CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to United States Utility Application No. 14/019,649, filed on September 6, 2013, and the benefit of United States Provisional Patent Application No. 61 /698,271 filed on September 7, 2012. The entire disclosure of the above application is incorporated herein by reference. FIELD

[0002] The present disclosure relates to a modular instrument kit, such as for surgical instruments.

BACKGROUND

[0003] This section provides background information related to the present disclosure which is not necessarily prior art.

[0004] Surgical instruments, such as forceps, scissors, trocars, picks, sponges, elevators, speculas, mallets, suction tubes, and various other instruments, particularly instruments for ear, nose, and throat (ENT) procedures, are often organized and stored in sterilized trays or containers. While the containers sometimes include a variety of instrument mounts, the containers often lack sufficient mounts and features that allow the instruments to be sufficiently organized in an order that will maximize storage efficiency and access during surgical procedures. For example, ENT instruments are often merely seated within the storage container on a bottom surface thereof in an unorganized fashion. Therefore, a container with enhanced surgical instrument mounts, particularly for ENT instruments, sufficient to arrange and present the instruments for use during surgery in a more efficient and accessible manner would be desirable. SUMMARY

[0005] This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

[0006] The present teachings provide for a modular instrument kit including a container configured to receive a plurality of instrument trays therein. At least one tray includes a planar base configured to support the at least one tray upright on a planar surface. A flange is configured to hang the tray from a sidewall of the container. An instrument support is configured to support a plurality of surgical instruments and couple the plurality of surgical instruments to the at least one tray.

[0007] The present teachings further provide for a modular instrument kit configured to receive a plurality of instrument trays therein. At least one of the trays includes a planar base, a rear wall orientated at an angle relative to the base, a flange, and an instrument support configured to support a plurality of surgical instruments. The at least one tray is configured to be seated on a generally planar surface in a free-standing position to support the plurality of surgical instruments such that tips or handles of the instruments extend upward so as to be readily viewable in an operating room. The at least one tray is configured to be hung from a sidewall of a container of the kit, or on any other surface in an operating room such as an operating room table, with the rear wall generally flush against a first surface of the sidewall and the flange in contact with a second surface of the sidewall that is generally opposite to the first surface.

[0008] The preset teachings also provide for a modular instrument kit including a container, a first tray, and a second tray. The first tray is configured to be seated within the container and includes a plurality of instrument mounts. The second tray includes a planar base configured to support the second tray upright on a planar surface, a flange configured to hang the second tray from a sidewall of the container, and an instrument support configured to support a plurality of surgical instruments and couple the plurality of surgical instruments to the second tray.

[0009] Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

[0010] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

[0011] Figure 1 is a perspective view of a modular instrument kit according to the present teachings;

[0012] Figure 2 is an exploded view of the modular instrument kit of

Figure 1 ;

[0013] Figure 3 is another exploded view of the modular instrument kit of Figure 1 ;

[0014] Figure 4 illustrates various instrument trays and racks of the modular instrument kit;

[0015] Figure 5 is a perspective view of a container of the modular instrument kit;

[0016] Figure 6 is another perspective view of the container with a first instrument tray seated therein;

[0017] Figure 7 illustrates the first instrument tray of Figure 6 with a pair of tray inserts separated therefrom;

[0018] Figure 8 is a perspective view of the container with a second instrument tray seated over and covering the first instrument tray;

[0019] Figure 9 is a top view of the second instrument tray seated in the container;

[0020] Figure 10 illustrates the second instrument tray separated from the container;

[0021] Figure 1 1 illustrates a first rack being removed from cooperation with the second instrument tray;

[0022] Figure 12 is a perspective view of the first rack of the modular instrument kit;

[0023] Figure 13 illustrates the first rack separated from the modular instrument kit and seated upright on a flat surface; [0024] Figure 14 is similar to Figure 13 and includes a plurality of surgical instruments mounted to the first rack;

[0025] Figure 15 illustrates the first rack coupled to a sidewall of the container, as well as the first tray and a second rack seated spaced apart from the container;

[0026] Figure 16 is similar to Figure 15, but with both the first rack and the second rack mounted to the sidewall of the container;

[0027] Figure 17 is a side view of the first rack coupled to the sidewall of the container;

[0028] Figure 18 is another view of the first rack coupled to the sidewall of the container;

[0029] Figure 19 illustrates both the first rack and the second rack coupled to the sidewall of the container on opposite sides of the sidewall;

[0030] Figure 20 is a top view of the first and second racks coupled to opposite sides of the sidewall of the container; and

[0031] Figure 21 is a general side view of the container illustrating the first and second racks mounted to the sidewall on opposite sides of the sidewall.

[0032] Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

[0033] Example embodiments will now be described more fully with reference to the accompanying drawings.

[0034] With initial reference to Figures 1 -3, a modular instrument kit according to the present teachings is generally illustrated at reference numeral 10. The modular instrument kit 10 includes a container 12 with four sidewalls 14A-14D and a lid 16 removably mounted to the container 12. The lid 16 includes a first lock 18A and a second lock 18B. The first and second locks 18A and 18B are configured to couple with the container 12 to selectively secure the lid 16 to the container 12. The first and second locks 18A and 18B can be any locking device or feature suitable to secure the lid 16 to the container 12.

[0035] The container 12 can be made of any suitable material sufficient for the storage of medical instruments therein and for use in an operating room. For example, the container 12 can be made of a suitable material that can be sterilized in an autoclave, such as aluminum. The lid 16 can be made of any suitable material also sufficient to be sterilized in an autoclave, for example, such as a suitable polymer.

[0036] With continued reference to Figures 1 -3 and additional reference to Figure 4, the modular instrument kit 10 further includes a first tray 20, a second tray 22, a first instrument rack 24, and a second instrument rack 26. Each of the first tray 20, the second tray 22, the first instrument rack 24, and the second instrument rack 26, can be removably seated and housed within a storage chamber 28 defined by the sidewalls 14A-14D of the container 12. The container 12, the first tray 20, the second tray 22, the first rack 24, and the second rack 26, will now each be individually described in further detail.

[0037] With additional reference to Figure 5, the container 12 includes a base 30, which is generally planar. The sidewalls 14A-14D extend from the base 30 to define the storage chamber 28. The first and second sidewalls 14A and 14B are spaced apart from one another on opposite sides of the base 30 and generally extend parallel to one another. The second and third sidewalls 14C and 14D extend generally parallel to one another and perpendicular to the first and second sidewalls 14A and 14B. The third and fourth sidewalls 14C and 14D are at opposite ends of each of the first and second sidewalls 14A and 14B. The sidewalls 14A-14D can be modular portions fastened together in any suitable manner, or may be unitary, as illustrated in Figure 5 for example.

[0038] Seated on and fastened to the base 30 is an instrument storage pad 32. The instrument storage pad 32 is generally planar and made of any suitable material to retain instruments thereon, such as silicone. The instrument storage pad 32 may have raised sidewalls 34A and 34B at opposite ends thereof to help retain instruments on the storage pad 32. The instrument storage pad 32 is particularly suitable for retaining larger instruments thereon, such as trocars, suture carriers, and forceps. The instrument storage pad 32 can be mounted to the base 30 in any suitable manner to prevent the storage pad 32 from becoming disconnected from the base 30. For example, the base 30 can include any suitable retention feature or adhesive sufficient to mate with the instrument storage pad 32 to retain the instrument storage pad 32 against the base 30. [0039] The base 30 may further include a plurality of base instrument retention members 36 on opposite sides of the instrument storage pad 32. The base instrument retention members 36 are generally sufficient to clamp or secure a portion of a surgical instrument thereto to prevent the instruments from moving within the storage chamber 28, particularly during transportation of the modular instrument kit 10. To facilitate placement of instruments at the base 30 and in connection with the base instrument retention members 36, the base 30 can include instrument outlines 38 drawn thereon or etched within the base 30. The instrument outlines 38 can be an outline of any instrument suitable to be mounted at the base 30.

[0040] With continued reference to Figure 5, the first sidewall 14A includes a first retention flange 40A and a second retention flange 40B. The second sidewall 14B includes a third retention flange 40C opposite to the first retention flange 40A and a fourth retention flange 40D opposite to the second retention flange 40B (only fasteners of the third and fourth retention flanges 40C and 40D are viable; the third and fourth retention flanges 40C and 40D are substantially similar to the first and second retention flanges 40A and 40B respectively).

[0041] With respect to the first retention flange 40A, it generally includes a first portion 42A which extends from the first sidewall 14A generally parallel to the base 30, and a second portion 44A that extends from the first portion 42A. The second portion 44A extends generally perpendicular to the first portion 42A, and thus the second portion 44A is also generally perpendicular to the base 30. The second portion 44A extends from a side of the first portion 42A that is generally opposite to the second retention flange 40B. The second retention flange 40B is substantially similar to the first retention flange 40A. The second portion 44B of the second retention flange 40B extends from a side of the second retention flange 40B that is opposite to the first retention flange 40A. The third retention flange 40C, which extends from the second sidewall 14B in a position generally opposite to the first retention flange 40A, is configured and arranged substantially similar to the first retention flange 40A. The fourth retention flange 40D, which extends from the second sidewall 14B opposite to the second retention flange 40B is arranged generally similar to the second retention flange 40B. The first, second, third, and fourth retention flanges 40A- 40D are spaced apart from the base 30 to support the first tray 20 within the storage chamber 28 spaced apart from and suspended above the base 30, as further described herein.

[0042] Extending from the first sidewall 14A between the first retention flange 40A and the third sidewall 14C is a first retention pin 46A. Extending also from the first sidewall 14A, but between the second retention flange 40B and the fourth sidewall 14D, is a second retention pin 46B. Extending from the second sidewall 14B opposite to the first retention pin 46A is a third retention pin 46C. Extending from the second sidewall 14B opposite to the second retention pin 46B is a fourth retention pin 46D. Each of the first, second, third, and fourth retention pins 46A-46D extend to within the storage chamber 28 to support the second tray 22 within the storage chamber 28 spaced apart from both the base 30 and the first tray 20, as further described herein. The sidewalls 14A-14D can further include a plurality of openings 48 defined therein that extend therethrough to provide the storage chamber 28 with suitable ventilation. As illustrated throughout the figures, the container 12, the first tray 20, the second tray 22, the first rack 24, the second rack 26, and the lid 16 all include similar openings to facilitate autoclaving of the modular instrument kit 10 to sterilize it.

[0043] With additional reference to Figure 6, the first tray 20 is illustrated seated within the storage chamber 28 on each of the first, second, third, and fourth retention flanges 40A-40D. With continued reference to Figure 6 and additional reference to Figure 7, the first tray 20 generally includes a first tray sidewall 50 extending about a perimeter of the first tray 20. Extending across the first tray 20 to generally divide the first tray 20 in half, is a first tray divider 52. The first tray divider 52 can be any suitable feature or device to divide a first tray 20 generally in half, such as a nylon divider wall. The first tray divider 52 can be secured to the first tray 20 in any suitable manner, such as with a suitable adhesive or a suitable mechanical connection.

[0044] The first tray 20 includes a pair of first tray inserts 54A and 54B.

Each of the first tray inserts 54A and 54B include a base 56A and 56B respectively with suitable instrument retention members 58 extending therefrom. The instrument retention members 58 can be any suitable devices or features to retain surgical instruments thereto, such as ENT instruments. For example, the members 58 can be made of a flexible and resilient autoclavable nylon material configured to cooperate with or clamp onto the surgical instruments to retain the surgical instruments to the first and second tray inserts 54A and 54B. Each base 56A and 56B can include instrument outlines 60A and 60B respectively to facilitate positioning of the instruments on the bases 56A and 56B. Any other suitable designation or identifier representing one or more particular surgical instruments may also be included on the bases 56A and 56B to further facilitate placement of the instruments, such as the designations "L," "M," "S," which designate large, medium, and small respectively. The first tray inserts 54A and 54B can further include handles 62 extending from the bases 56A and 56B respectively to facilitate removal of the first tray inserts 54A and 54B from the first tray 20.

[0045] With additional reference to Figure 8, the second tray 22 is illustrated seated within the storage chamber 28 above the first tray 20 and spaced apart from the first tray 20. Specifically, the second tray 22 is seated on each of the first, second, third, and fourth retention pins 46A-46D to suspend the second tray 22 above the first tray 20. With continued reference to Figure 8 and additional reference to Figures 9-1 1 , the second tray 22 includes a base 70, which is generally planar and sized to extend from the first sidewall 14A to the second sidewall 14B of the container 12. Extending generally vertically from the base 70 are a plurality of instrument retention features 72 arranged and configured to retain any suitable surgical instrument, such as ENT surgical instruments, to the second tray 22. Instrument outlines 74 can also be included on the base 70 to facilitate placement of the surgical instruments thereon.

[0046] As illustrated in Figure 10 for example, the second tray 22 further includes a first flange 76A extending downward from the base 70 generally along the length of the tray 22. A second flange 76B extends downward from the base 70 from a side of the second tray 22 generally opposite to the first flange 76A, which can be seen in Figures 2, 4, 9, and 10, for example. Each of the first flange 76A and the second flange 76B define recesses 78 at opposite ends thereof. The recesses 78 are generally sized and arranged to individually cooperate with a different one of a first, second, third, and fourth retention pins 46A-46D to support the second tray 22 within the storage chamber 28 above the first tray 20.

[0047] The second tray 22 further includes first and second handles 80A and 80B respectively at opposite ends of the second tray 22 to facilitate insertion and withdrawal of the second tray 22 within the storage chamber 28. The first handle 80A defines a first opening 82A and the second handle 80B defines a second opening 82B to facilitate grasping of the first handle 80A and the second handle 80B respectively.

[0048] The base 70 defines a first aperture 84A proximate to the first handle 80A and a second aperture 84B proximate to the second handle 80B. As further described herein, the first aperture 84A is configured to receive the first instrument rack 24 and the second aperture 84B is configured to receive the second instrument rack 26. Proximate to the first aperture 84A and the second aperture 84B, the base 70 defines a plurality of receptacles 86A for receiving portions of the first and second instrument racks 24 and 26 to retain the instrument racks 24 and 26 substantially planar to the base 70. Proximate to each of the first handle 80A and the second handle 80B, the base 70 defines receptacles 86B, which receive an additional portion of the first and second racks 24 and 26 to further retain the first and second racks 24 and 26 to the second tray 22 as further described herein.

[0049] With additional reference to Figures 12 and 13, the first instrument rack 24 will be described in detail. The first instrument rack 24 includes a rack base 102, which is generally planar. Extending from a first side of the rack base 102 is a base flange 104. The base flange 104 extends from the rack base 102 generally at an angle. Extending from a second side of the rack base 102 that is opposite to the first side, is an intermediate rack portion 106, which also extends from the rack base 102 at an angle. Extending from a side of the intermediate rack portion 106 opposite of the rack base 102 is a rack rear wall 108. The rack rear wall 108 extends from the intermediate rack portion 106 at an angle such that both the rack rear wall 1 08 and the rack base 102 generally oppose one another.

[0050] The first instrument rack 24 further includes an instrument support base 1 10. The instrument support base 1 10 is proximate to, or extends from, the rack rear wall 108. The instrument support base 1 10 is further supported by a first post 1 12A and a second post 1 12B, which are arranged on opposite sides of the base flange 104 and connected to a flange support 1 14 to which the base flange 104 is mounted to. The instrument support base 1 10 extends between the first post 1 12A and the second post 1 12B.

[0051] Extending from a first side of the instrument support base 1 10 is a first rack flange 120A, which extends over the first post 1 12A. Similarly, the second rack flange 120B extends from a side of the instrument support base 1 10 that is opposite to the first rack flange 120A. The second rack flange 120B extends over the second post 1 12B. Each of the first rack flange 120A and the second rack flange 120B include a proximal portion 124 and a distal portion 126. The proximal portion 124 is between the instrument support base 1 10 and the distal portion 126. The proximal portion 124 is mounted directly to either the first post 1 12A or the second post 1 12B and is generally wider than the distal portion 126.

[0052] Mounted to the first post 1 12A is a first coupling member 130A, and mounted to the second post 1 12B is a second coupling member 130B. Each of the first and second coupling members 130A and 130B include a first portion 132A and 132B (see Figures 17 and 18 for example) respectively that extends generally parallel to the distal portions 126 of the first and second rack flanges 120A. Extending from each of the first portion 132A and 132B are second portions 134A and 134B respectively. The second portions 134A and 134B extend generally co-planar with the rack base 102, and thus further support the first instrument rack 24 in an upright position when seated on a flat surface at a first location. The first and second coupling members 130A and 130B are generally sized and shaped to be received within the receptacles 86B of the second tray 22, and the first and second rack flanges 120A and 120B are sized and shaped to be received within the receptacles 86A of the second tray 22 to couple the first instrument rack 24 to the second tray 22 at the first aperture 84A such that the rack base 102, the intermediate rack portion 106, and at least the rack rear wall 108 extend through the first aperture 84A, with the remainder of the first instrument rack 24 being supported on the base 70 of the second tray 22. [0053] The first instrument rack 24 further includes a first instrument support 140 and a second instrument support 142. The first instrument support 140 extends from the instrument support base 1 10 generally towards the base flange 104. The second instrument support 142 extends from the instrument support base 1 10 in a direction generally opposite to the direction in which the first and second rack flanges 120A and 120B extend. The first and second instrument supports 140 and 142 extend from the instrument support base 1 10 at generally opposite ends of the instrument support base 1 10. The first instrument support 140 includes a plurality of teeth 144 that are spaced apart to define slots 146 therebetween. Similarly, the second instrument support 142 includes a plurality of teeth 148, which define a plurality of slots 150 therebetween. The teeth 144 of the first instrument support 140 are somewhat narrower than the teeth 148 of the second instrument support 142, and thus the slots 146 are generally wider than the slots 150. Furthermore, the teeth 144 include a tip portion 152 and the teeth 148 include a tip portion 146, which are each generally wider than the remainder of the teeth 144 and 148 respectively associated therewith. The tips 152 and 156 are operable to facilitate retention of instruments in the slots 146 and 150.

[0054] The first instrument support 140 and the second instrument support 142 can be made of any suitable autoclavable material that is generally flexible and resilient to retain instruments between the teeth 144 and 148 respectively. For example, the first instrument support 140 and the second instrument support 142 can be made of a suitable flexible silicone. The first instrument support 140 and the second instrument support 142 can each be secured to the instrument support base 1 10 in any suitable manner, such as with a suitable adhesive or mechanical connection. The second instrument rack 26 is substantially similar, and may be identical to, the first instrument rack 24, and thus the description of the first instrument rack 24 is also sufficient to describe the second instrument rack 26.

[0055] With reference to Figures 13 and 14 for example, the first instrument rack 24 can be self-supported in an upright position when the rack base 102 is seated on a planar surface at a first location. As illustrated in Figure 14, when seated on a planar surface, the first instrument rack 24 will support instruments in a generally upright position, such as forceps 160. As illustrated in Figures 14-16, the forceps 160 are arranged such that a handle 162 of each of the forceps 160 is seated against, or proximate to, base flange 104. The tips 164 are thus arranged such that they extend generally upright from the second instrument support 142. Portions of the forceps 160 between the handles 162 and the tips 164 are arranged within the slots 146 and 150 of the first and second instrument supports 140 and 142 respectively to retain the forceps 160 in cooperation with the first instrument rack 24. Although the instruments are illustrated as forceps 160, any suitable instrument, particularly an ENT instrument, can be coupled to the first instrument rack 24. Furthermore, the orientation of the instruments can be generally reversed such that the handles 162 are upright and extend generally vertically, and the tips 164 are seated against, or proximate to, base flange 104.

[0056] Supporting the tips 164 upright as illustrated in Figure 14 is advantageous for a number of reasons. For example, the surgeon or other operating room personnel can easily view the tips 164 and thus distinguish between different types of, for example, forceps 160. Because the handles 162 of the different forceps 160 are identical or similar, it would be difficult to distinguish between the different forceps 160 if the tips 164 were not clearly visible. The visibility of the tips 164 is enhanced when in the upright position of Figure 14 because the unidirectional lights typically used in an operating room will clearly illuminate the tips 164, and by arranging the tips 164 upright apart from other structural features of the first instrument rack 24, shadows caused by the unidirectional operating room lights will be diminished, and thus the vision of the surgeon or other operating room personnel will not be obstructed and he or she will be able to easily select the desired forceps 160. To further facilitate selection of the desired forceps 160, the instrument support base 1 10 includes a plurality of visual indicators, such as the numerals "1 " through "12" aligned with each of the slots 146 and 150. Therefore, if a particular surgical procedure calls for an instrument arranged in slots 146 and 150 designated with number "1 ," the surgeon or appropriate operating room personnel will be able to clearly identify position number "1 " and select the forceps 160 seated at that position. [0057] With additional reference to Figures 15-21 , the first instrument rack 24 and/or the second instrument rack 26 can be coupled to any of the sidewalls 14A-14D of the container 12 at a second location, particularly the longer sidewalls 14A and 14B. Coupling the first and/or second instrument racks 24 and 26 to the container 12 is advantageous for a plurality of different reasons. For example, suspending the first and/or second instrument racks 24 and 26 on the container 12 will free valuable operating room space and suspend the instruments, such as the forceps 160, above other surgical instruments, thereby making it easier to select the desired forceps 160 and eliminate shadows that may be caused by the unidirectional operating room lights when the lights contact surrounding instrumentation and/or equipment. The first and/or second instrument racks 24 and 26 can be coupled to any vertical or generally vertical surface in the same way that the racks 24 and 26 are coupled to the sidewalls 14A-14D of the container 12. For example, the first and/or second instrument racks 24 and 26 can be coupled to an operating room table. Therefore, the first and/or the second instrument racks 24 and 26 can be generally integral with the operating room and other devices of the operating room to facilitate accesses to and use of instruments seated on or in the instrument racks 24 and 26, and thus increase the efficiency and overall ease of the surgical procedure.

[0058] The first and second instrument racks 24 arrange the forceps

160 at generally a 45 degree angle, which further facilitates viewing of the tips 164 and the ability to distinguish between the tips 164. Coupling the first and second instrument racks 24 and 26 to the container sidewalls 14A and 14B further protects the forceps 160 from being damaged by positioning the tips 164 spaced apart from surrounding equipment, which could damage the tips 164 should the equipment accidentally come into contact with the tips 164.

[0059] As illustrated in Figures 17 and 18, for example, the first and second instrument racks 24 are arranged such that the rack rear wall 108 contacts the desired sidewall 14A-14D and is generally flush with the particular sidewall 14A-14D. The first and second rack flanges 120A and 120B extend over the particular sidewall 14A-14D such that the distal portion 126 contacts a surface of the sidewall 14A-14D that is opposite to the surface that the rack rear wall 108 abuts. Therefore, the particular sidewall 14A-14D is arranged and wedged between the rack rear wall 108 and the first and second rack flanges 120A and 120B. The first and second rack flanges 1 20A and 120B together with the rack rear wall 108 and the rack base 102 generally provide a coupling mechanism. As illustrated in Figure 19, the first and second instrument racks 24 and 26 can be coupled to opposite sides of any of the sidewalls 14A-14D.

[0060] The modular instrument kit 10 can be configured to present instruments to the surgeon or other suitable operating room personnel in the anticipated order of use during a particular surgical procedure. For example, instruments that are likely to be used early in the surgical procedure, such as the forceps 160, can be arranged proximate to the lid 16 such that upon removal of the lid 16 the instruments may be accessed first. Instruments that are likely to be used later during the surgical procedure, or instruments that may be optional or less likely to be used at all, may be arranged deep within the container 12, such as on the instrument storage pad 32. Instrumentation that is likely to be used during the midpoint of the surgical procedure may be arranged on either the second tray 22 or the first tray 20 with instrumentation to be used earlier during the procedure mounted to the second tray 22, while instrumentation likely to be used later during the procedure can be mounted to the first tray 20.

[0061] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.