a sterilizable item (including its container) in which a sterilizable item is placed into a flexible elongate tubular member (pouch), which tubular member is sized relative to the item being wrapped. After the tubular member is folded and secured as taught, the sterilizable item is sterilized. The packaging system can be opened and the item dispensed onto a sterile field in a manner that prevents the inadvertent contamination of the sterilized item.

[0005] The method and packaging system for packaging a sterilizable item of my U.S. Pat. No. 5,638,661 requires that the vertical orientation of the sterilizable item be reversed (turned over) as part of the packaging and unpackaging process. For many sterilizable items, this does not pose any problem, but for some sterilizable items, it is required that the vertical orientation not be reversed during or between packaging and unpackaging. That is, the item has an “up” side that must be maintained “up” at all times prior to use.

[0006] Accordingly, it is an object of the present invention to provide a method and packaging system for packaging a sterilizable item (including its container, if it has one) wherein the sterilizable item can be packaged, sterilized and unpackaged without inverting its orientation (turning it over). In achieving this objective, the present invention continues to possess all of the advantages of the invention disclosed in my prior U.S. Pat. No. 5,638,661.

[0007] Another object of the present invention is to provide a packaging element which has information printed thereon which is exposed after the packaging element is used according to the inventive packaging system and method.

[0008] The foregoing and other objectives, features and advantages of the invention will be more readily understood upon consideration of the following detailed description of the invention taken in conjunction with the accompanying drawings.

[0009] FIG. 1 is a representation of an exemplary packaging system for a sterilizable item embodying the present invention.

[0010] FIG. 2 is a representation of an inner packaging element for the packaging system shown in FIG. 1.

[0011] FIGS. 3-7 illustrate the placement of a sterilizable item into the inner packaging element shown in FIG. 2.

[0012] FIG. 8 is a representation illustrating the aseptic presentation of the item shown in FIG. 2.

[0013] FIG. 9 is a representation illustrating information printed on the packaging element for the packaging system shown in FIG. 1.

[0014] FIG. 10 is essentially the same as FIG. 9, except that the illustrated packaging element is made of transparent polyethylene material.

[0015] Referring now to an exemplary first embodiment illustrated in FIGS. 1-7, a packaging system 10 (FIG. 1) for a sterilizable item 12 includes an outer packaging element 14 surrounding an inner packaging element 16. The inner packaging element 16 is a sterilizable flexible pouch having a closed end 18 and an open end 19 (FIG. 3) and, in a preferred embodiment, is made by attaching a front panel 11 having an inside surface 11aand an outside surface 11bto a back panel 13 having an inside surface 13aand an outside surface 13bwith at least one side seam and a bottom seam. Thus, the pouch 16 has a closed end 18, an open end 19, inside surfaces 11aand 13a, and outside surfaces 11band 13b. The pouch 16 may be made from a reusable fabric, such as a woven fabric, or from a disposable, single-use material, such as a non-woven fabric or a polymeric film.

[0016] Thus the packaging element 16 of the invention is formed by a front panel 11 having an inside surface 11aand an outside surface 11b, a back panel 13 having an inside surface 13aand an outside surface 13battached to the front panel, with the inside surfaces of the front and back panels in facing relationship to form pouch 16 having a closed end 18, two sides and an open end 19 wherein the pouch is closed along at least one side.

[0017] The item 12 is placed into the pouch 16 (FIG. 4) so that the item contacts a portion of inside surfaces 11aand 13aat or near the closed end 18. The pouch 16 is sized in proportion to the particular item 12 to be enclosed. In general, the circumference of the open end of the pouch is preferably about 10-15% larger than the circumference of the item as measured when the item is oriented so that the widest part 12aof the item 12 corresponds with the width 16aof the pouch 16. Typically, the length of the pouch 16 is approximately 3.5 times the height 16bof item 12. For some items, however, that ratio will be different. In all cases, the length 16bof pouch 16 must be sufficient to enclose the hand, wrist and all or part of the forearm of a person unwrapping the item for presentation into a sterile field.

[0018] A border portion 22 (cuff) is formed on the pouch 16 so that a first edge 24 of the border portion defines opening 20, which opening terminates in corners 20aand 20b. A second opposing edge 26 of border portion 22 terminates in corners 22aand 22band is spaced apart from the first edge 24 by a width 30 of the border portion. The border portion 22 is preferably formed on the pouch 16 by folding over a circumferential cuff so that a first portion of the outside surfaces 11band 13bof the pouch 16 contact a second portion of the outside surfaces 11band 13b. A portion of the inside surfaces 11aand 13aof the pouch 16 are thus exposed and define the width 30 of the border portion 22 (FIG. 4).

[0019] The width of the opening 20 in the pouch 16 (FIG. 4) is reduced by approximately 50 to 80 percent to the reduced edge 27 by folding the corners 20aand 20binward along fold lines 21 onto the border portion 22 (FIG. 5). A reduced edge 27 of at least approximately 20 percent of the length 26cof second edge 26 (or of the original width of opening 20) is required to achieve a secure lock by tucking the reduced edge 27 of the border portion 22 under the second edge 26 of the border portion 22 between the border portion 22 and the outside surface 11bof the pouch 16. When the edge 27 is reduced to zero (e.g., edge 24 folded to a point), a secure lock will not be formed by tucking edge 24 under second edge 26.

[0020] A fold line 23 (FIG. 6) is formed in the border portion 22 and the pouch panels 11 and 13 above the item 12, preferably in a manner that permits at least a portion of the inside surface 11aof front panel 11 to be in contact with at least a portion of the inside surface 13aof back panel 13, so that the reduced edge 27 of the border portion is proximate the outside surface 11bof the front panel 11. The reduced edge 27 of the border portion 22 is then placed under the second edge 26 of the border portion between the border portion and the outside surface 11bof the front panel 11 (FIG. 7).

[0021] Typically the width 30 of the border portion 22 (FIG. 4) is sufficient both to locate the second unattached edge 26 of the border portion 22 proximate the middle third of the item 12 in the pouch 16, and to permit between one-third and one-fourth of the height 30 of the border portion 22 to be tucked under the second edge 26. The size and shape of item 12 to be wrapped by element 16 dictate where the unattached edge 26 is located. In some cases, it will be in the upper or lower third of the item 12. The fraction of the border portion 22 that is tucked under the unattached edge 26 can also vary from the typical one-third to one-fourth ratio.

[0022] When the reduced edge 27 of the border portion 22 has been secured under the second edge 26 on the front panel 11 of the pouch 16, portions 26aof the second edge 26 proximate the corners 22aand 22bremain accessible for grasping without turning over the item 12. Tape may be applied to the front panel 11, if desired, to tape the border portion 22 to the pouch 16 to form a tamper-proof seal. The item 12 in the sealed pouch 16 may be sterilized without additional packaging.

[0023] The packaging system 10 is completed by placing the inner packaging element—pouch 16—enclosing the item 12, into the outer packaging element 14. The outer packaging element 14 is a sterilizable container, such as a sealable two-piece, peel-apart pouch, or a CSR cover. The packaging system 10 is sterilized by any convenient method suitable for the item and the materials used in the packaging system. After sterilization, as long as the outer packaging element 14 remains unopened and undamaged, the inner packaging element—pouch 16—and the item 12 remain sterile and ready to use.

[0024] The packaging system 10 is readily opened for aseptic presentation of the sterile item 12. The non-scrubbed attendant opens the outer packaging element 14, for example, by peeling apart the two sections of the sealed pouch (FIG. 1) and removing the inner packaging element—pouch 16—(FIG. 2). The attendant holds the inner packaging element 16 in one hand 32 at the closed end 18 with its front panel 11 and the portion 26aof the edge 26 accessible for grasping facing the attendant. With a second hand 34, the attendant grasps one of the edge portion 26aof the border portion 22 at one side of the item 12. The attendant pulls on the edge portion 26aof the border portion 22 at alternate sides of the item 12 until the first edge 24 of the border portion 22 is released from its tucked-in position under the second edge 26. The attendant continues to pull on the edge portion 26auntil the pouch 16 has been turned inside out to expose generally the entire inside surfaces 11aand 13a, while, in the process, covering the attendant's hand 32 and forearm with the outside surfaces of the pouch 16 (FIG. 7). With hand 32 and forearm thus covered and protected, the non-scrubbed attendant may aseptically place the item 12 directly onto the sterile surgical field, eliminating the need for a scrubbed assistant.

[0025] At no step in the process of packaging, sterilizing, unpackaging or presenting the sterilized item into the sterile field is it necessary to invert the item being sterilized.

[0026] Importantly, the possibility of inadvertent contamination of the item and the sterile field is eliminated. Thus, one would expect a reduction in the incidence of post-operative infection when using the packaging system of the present invention in the operating room and a concomitant reduction in cost.

[0027] Referring to FIG. 9, the folding process of the present invention for a pouch 16 of opaque material not only leaves exposed portions 26aof second edge 26 for grasping to initiate the unpackaging process, but also exposes portions of the inside surface 11aof front panel 11 at areas 26bproximate second edge 26 at corners 22aand 22band above edge portions 26a. Areas 26bbeing exposed (visible) when the item 12 to be sterilized is in its required vertical orientation (“up”) provides the preferred location on which to print instructional information 28 in the form of words and/or symbols. Precisely where the edges 26aneed to be grasped, instructions for doing so appear. Moreover, the package can be unwrapped while maintaining proper vertical orientation and achieves the other important benefits of the invention. In the prior art, it is necessary to turn the package over after completing the folding process to find the location and instructions for initiating the unwrapping process. Additional instructional information 29 (including the representation of a thumb where the users thumb should be placed) is printed on surface 11bnear the bottom of panel 11.

[0028] “Printed” as used herein refers to any manner of creating visibly perceptible information on the inside or outside surfaces of front panel 11 or back panel 13.

[0029] Instructional information 28 relating to use of the invention is advantageously printed on the inside surface 11aof the front panel 11 after the border portion 22 is formed

[0030] Referring to FIG. 10, a pouch 16 is formed of a clear material, such as polyethylene, which is most advantageously manufactured by a process that does not readily permit the border portion 22 to be formed prior to printing. Thus, printed “PULL” instructions 35 and instructional information 29 appear on the outside pouch surface 11bonly. Because the pouch is made of transparent material, the “PULL” instructions 35 adjacent the edges 26 that underlay the border portion 22 can be seen. By printing the “PULL” instructions 35 all along the edges of panel 11 on surface 11b, there will be a “PULL” instruction adjacent each pull edge 26a, regardless of the location of the unattached edge 26 on panel 11. As with the opaque woven material, the instructional information 29 (including thumb locator) is printed near the bottom of panel 11 on surface 11b.

[0031] Of course, various changes, modifications and alterations in the teachings of the present invention may be contemplated by those skilled in the art without departing from the intended spirit and scope thereof.

[0032] As such, it is intended that the present invention only be limited by the terms of the appended claims.