Abstract
A packaging system includes a packaging unit and an article. The packaging unit includes a solid layer, a porous layer and a plastic layer with a cavity. The cavity is configured to receive and secure the article in an opening defined by the cavity that is flexible between a first and a second dimension. The packaging unit is fabricated by a 3D printing process. A tensioning device of a 3D printing machine tensions a feed filament during the 3D printing process.
Claims
1. A method for packaging an article, comprising the steps of: printing, by an additive manufacturing process, a packaging unit having an inner wall defining a cavity; and inserting the article into the cavity of the packaging unit such that the inner wall at least partially surrounds the article to secure the article.
2. The method of claim 1, wherein the article is a medical implant.
3. The method of claim 1, further comprising enclosing the article within the packaging unit such that the article is removable from the packaging unit without damaging the packaging unit.
4. The method of claim 1, wherein the printing step includes printing an elastomeric film.
5. The method of claim 1, wherein the printing step printing a cover on the packaging unit and over the inserted article.
6. The method of claim 5, wherein the step of printing a cover includes printing a cover that is hingedly attached to the packaging unit.
7. The method of claim 6, wherein the cover is inseparable from the packaging unit without fracturing at least one of the packaging unit and the cover.
8. The method of claim 6, further comprising a step of sealing the cavity by heating or utilizing a chemical polymerization process to fuse the packaging unit and the cover and form a sterilized barrier for the inserted article.
9. The method of claim 1, wherein the step of inserting the article includes flexing an opening of the cavity to a first dimension to insert the article into the cavity and allowing the opening to return to a second dimension to secure the article, wherein the second dimension is less than the first dimension, the first and second dimension being measured along a line extending across the opening.
10. A method for packaging an article, comprising the steps of: printing, by an additive manufacturing process, a packaging unit having a substantially solid first portion defining an exterior of the packaging unit, a porous second portion and a plastic third portion defining a cavity with a single opening defining a first dimension, the second portion being disposed between the first and third portions; and inserting the article into the cavity of the packaging unit such that third layer at least partially surrounds the article to secure the article, the article defining a second dimension greater than the first dimension, the first and second dimension being measured along a line extending across the opening.
11. The method of claim 10, wherein the printing step includes printing a monolithic packaging unit.
12. The method of claim 10, wherein the article is a medical implant.
13. The method of claim 10, further comprising enclosing the article within the packaging unit such that the article is removable from the packaging unit without damaging the packaging unit.
14. The method of claim 10, wherein the printing step includes printing an elastomeric film.
15. The method of claim 10, wherein the printing step includes printing a cover on the packaging unit and over the inserted article.
16. The method of claim 15, wherein the step of printing the cover includes printing a cover that is hingedly attached to the first portion.
17. The method of claim 15, wherein the cover is inseparable from the first portion without fracturing at least one of the first portion and the cover.
18. The method of claim 15, further comprising a step of sealing the cavity by heating or utilizing a chemical polymerization process to fuse the packaging unit and the cover and form a sterilized barrier for the inserted article.
19. The method of claim 10, wherein the step of inserting the article includes flexing the opening of the cavity to a third dimension to insert the article into the cavity and allowing the opening to return to the first dimension to secure the article, wherein the third dimension is equal to or greater than the second dimension, the third dimension being measured along the line extending across the opening.
20. A method for packaging an article, comprising the steps of: printing, by an additive manufacturing process, a monolithic packaging unit having a substantially solid first portion defining an exterior of the packaging unit, a porous second portion and a plastic third portion defining a cavity, the second portion being disposed between the first and third portions; and inserting the article into the cavity of the packaging unit such that the third portion at least partially surrounds the article to secure the article.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] A more complete appreciation of the subject matter of the present invention and the various advantages thereof may be realized by reference to the following detailed description, in which reference is made to the following accompanying drawings:
[0023] FIG. 1 is a perspective view of a packaging system in accordance with an embodiment;
[0024] FIG. 2 is a cross-sectional side view of a representation of the packaging system in FIG. 1 at a position along line A-A;
[0025] FIG. 3 is a cross-sectional side view of a packaging system in accordance with another embodiment;
[0026] FIG. 4 is a cross-sectional side view of a packaging system in accordance with another embodiment;
[0027] FIGS. 5A and 5B are perspective views of a tensioning device in accordance with another embodiment;
[0028] FIG. 6 is a cross-sectional side view of the tensioning device of FIGS. 5A and 5B;
[0029] FIG. 7 is a side view of a 3D printing assembly, including the tensioning device of FIGS. 5A and 5B, in accordance with another embodiment; and
[0030] FIG. 8 is a process flow diagram of a process for packaging an article in accordance with an embodiment.
DETAILED DESCRIPTION
[0031] Referring now to the drawings, as shown in FIG. 1, packaging system 100 includes packaging unit 112 and article 114. Packaging unit 112 includes solid exterior layer 116, intermediate porous layer 118, and inner layer 120 defining cavity 122. Packaging unit 112 may be an integral, i.e., monolithic, structure, such that exterior layer 116, porous layer 118, and inner layer 120 are inseparable from each other without fracture of any one of these layers. In the example shown, packaging unit 112 is in the form of a cube, although the packaging unit may be in other forms that retains article 114. Packaging unit 112 may be but is not limited to being made of materials such as plastics, which may be but are not limited to being polyamides, alumides, acrylonitrile butadiene styrene (“ABS”), TPU, medical-grade TPU, etc. In the preferred arrangement shown, packaging unit 112 is made of medical-grade TPU.
[0032] Referring now to FIG. 2, cavity 122 of inner layer 120 of packaging system 100 includes opening 124 defined by first dimension D1. Inner layer 120, which in this example is spherical in shape, separates intermediate porous layer 118 from cavity 122. Article 114 is defined by second dimension D2, which is larger than first dimension D1. In the example shown, dimensions D1 and D2 define dimensions of diameters of the respective opening 124 and article 114. As best seen in FIG. 2, except at opening 124, inner layer 120 completely encloses article 114 when article 114 is placed in cavity 122. Consequently, inner layer 120 provides full surface support and insulation for article 114. Due to the elasticity of inner layer 120, opening 124 flexes and expands such that article 114 may be pushed through opening 124 into cavity 122 as shown in FIG. 2. In this manner, article 114 may be securely retained in cavity 122 and prevented from be ejected due to gravity or other forces experienced by packaging unit 112 during shipping. Article 114 may be removed from cavity 122 by manual extraction when required.
[0033] Exterior layer 116 and intermediate porous layer 118 provide external puncture protection and internal impact resistance, respectively, for article 114. The hardness of exterior layer 116 may be controlled by altering the density of this layer. For example, if an additive manufacturing process such as 3D printing is used to create packaging system 100, a dense exterior layer 116 may be printed to provide a relatively solid external barrier. The porosity of porous layer 118 may be adjusted such that the porous layer acts as a resilient member to provide a sufficient level of shock absorption and thermal insulation for article 114. Porous layer 118 may be, but is not limited to being, in the form of a honeycomb structure, a lattice structure, a truss structure, a bubble structure and a unit cell structure as disclosed in U.S. Patent Publication No. 2015/0258735, U.S. Pat. Nos. 8,728,387 and 9,180,010, the disclosures of all of which are hereby incorporated by reference herein as it is fully set forth herein. Inner layer 120 may be substantially solid, i.e., substantially non-porous, and substantially elastic.
[0034] As shown in FIG. 3, packaging system 200 is substantially the same as packaging system 100 with the notable exception that cavity 224 and article 214 are rectangularly shaped in this embodiment. Like elements for packaging system 200 are referenced with similar reference numerals within the 200-series. In this example, first dimension D1 defining opening 224 of cavity 222 is smaller than second dimension D2 of rectangularly shaped article 214. Inner layer 220 may be elastically deformed by pushing article 214 through opening 224 to secure the article within cavity 222. While circular and rectangular articles and corresponding inner layers of packaging units are illustrated in packaging systems 100 and 200, respectively, articles and corresponding inner layers of packaging units with other shapes may be used so long as the article is retained and protected by the packaging unit.
[0035] As shown in FIG. 4, packaging system 300, which is also substantially similar to packaging system 100 with the notable exception that packaging system 300 includes self-locking lid 326. Like elements for packaging system 300 are referenced with similar reference numerals within the 300-series. Lid 326 includes hinged end 330 and locking end 328 on an end opposite the hinged end. After article 314 is secured in cavity 322, lid 326 may be locked in place by overlapping locked end 328 and rim 329 of packaging unit 312 which extends around an upper edge of exterior layer 316. In alternative arrangements, the locking end may include undercuts, snap-fit elements, grooves, slots, etc., to interface with corresponding features of the rim of the packaging unit. As shown in this example, packaging unit 312 completely covers and insulates article 314 when lid 326 is placed over cavity 322 and is secured to rim 329. As further shown, lid 326 may include solid exterior layer 334 over the exposed surfaces of the lid, inner layer 332 over the surface of the lid that contacts and interfaces with inner layer 320, and, in some arrangements, an intermediate porous layer (not shown) between the exterior layer and the inner layer. Exterior layer 334 may be made of the same material and have the same flexibility as exterior layers 116, 216, 316, the intermediate porous layer may be made of the same material as intermediate porous layer 118, 218, 318, and inner layer 332 may be made of the same material as inner layer 320. As in this example, lid 326 may be made of the same material, although in other arrangements, the various layers may be made of different materials than the other layers.
[0036] Packaging units, such as packaging units 112, 212, 312, may be fabricated using additive manufacturing techniques, such as but not limited to stereolithography (SLA), fused deposition modeling (FDM), continuous liquid interface production (CLIP), selective laser sintering (SLS), selective laser melting (SLM), electron beam melting (EBM), and other 3D printing technologies known to those of skill in the art. Medical-grade TPU and similar materials that provide a sterile packaging unit requiring no additional sterile barriers are available for use for the safe storage shipping and handling of articles such as medical devices as stand-alone materials.
[0037] Referring now to FIGS. 5A and 5B, tensioning device 400 is a system for adjusting the tension of highly elastic filaments, such as medical-grade TPU, used with a 3D printing machine, e.g., the MakerBot Replicator® 2X. Tensioning device 400 includes frame 402 having two parallel arms 426, 428 each attached at one end to respective flanges 430, 432 that extend toward each other to define inlet port 404 and attached at their other ends to base 410 defining outlet port 406. As shown, feed filament 408 is received through both inlet port 404 and outlet port 406. Feed filament segment 422 of feed filament 408 may be connected to a feed spool (not shown), such as that used in the MakerBot Replicator® 2X, or any other filament feeding elements. Base 410 of frame 402 may be attached to printing head portion 424, as shown in FIG. 6, of a 3D printer (not shown).
[0038] As further shown in FIGS. 5A, 5B and 6, tensioning device 400 includes band 412 around frame 402. Band 412 includes projection 416 configured to engage with corresponding groove 414 on frame 402. Rotating band 412 in a first direction as indicated by directional arrow 418 will progressively engage projection 416 with groove 414, which will lead to narrowing of inlet port 404. In this example, band 412 is configured to apply a discrete amount of tension as best shown in FIG. 5B. As inlet port 404 is narrowed, it progressively contacts filament 422 thereby applying a compressive force between inlet port 404 and filament 422 which in turn creates tension in feed filament 408 between inlet port 404 and print head 424. In this manner, rotating band 412 alters the tension on feed filament 408 between inlet port 404 and printing head portion 424 and thereby allows for tension adjustment of feed filament 408 as it enters the printing head. Other configuration and processes to apply a discrete or a progressive amount of tension to the filament may also be used.
[0039] As shown in FIG. 7, 3D printing assembly 500 includes a 3D printing machine and tensioning device 400. Feed filament 408 from a supply element such as a feed spool (not shown) is attached to tensioning device 400. The feed filament may be formed by converting a resin of the filament material, such as medical-grade TPU, into a molten state and then extruding the molten material into the feed filament. Base 410 of tensioning device 400 is mounted on a head portion 424 of printing head 502 of a 3D printing machine. The 3D printing machine includes frame 506 and build platform 504. Feed filament tension may be further adjusted depending on the feed filament material being used by rotating band 412 on tensioning device 400. In this manner, proper feed filament tension entering the printing head is maintained during printing to avoid jamming gears in the printing head. While a 3D printing assembly with tensioning device 400 is shown, other additive manufacturing techniques may also utilize the tensioning device.
[0040] As shown in FIG. 8, via process 600, a monolithic multi-layered and multi-functional packaging unit with a cavity as disclosed herein is fabricated by 3D printing. In step 610, suitable feed filament material, e.g., elastomeric material that provides rigidity, shock absorption and sterile protection, such as medical-grade TPU, is loaded on a feed element such as a feed spool of a 3D printing assembly, such as but not limited to 3D printing assembly 500. In step 620, based on the material selection and the 3D printer requirements, a tensioning device, such as but not limited to tensioning device 400, located between the feed element and the printing head is suitably calibrated for the proper feed filament tension at the printing head. In step 630, the 3D printer with the calibrated tensioning device is used to generate the multi-layered packaging unit, such as but not limited to packaging units 112, 212, 312, having a cavity with an opening defining a first dimension. In step 700, an article, such as articles 114, 214, 314, defining a second dimension which is less than the first dimension is inserted through the opening and into the cavity such that the article is firmly secured within the packaging unit. In step 800, the cavity is sealed by placing a lid over the cavity and heating or utilizing a chemical polymerization process known to those skilled in the art thereby creating a sterile barrier to protect the packaged article. Alternative arrangements of this process may include additional steps of forming a packaging unit with a self-locking lid, and closing this lid after inserting the article to fully enclose the article on all sides While the present disclosure generally discusses articles which are medical devices, other articles may also be retained and protected by packaging units similar to those described in the present disclosure.
[0041] Furthermore, although the invention disclosed herein has been described with reference to particular features, it is to be understood that these features are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications, including changes in the sizes of the various features described herein, may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention. In this regard, the present invention encompasses numerous additional features in addition to those specific features set forth in the paragraphs below. Moreover, the foregoing disclosure should be taken by way of illustration rather than by way of limitation as the present invention is defined in the examples of the numbered paragraphs, which describe features in accordance with various embodiments of the invention, set forth in the paragraphs below.
