Packaging Assembly

Abstract

A packaging assembly for a medical device includes at least one pouch, such as a first pouch and a second pouch, sealed so as to provide a sterile barrier between the environment and the medical device received in the first pouch, which in turn is received in the second pouch. The packaging assembly further includes at least one support member, wherein, in an assembled configuration, at least the first pouch and the support member are secured against movement relative to each other by at least one of the first and second pouches being folded around the support member. The at least one of the first and second pouches is folded around the support member such that at least the first pouch and the support member are secured against movement relative to each other, either before or after inserting the first pouch with the medical device into the second pouch. The support member may hold the packaging assembly within a secondary packaging, which corresponds in size and shape to the packaging assembly.

Claims

1. A packaging assembly for a medical device, comprising: at least a first pouch and a second pouch sealed so as to provide a sterile barrier between an environment and the medical device received in the first pouch, which in turn is received in the second pouch; and at least one support member, wherein, in an assembled configuration, at least the first pouch and the support member are secured against movement relative to each other by at least one of the first and second pouches being folded around the support member.

2. The packaging assembly of claim 1, wherein the support member is one of: (a) disposed outside the second pouch, (b) disposed between the first pouch and the second pouch, and (c) disposed inside the first pouch.

3. The packaging assembly of claim 1, wherein the support member is sized and shaped to support at least the first pouch such that at least a portion of a rim region of the first pouch extends beyond the support member, wherein the portion of the rim region is folded around the support member.

4. The packaging assembly of claim 3, wherein the first pouch has a substantially rectangular shape, and the portion of the rim region of the first pouch includes at least one edge of the first pouch.

5. The packaging assembly of claim 3, wherein the first pouch has a substantially rectangular shape, and the portion of the rim region of the first pouch includes at least two opposing edge portions of the first pouch.

6. The packaging assembly of claim 1, wherein the support member is sized and shaped to support at least the second pouch, such that at least a portion of a rim region of the second pouch extends one of into and beyond a rim region of the support member, wherein the rim region of the support member is defined by at least one predetermined fold line.

7. The packaging assembly of claim 1, wherein the support member is sized and shaped to support at least the second pouch, such that at least two opposing edge portions of the second pouch extend one of into and beyond a rim region of the support member, wherein the rim region of the support member is defined by at least one predetermined fold line.

8. The packaging assembly of claim 6, wherein at least a portion of the rim region of the support member is folded along the predetermined fold line, wherein at least the second pouch is folded along with the support member to secure the second pouch relative to the support member.

9. The packaging assembly of claim 7, at least two opposing edge portions of the support member are folded along the predetermined fold line, wherein at least the second pouch is folded along with the support member to secure the second pouch relative to the support member.

10. A packaging system for a medical device, comprising: a packaging assembly of claim 1; and a secondary packaging, wherein the secondary packaging is sized and shaped to receive the packaging assembly, wherein inner dimensions of the secondary packaging correspond to outer dimensions of the packaging assembly to secure the packaging assembly against relative movement with respect to the secondary packaging.

11. A method for packaging a medical device, comprising: a) inserting the medical device into a first pouch and sealing the first pouch to provide a sterile barrier between the medical device and an environment; b) inserting the first pouch containing the medical device into a second pouch; c) providing at least one support member; and d) folding at least one of the first and second pouches around the support member such that at least the first pouch and the support member are secured against movement relative to each other, wherein steps c) and d) are carried one of before and after step b).

12. The method of claim 11, wherein folding the first pouch around the support member is performed before inserting the first pouch containing the medical device into the second pouch.

13. The method of claim 11, further comprising: inserting the support member along with the first pouch containing the medical device into the second pouch.

14. The method of claim 11, wherein the support member is sized and shaped to support at least the first pouch such that at least a portion of a rim region of the first pouch extends one of into and beyond a rim region of the support member, wherein the folding step includes folding the portion of the rim region around the support member.

15. The method of claim 11, wherein the support member is sized and shaped to support at least the first pouch such at least two opposing edge portions of the first pouch extends beyond the support member, wherein the folding step includes folding the portion of the rim region around the support member.

16. The method of claim 11, further comprising: placing the second pouch containing the first pouch and the medical device on the support member after sealing the second pouch, wherein folding at least one of the first and second pouches around the support member is carried out after placing the second pouch on the support member.

17. The method of claim 11, wherein the support member is sized and shaped to support at least the second pouch, such that at least a portion of a rim region of the second pouch extends into or beyond a rim region of the support member, wherein the rim region of the support member is defined by at least one predetermined fold line.

18. The method of claim 11, wherein the support member is sized and shaped to support at least the second pouch, such that at least two opposing edge portions of the second pouch extends into or beyond a rim region of the support member, wherein the rim region of the support member is defined by at least one predetermined fold line.

19. The method of claims 11, wherein the folding step includes folding at least a first portion of the rim region of the support member along the predetermined fold line.

20. The method of claims 11, wherein the folding step includes folding at least two opposing edge portions of the support member along the predetermined fold line.

21. The method of claim 19, wherein the folding step further includes folding at least a second portion of the rim region of the support member along a predetermined fold line in an opposing direction with respect to the first portion of the rim region of the support member, wherein at least the second pouch is folded along with the support member to secure the second pouch relative to the support member.

22. The method of claim 20, wherein the folding step further includes folding at least two opposing edge portions of the support member along a predetermined fold line in an opposing direction with respect to the first portion of the rim region of the support member, wherein at least the second pouch is folded along with the support member in order to secure the second pouch relative to the support member.

23. The method of claim 11, further comprising: placing the packaging assembly in a secondary packaging, wherein the secondary packaging is sized and shaped to receive the packaging assembly, wherein inner dimensions of the secondary packaging correspond to outer dimensions of the packaging assembly to secure the packaging assembly against relative movement with respect to the secondary packaging.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The foregoing summary, as well as the following detailed description of preferred embodiments, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, reference is made to the drawings. The scope of the disclosure is not limited, however, to the specific embodiments disclosed in the drawings. In the drawings:

[0025] FIGS. 1A to 1H show views of a packaging assembly according to a first embodiment during different stages of a packaging method according to a first embodiment; and

[0026] FIGS. 2A to 2F show views of a packaging assembly according to a second embodiment during different stages of a packaging method according to a second embodiment.

DETAILED DESCRIPTION

[0027] Referring to FIGS. 1A to 1H, a packaging assembly according to a first embodiment and respective stages of a method of packaging a medical device are illustrated. A medical device 100, such as an intramedullary femoral part of an artificial hip joint, is provided in a first pouch 101. However, the medical device 100 may be any other bone implant, plate, or the like. The medical device 100 is inserted into the first pouch 101, which is then vacuumed and sealed along a seam 107 which allows the first pouch 101 to be opened by tearing or peeling the seam 107. The first pouch 101 has a substantially rectangular shape, with first and second opposing longitudinal edges 105, 106 and first and second opposing narrow edges 103, 104. It will be appreciated that the first pouch 101 may be closed at three of the edges before insertion of the medical device 100 by means of the seam 107, and the seam 107 is closed at the forth edge after insertion of the medical device 100 (here the edge 104). As shown in FIG. 1A, a support member 102 is provided. In this embodiment, the support member 102 is a sheet of plastics material, preferably PETG. Any other material fulfilling the requirements of sterile barrier components may be chosen. The support member 102 has a substantially rectangular shape, with first and second opposing longitudinal edges 110, 111 and first and second opposing narrow edges 108, 109. The length of the first pouch 101 is greater than the length of the support member 102, while the width of the first pouch 101 is substantially equal to the width of the support member 102. The first pouch 101, like any of the pouches described in the following, is preferably made of transparent plastic sheet or film. It will be appreciated that other materials, in particular nontransparent or opaque materials, can be chosen, such as nontransparent plastics or aluminum foil.

[0028] As indicated in FIGS. 1B and 1C by arrows, the rim region of the first pouch 101 adjacent the opposing narrow edges 103, 104 is folded around the respective narrow edges 108, 109 of the support member 102. As shown in FIG. 1C, the first pouch 101 is folded closely around the support member 102, i.e. folds of the first pouch 101 substantially coincide with the narrow edges 108, 109 of the support member 102. Thus, the first pouch 101 is held relative to the support member 102.

[0029] In order to hold the folded configuration of the first pouch 101 in place, the first pouch 101 along with the support member 102 is inserted into a second pouch 103 as indicated in FIG. 1D. The relatively stiff support member 102 may help to guide the first pouch 101 into the second pouch 103. Like the first pouch 101, the second pouch 103 is preferably made of transparent plastic sheet that is bonded along a seam 117 so as to allow the second pouch 103 to be opened by tearing or peeling the seam 117. The second pouch 103 has a substantially rectangular shape, with first and second opposing longitudinal edges 115, 116 and first and second opposing narrow edges 113, 114. An opening 112 is formed for insertion of the first pouch 101 along with the support member 102 and the medical device 100. The second pouch 103 is then vacuumed and sealed. The vacuum in the second pouch 103 improves fixation of the folded configuration of the first pouch 101 although the close fit in the second pouch 103 already holds the folded configuration of the first pouch 101 in place. The second pouch 103 has a size and shape suitable for receiving the first pouch 101.

[0030] The vacuumed and sealed second pouch 103 including the first pouch 101 with the medical device 100 and the support member 102 is shown in FIG. 1E. Arrows indicate that the narrow edges 113, 114 of the second pouch 103 are folded. The final configuration of the packaging assembly is shown FIG. 1F. The folded edges 113, 114 of the second pouch 103 do not have to be secured to the bottom surface of the second pouch 103. They will be held in place by a secondary packaging 118 in which the packaging assembly is inserted as shown in FIG. 1G. The secondary packaging 118 has an opening 119 for insertion of the packaging assembly. The secondary packaging 118 may be opened by a customer by means of a tearing flap 120. It will be appreciated that the secondary packaging 118 may be any suitable packaging with other insertion openings and opening mechanisms. However, the size and shape of the secondary packaging 118, in particular its inner dimensions, correspond to the size and shape of the packaging assembly, in particular its outer dimensions. The loose folded edges 113, 114 may also contribute to fixation of the packaging assembly within the secondary packaging 118 without further cushioning material or protective components.

[0031] Referring now to FIGS. 2A to 2F, a packaging assembly according to a second embodiment and respective stages of a method of packaging a medical device are illustrated. In contrast to the first embodiment of FIGS. 1 A to 1H, the packaging assembly of the second embodiment comprises a support member 202 that is disposed outside the sterile barrier, i.e. outside the pouches, as will be described in more detail below. The support member 202 is shown in an unassembled configuration in FIG. 2A. The support member 202 is formed of cardboard and has a substantially planar shape.

[0032] The support member 202 has a substantially rectangular shape, with first and second opposing longitudinal edges 210, 211 and first and second opposing narrow edges 208, 209. The support member 202 has a central body portion 240 that is bordered by predetermined fold lines 228, 229, 230, 231. The longitudinal fold lines 228, 229 define longitudinal portions 224, 225 of the rim region, while the transverse fold lines 230, 231 define transverse portions 226, 227 of the rim region. Corners 232, 233, 234, 235 are formed that may be regarded as belonging to both the longitudinal rim regions and the transverse rim regions. Connecting portions 236, 237, 238, 239 are formed by additional oblique fold lines. In this embodiment, the width of the support member 202 increases in a longitudinal direction towards the narrow edges 208, 209 (see FIG. 2B), which, however, is not absolutely necessary. The width may be constant along the entire length.

[0033] As shown in FIG. 2B, a medical device 200 is provided in a double sterile barrier formed of a vacuumed and sealed first, inner pouch 201 and a vacuumed and sealed second, outer pouch 203, similar to the first embodiment of FIGS. 1 A to 1H (in FIG. 2B the first pouch 201 is only indicated by its reference sign but not separately shown for the sake of simplicity). Vacuuming of the pouches 201, 203 is not absolutely necessary but advantageous for fixating the implant. The second pouch 203 has a substantially rectangular shape, with first and second opposing longitudinal edges 215, 216 and first and second opposing narrow edges 213, 214. The second pouch 203 extends beyond the narrow edges 208, 209 of the support member 202 in a longitudinal direction. However, a width of the second pouch 202 is smaller than a distance between the longitudinal fold lines 228, 229 of the support member 202. The first pouch 201 may extend beyond the fold lines 230, 231 or beyond the narrows edges 208, 209 of the support member 202 or may have a shorter length.

[0034] As illustrated in FIG. 2C, the support member 202 is folded along the fold lines 228, 229, 230, 231 in order secure the pouches 201, 203 containing the medical device 200 relative to the support member 202. In particular, in a first folding step, the longitudinal portions 224, 225 are folded towards a top surface of the support member 202, i.e. a surface carrying the pouches 201, 203, along the fold lines 228, 229 so that the folded portions 224, 225 extend partly over the pouches 201, 203. This creates a fixation of the pouches 201, 203 relative to the support member 202 in a transverse direction. Then, in a second folding step, the transverse portions 226, 227 of the support member 202 are folded in an opposing direction towards a bottom surface of the support member 202 in order to longitudinally secure the pouches 201, 203 relative to the support member 202. Due to its length, the second pouch 203 is folded together with the support member 202 in this second folding step. Also, the folded longitudinal portions 224, 225 engage the second pouch 203 so that the second pouch is easily folded along with the support member 202. As can be seen in the perspective view of FIG. 2C, the triangular connecting portions 236, 237, 238, 239 have the effect that the longitudinal portions 224, 225 do not abut against the top surface of the support member 202 but form a receptacle for the medical device 200. The transverse portions 226, 227 extend at an angle relative to the central portion 240 in the folded configuration.

[0035] The packaging assembly is then inserted into a secondary packaging 218, which may be in the form of a cardboard box. In order to visibly access the medical device 200 in the closed secondary packaging 218, the secondary packaging 218 has windows 220, 221 covered by a transparent plastic film 219. It will be appreciated that the windows 220, 221 can be omitted. The secondary packaging 218 is shown as a box that opens toward the top. It will be appreciated that any other suitable secondary packaging can be used. However, the size and shape of the secondary packaging 218, in particular its inner dimensions, correspond to the size and shape of the packaging assembly, in particular its outer dimensions. In particular the outer dimensions of the support member 202 secure the packaging assembly in the secondary packaging 218. The angled portions 226, 227 also contribute to fixation of the packaging assembly in a transverse direction towards the bottom within the secondary packaging 218 without further cushioning material, as can be seen in the side view of FIG. 2F. The angled portions 224, 225 prevent the packaging assembly from moving upwards within the secondary packaging 218. Further fixation is achieved by flaps 222, 223 extending from the lid of the secondary packaging 218.

[0036] It will be appreciated by those skilled in the art that changes may be made to the embodiments described above without departing from the inventive concept thereof. It should further be appreciated that structural features and methods associated with one of the embodiments can be incorporated into other embodiments. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but rather modifications are also covered within the scope of the present invention as defined by the appended claims.

[0037] The preferred embodiments will be described in the following numbered items 1 to 32. The invention is defined in the appended claims. [0038] 1. A packaging assembly for a medical device, comprising at least one pouch sealed so as to provide a sterile barrier between the environment and the medical device received in the at least one pouch, the packaging assembly further comprising at least one support member, wherein, in an assembled configuration, the at least one pouch and the support member are secured against movement relative to each other by the at least one pouch being folded around the support member. [0039] 2. The packaging assembly of item 1, wherein the at least one pouch comprises at least two pouches, which comprise a first pouch and a second pouch, wherein the first pouch is sized and shaped to receive the medical device and the second pouch is sized and shaped to receive the first pouch. [0040] 3. The packaging assembly of item 1 or 2, wherein the support member is sized and shaped to support the at least one pouch, preferably the first pouch, such that at least a portion of a rim region of the pouch extends beyond the support member, wherein said portion of the rim region is folded around the support member. [0041] 4. The packaging assembly of item 3, wherein the at least one pouch has a substantially rectangular shape, and said portion of the rim region of the pouch comprises at least one edge of the pouch, preferably at least two opposing edge portions of the pouch. [0042] 5. The packaging assembly of item 3 or 4, wherein a position of said folded portion of the rim region of the first pouch is secured by a vacuum in the second pouch. [0043] 6. The packaging assembly of any one of items 2 to 5, wherein at least a portion of a rim region of the second pouch, preferably at least two opposing edge portions of the second pouch, is folded around the support member with the folded first pouch. [0044] 7. The packaging assembly of any one of claims 3 to 6, wherein the support member is disposed inside the at least one pouch, or outside the at least one pouch, wherein the support member is preferably disposed outside the first pouch inside the second pouch. [0045] 8. The packaging assembly of item 1 or 2, wherein the support member is sized and shaped to support the at least one pouch, preferably the second pouch, such that at least a portion of a rim region of the at least one pouch, preferably the second pouch, preferably at least two opposing edge portions of the at least one pouch, preferably the second pouch, extends into or beyond a rim region of the support member, wherein the rim region of the support member is defined by at least one predetermined fold line. [0046] 9. The packaging assembly of item 8, wherein at least a first portion of the rim region of the support member, preferably at least two opposing edge portions of the support member, is folded along the predetermined fold line. [0047] 10. The packaging assembly of item 9, wherein, in an assembled configuration, the folded first portion of the rim region of the support member encloses an angle with a central portion of the support member in order to define a receptacle for the medical device. [0048] 11. The packaging assembly of item 9 or 10, wherein at least a second portion of the rim region of the support member, preferably at least two opposing edge portions of the support member, is folded along a predetermined fold line in an opposing direction with respect to the first portion of the rim region of the support member, wherein the at least one pouch is folded along with the support member in order to secure the at least one pouch relative to the support member. [0049] 12. The packaging assembly of item 11, wherein, in an assembled configuration, the folded second portion of the rim region encloses an angle with the central portion of the support member. [0050] 13. The packaging assembly of any one of items 8 to 12, wherein the support member is disposed outside the at least one pouch preferably outside the second pouch. [0051] 14. The packaging assembly of any one of items 1 to 13, wherein the support member has, at least in an unassembled configuration, a substantially planar body. [0052] 15. The packaging assembly of any one of items 1 to 14, wherein the at least one pouch is, preferably the first and second pouches are, configured to be vacuumed. [0053] 16. The packaging assembly of any one of items 1 to 15, wherein the support member comprises cardboard or a plastics material, preferably PETG. [0054] 17. A packaging system for a medical device, comprising the packaging assembly of any one of items 1 to 16 and a secondary packaging, wherein the secondary packaging is sized and shaped to receive the packaging assembly, wherein inner dimensions of the secondary packaging correspond to outer dimensions of the packaging assembly in order to secure the packaging assembly against relative movement with respect to the secondary packaging. [0055] 18. A method of packaging a medical device, the method comprising the steps of: [0056] a) inserting the medical device into at least one pouch and sealing the at least one pouch to provide a sterile barrier between the medical device and the environment, [0057] b) providing at least one support member, and [0058] c) folding the at least one pouch around the support member such that the at least one pouch and the support member are secured against movement relative to each other. [0059] 19. The method of item 18, wherein the at least one pouch is a first pouch, the method further comprising, either before or after carrying out steps b) and c), the step of inserting the first pouch containing the medical device into a second pouch. [0060] 20. The method of item 19, wherein folding the first pouch around the support member is performed before inserting the first pouch containing the medical device into the second pouch. [0061] 21. The method of item 20, further comprising the step of inserting the support member along with the first pouch containing the medical device into the second pouch. [0062] 22. The method of any one of items 18 to 21, wherein the support member is sized and shaped to support the at least one pouch such that at least a portion of a rim region of the at least one pouch, preferably at least two opposing edge portions of the at least one pouch, extends beyond the support member, wherein the folding step comprises folding said portion of the rim region around the support member. [0063] 23. The method of item 22, wherein a position of said folded portion of the rim region of the first pouch is secured by vacuuming the second pouch. [0064] 24. The method of any one of items 18 to 23, wherein the folding step comprises folding at least a portion of a rim region of the at least one pouch, preferably at least two opposing edge portions of the at least one pouch, around the support member with the folded first pouch. [0065] 25. The method of item 19, further comprising the step of placing the second pouch containing the first pouch and the medical device on the support member after sealing the second pouch, wherein folding at least one of the first and second pouches around the support member is carried out after placing the second pouch on the support member. [0066] 26. The method of item 18, 19 or 25, wherein the support member is sized and shaped to support the at least one pouch, such that at least a portion of a rim region of the at least one pouch, preferably at least two opposing edge portions of the pouch, extends into or beyond a rim region of the support member, wherein the rim region of the support member is defined by at least one predetermined fold line. [0067] 27. The method of any one of items 18, 19, 25 and 26, wherein the folding step comprises folding at least a first portion of the rim region of the support member, preferably at least two opposing edge portions of the support member, along the predetermined fold line. [0068] 28. The method of item 27, wherein the first portion of the rim region of the support member is folded such that it encloses an angle with a central portion of the support member in order to define a receptacle for the medical device. [0069] 29. The method of item 27 or 28, wherein the folding step further comprises folding at least a second portion of the rim region of the support member, preferably at least two opposing edge portions of the support member, along a predetermined fold line in an opposing direction with respect to the first portion of the rim region of the support member, wherein at least the second pouch is folded along with the support member in order to secure the second pouch relative to the support member. [0070] 30. The method of item 29, wherein the second portion of the rim region is folded such that it encloses an angle with the central portion of the support member. [0071] 31. The method of any one of items 18 to 30, further comprising the step of creating a vacuum in the at least one pouch. [0072] 32. The method of any one of items 18 to 31, further comprising the step of placing the packaging assembly in a secondary packaging, wherein the secondary packaging is sized and shaped to receive the packaging assembly, wherein inner dimensions of the secondary packaging correspond to outer dimensions of the packaging assembly in order to secure the packaging assembly against relative movement with respect to the secondary packaging.