Abstract:
A plurality of containers and system and method for making a plurality of different containers from a minimum number of molds, with some inserts, provides multiple container sizes from the same mold utilizing inserts to reduce the size of the mold. In one embodiment, to accommodate various lid designs, a rim is connected to the upper edge of the container. The rim can be formed in various configurations from a single mold using mold inserts. The various rim configurations accommodate different lids. Providing the mold inserts on the rim (which is a very shallow part) is much simpler than providing such inserts on the container itself.

Description:
[0001]    This application claims priority to U.S. Provisional Application Ser. Nos. 60/982,581, filed Oct. 25, 2007 and 61/022,178, filed Jan. 18, 2008. 
     
    
     BACKGROUND 
       [0002]    The present invention relates generally to containers with removable lids, in particular, containers and lids that are particularly useful for disposing of medical products. 
       SUMMARY 
       [0003]    The present invention provides a plurality of various individually inventive containers, which are described in detail below and shown in the drawings. Additionally, the present invention provides an inventive group or system of containers and system and method for making a plurality of different containers from a minimum number of molds, with some inserts. Generally, multiple container sizes can be provided from the same mold utilizing inserts to reduce the size of the mold. 
         [0004]    In one embodiment, to accommodate various lid designs, the present invention provides a rim that is connected to the upper edge of the container. The rim can be formed in various configurations (described below) from a single mold using mold inserts. The various rim configurations accommodate different lids. Providing the mold inserts on the rim (which is a very shallow part) is much simpler than providing such inserts on the container itself. 
         [0005]    These and other features of the application can be best understood from the following specification and drawings, the following of which is a brief description. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  is a perspective view of a container according to a first embodiment. 
           [0007]      FIG. 2  is a perspective view of a container according to a second embodiment, nested in a similar container. 
           [0008]      FIG. 3  illustrates the container of  FIG. 2  with the lid removed. 
           [0009]      FIG. 4  is an enlarged view of the hinge area of the container of  FIG. 2 . 
           [0010]      FIG. 5  is bottom perspective view of an alternate version of the container of  FIG. 2 . 
           [0011]      FIG. 6  illustrates an alternate lid. 
           [0012]      FIG. 7  is a perspective view of a container according to a third embodiment and alternate lid. 
           [0013]      FIG. 8  illustrates the container of  FIG. 7  with the lid open. 
           [0014]      FIG. 9  illustrates a container assembly according to a fourth embodiment. 
           [0015]      FIG. 10  illustrates the container assembly in another position. 
           [0016]      FIG. 11A  is a perspective view of the base of  FIG. 9 . 
           [0017]      FIG. 11B  is a side perspective view of the base of  FIG. 11A . 
           [0018]      FIG. 11C  is a bottom perspective view of the base of  FIG. 11A . 
           [0019]      FIG. 11D  is a bottom view of the base of  FIG. 11A . 
           [0020]      FIG. 12  is a perspective view of a plurality of stacked bases. 
           [0021]      FIG. 13  is an exploded view of the container of  FIG. 9  with a first rim. 
           [0022]      FIG. 14  shows the first rim of  FIG. 13  mounted to the container. 
           [0023]      FIG. 15  illustrates a jig for removing the rim from the container of  FIG. 14 . 
           [0024]      FIG. 16  illustrates the container and rim of  FIG. 14  being inserted into the jig of  FIG. 15 . 
           [0025]      FIG. 17  illustrates a first step in removing the rim from the container with the jig. 
           [0026]      FIG. 18  illustrates a second step in removing the rim. 
           [0027]      FIG. 19  illustrates a third step in removing the rim. 
           [0028]      FIG. 20  illustrates the rim connected to a pair of lids on the container. 
           [0029]      FIG. 21  illustrates the rim and lids of  FIG. 20 . 
           [0030]      FIG. 22  is an exploded view of the rim and lids of  FIG. 21 . 
           [0031]      FIG. 23  is an exploded view of the rim with an alternate crossbar and lids. 
           [0032]      FIG. 24  is an assembled view of the rim and lids of  FIG. 23 . 
           [0033]      FIG. 25  illustrates the container of  FIG. 9 , a similar smaller container and a second rim. 
           [0034]      FIG. 26  illustrates the second rim of  FIG. 25  with attached lids secured to the container. 
           [0035]      FIG. 27  is a perspective view of the second rim and open lids. 
           [0036]      FIG. 28  shows the second rim and lids with one lid closed. 
           [0037]      FIG. 29  shows the second rim and closed lids. 
           [0038]      FIG. 30  is an exploded view of a third rim and lids. 
           [0039]      FIG. 31  is an assembled view of the third rim and lids of  FIG. 30  in a closed position. 
           [0040]      FIG. 32  illustrates the third rim and lids of  FIG. 31  with the lids open. 
           [0041]      FIG. 33  illustrates a rim and lid according to another embodiment. 
           [0042]      FIGS. 34A and 34B  illustrate the rim and lid of  FIG. 33  in different positions during use. 
           [0043]      FIGS. 35-37  illustrate the rim and lid of  FIG. 32  with an alternate tray. 
           [0044]      FIG. 38  illustrates a container with a rim and lids according to another embodiment. 
           [0045]      FIG. 39  shows the container of  FIG. 38  with the lids open. 
           [0046]      FIG. 40  is an exploded view of the rim and lids of  FIG. 38 . 
           [0047]      FIG. 41  illustrates a container with a rim and lids according to another embodiment. 
           [0048]      FIG. 42  is an exploded view of  FIG. 41 . 
           [0049]      FIG. 43  shows the lid of  FIG. 41 , partially broken away. 
           [0050]      FIG. 44  shows the lid of  FIG. 31  during installation onto the rim and container. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0051]    A container assembly for collecting medical waste according to a first embodiment of the present invention is shown in  FIG. 1 . The medical waste could be biological material, medical devices, etc. Some medical devices, such as metal or Titanium-containing devices may be recycled. The container assembly includes a container  10  having a base wall  12 , side walls  14 , a front wall  16  and a rear wall  18 . A lip  20  protrudes outwardly from the upper edge of the side walls  14 , front wall  16  and rear wall  18 . Handles  22  protrude outwardly from the front wall  16  and rear wall  18 . 
         [0052]    A lid  24  is pivotably secured to the container  10  by a hinge  26 . Front latches  28  are integrally molded with the lid  24  and snap-fit to the lip  20  adjacent the front wall  16 . Additional side latches  29  snap-fit to the lip  20  adjacent side walls  14 . The front latches  28  are substantially difficult to unlatch by hand without a tool. A single front latch  28  could be used instead of two. 
         [0053]    An alternate container assembly is shown in  FIG. 2  nested with a similar alternate container assembly. Each container assembly includes an alternate container  110 , which is simply a taller version of the container  10  of  FIG. 1 . The same lid  24  pivotably attaches to the alternate container  110  in the same way. 
         [0054]      FIG. 3  shows the alternate container  110  without the lid  24 . The upper end of the container  10  of  FIG. 1  would be similar. At the upper end of the rear wall  118 , hinge pins  134  protrude laterally from an upwardly protruding hinge support  132 . The side walls  114 , front wall  116  and rear wall  118  are similar to their counterparts in the container  10  of  FIG. 1 , but taller. 
         [0055]      FIG. 4  illustrates the upper end of the container  110  with the lid  24  open. The hinge pins  134  are snap-fit into hinge receivers  38  formed on the lid  24 . The connection to the container  10  of  FIG. 1  would be similar. 
         [0056]    A second alternate container  110 A is shown in  FIG. 5 . The second alternate container  110 A is identical to the container  110  of  FIGS. 2-4 , with the exception of the base wall  112 A. The base wall  112 A in  FIG. 5  includes a drag rail  140 A protruding downwardly from the periphery of the base wall  112 A. A plurality of ribs  142 A extend across the base wall  112 A. A similar base wall  112 A could be formed on the container  10  of  FIG. 1 . Generally, the base walls  12 ,  112  of the containers  10 ,  110  of  FIGS. 1-4  could be used with disposable containers, while it might be preferable to use the base wall  112 A with reusable containers. In fact, disposable and reusable versions of the containers could be formed in the same mold, by adding an insert into the mold that forms the drag rails  140 A and ribs  142 A. 
         [0057]      FIG. 6  illustrates an alternate lid  124 . In  FIG. 6 , the lid  124  is shown on container  110 , but is interchangeable and could be used on containers  10 ,  110 A, and any other container in this application. The lid  124  is substantially similar to the lid  24  of  FIG. 1 , including front latches  128  and is pivotably connected to the container  110  by a hinge  126 . However, the lid  124  includes a central opening  144  therethrough so that medical waste can be dropped into the container  110  through the opening  144 . The lid  124  further includes an integrally molded cap  146  adapted to snap-fit to a peripheral rib around the opening  144 . The cap  146  is connected to the lid  124  via an integrally molded tether  148 . The lid  124  of  FIG. 6  would have particular use for chemotherapy waste, such as syringes, platelets, etc., in which case the entire container assembly and contents may be periodically gathered and incinerated. 
         [0058]    An alternate container  210  and alternate lid  224  are shown in  FIG. 7 . Again, all lids and containers in this application are interchangeably useable. The alternate container  210  is identical to the container  110  and additionally includes wheels  50 . The wheels  50  are within the envelope of the container  210  such that the container  210  is still nestable within a similar container  210  when empty. 
         [0059]    The lid  224  includes a rear portion  252  and a front portion  254  connected via a living hinge  256 . The side latches  229  secure the rear portion  252  to the container  210 , while the front latches  228  further secure the front portion  254  to the container  210 . 
         [0060]    As shown in  FIG. 8 , the front portion  254  of the lid  224  can be opened without opening the rear portion  252 . Medical waste can be placed in the container  210  via the opened front portion  254 , which can then be reclosed. As is also shown in the lid  224 , a gasket  256  may be formed around the periphery of the lid  224  so that it seals with the container  210 . Of course, the gasket  256  could be formed on any of the lids disclosed in this application. Similarly, the wheels  50  could be used on any of the container disclosed in this application. Again, this container assembly could be made reusable or disposable. 
         [0061]      FIG. 9  shows a container assembly including a container  310  and a support  312 . The support  312  includes a base portion  314  up from which extend a front wall  316  and rear wall  318 , defining therebetween a channel  320 . The container  310  may be an injection molded container  310  having end walls  322  and side walls  324  and a base wall  326  opposite a container opening. 
         [0062]    The support  312  may optionally include castors  315 , which may be snap-fit or otherwise removably secured to the support  312 . The rear wall  318  of the support  312  includes spaced apart pillars  332  between which is defined a rear channel  330 . As shown in  FIG. 9 , the container  310  can be supported on the support  312 , with the base wall  326  of the container  310  received in the rear channel  330  and on the base portion  314  of the support  312  and secured between the pillars  332 . One end wall  322  is tilted toward the front wall  316 . In this position, the container  310  is supported at an angle, with the base wall  326  supported by rear wall  318 . 
         [0063]    The container  310  and support  312  can also be configured as shown in  FIG. 10 , in which the base wall  326  of the container  310  is disposed within the channel  320  between the front wall  316  and the rear wall  318  of the support  312 . The side walls  324  are adjacent the front wall  316  and rear wall  318 . In this configuration, the support provides stability to the container  310  and may be used as a dolly with the optional castors  315 . 
         [0064]    The support  312  is also preferably injection molded from a thermoplastic. The support  312  is shown in more detail in  FIGS. 11A-11D . Referring to  FIG. 12 , multiple supports  312  can stack on one another and partially nest with one another to reduce the overall stacking height and increase the stability of the stack. 
         [0065]    The support  312  and container  310  arrangement is usable with all of the embodiments of containers, lids, etc. described below. 
         [0066]    Referring to  FIG. 13 , the container  310  may include a peripheral lip  335  protruding outwardly and then downwardly from upper most edges of the end walls  322  and side walls  324 . At several locations, latches  336  are formed along the peripheral lip  335 . This provides a removable connection to one of many optional rims, some of which will be described herein. 
         [0067]    The first rim  340  is shown in  FIG. 13  and includes a peripheral portion  342  that is configured to fit over the peripheral lip  335  of the container  310 . The rim  340  further includes latch portions  344  complementary to the latches  336  for removably securing the rim  340  to the container  310 . The rim  340  further includes a crossbar  346  forming a chord across the peripheral portion  342 . Two sets of hinge receivers  348  are formed adjacent openings in the rim  340  defined by the peripheral portion  342  and the crossbar  346 . 
         [0068]    As shown in  FIG. 14 , the rim  340  is snap-fit onto the container  310  via the latch portions  344  and latches  336 . The rim  340  (and any other rim described herein) may be secured to the container  310  over a plastic bag (not shown) inserted in the container  310  and draped over the upper edges of the container  310 . If the rim  340  (or other rims below) includes a gasket, a leakproof seal can be provided at the rim/container interface with or without using a plastic bag. 
         [0069]    The rim  340  is designed such that it cannot easily be removed from the container  310  by hand. Instead, a jig  350  is provided for removing the rim  40  from the container  310 . The jig  350  is shown in  FIG. 15 . The jig  350  may be metal, aluminum, or injection molded of a thermoplastic. The jig  350  includes a peripheral portion  352  up from which extend a plurality of fingers  354  which are tapered to be received behind the latches  336 , as shown in  FIG. 16 . When the container  310  is placed in the jig  350 , the weight of the container forces the fingers  354  up behind the latches  336 , as shown more clearly in  FIGS. 17-19 . The taper of the fingers  354  causes the latches  336  to deflect, thereby releasing the latches  336  from the latch portions  344  of the rim  340  and the rim  340  can be removed from the container  310  and either replaced (if damaged) or provided with a different type of rim (several potential designs of which are described herein). Because the jig  350  activates the latch from below, the jig  350  does not have to penetrate a lid or a rim to disengage the latch, which enhances the ability to resist leakage. The lids of  FIGS. 1-8  could also be adapted to require the jig  350  for removal. 
         [0070]    As shown in  FIGS. 20-22 , the rim  340  is connected to a pair of lids  360 ,  368  to form a lid assembly. The lids  360 ,  368  include integrally molded hinge portions  362  complementary to the hinge receiver portions  348  on the rim  340 . One of the lids  360  includes an opening  364  therethrough, through which objects, such as sharps or other medical waste, can be inserted. A secondary lid  366  is hingeably connected to the hinge portion  362  and hinge receivers  348  to selectively cover the opening  364 , as shown. 
         [0071]    As shown in  FIGS. 23 and 24 , the rim  340  can also be provided with an off-center crossbar, which can occur with a different mold insert. This permits the attachment of different lids  370 ,  378 . The lid  370  includes a large semicircular opening  372  having a matched semicircular portion  374  having semi-annular recesses  375  for accommodating a semicircular door  376 . The door  376  is rotatably connected to the semicircular portion  374  for selectively closing the opening  372  through the lid  370 . 
         [0072]      FIG. 25  illustrates the container  310  and a similar, smaller container  410 . The smaller container  410  connects to the rims in the same manner as the larger container  310 . The smaller container  410  can be made in the same mold as the container  310 , through the use of mold inserts. 
         [0073]      FIG. 25  also illustrates a second rim  380  including a peripheral portion  382  from which a plurality of hinge receivers  384  extend upwardly. The second rim  380  and container  310  are shown in more detail in  FIGS. 26-29 . A pair of lids  386  having integrally molded hinge portions  388  are hingeably connected to the hinge receiver portions  384  on the container  310 . In this embodiment, the containers  310  with attached rims  380  and lids  386  can be nested within similar containers  310  with attached rims  380  and lids  386 , thus reducing shipping and storage space. 
         [0074]      FIGS. 30-32  illustrate a rim  390  according to another embodiment having a cross member  396  with hinge receivers  394  formed thereon. In this case, a pair of identical lids  397  having integrally molded hinge portions  398  are connected to the hinge receivers  394  on the rim  390 . Again, the second rim  390  can be selectively connected to the container  310  (with or without the optional latch portion  344 ,  FIG. 16 ). 
         [0075]      FIGS. 33 ,  34 A and  34 B illustrate a rim  400  according to another embodiment. The rim  400  includes a peripheral portion  401  (for receiving the peripheral lip  335  of the container  310 ) and an upper wall  403  in which is formed an opening  404 . A tray  402  is hingeably connected to the peripheral portion  401  of the rim  400  in the opening  404 . The tray  402  preferably occupies all or substantially all of the opening  404  in the at rest position as shown in  FIG. 33  (i.e., the tray  402  pivots to this position due to gravity). The tray  402  includes an integrally molded handle portion  405  protruding over a portion of the upper wall  403 . In use, a user places an object, such as a used medical device, in the tray  402 , then, using the handle  405 , pivots the tray  402  until the object is dumped into the container ( FIG. 34B ). When released, the tray  402 , due to gravity, then returns to it&#39;s at rest position, as shown in  FIG. 33 . 
         [0076]    An alternate tray  406  is shown in  FIGS. 35-37 . Whereas the tray  402  of  FIGS. 33 ,  34 A-B was completely opened above a plane near the axis of rotation of the tray  402 , the tray  406  extends almost  270  degrees about the axis of rotation. This ensures that the opening  404  is always closed, no matter the position of the tray  406 . A pair of handles  408  are provided to assist with dumping the tray  406  through the opening  404 . 
         [0077]    A fourth alternate rim  410  is shown in  FIGS. 38-40 . The rim  410  includes a peripheral portion  412  having integrally molded hinge receivers  414 . A pair of identical lids  416  are hingeably connected to the hinge receivers  414  by integrally molded hinge portions  418 . Each lid  416  includes a wide portion  420  extending across a midpoint of the container  310  and a narrow portion  422 , complementary to the wide portion  420 . This provides a wider (squarer) opening into the container  310  when only one lid  416  is flipped open. In this embodiment, the containers  310  with attached rims  410  and lids  416  can be nested within similar containers  310  with attached rims  410  and lids  416 , thus reducing shipping and storage space. 
         [0078]    An alternate assembly is shown in  FIG. 41-44 , although certain features could be used in combination with those described above. An alternate container  310 ′ includes integrally molded latch receivers  432  and an upper edge thereof around the container opening. A peripheral lip  446  protrudes outwardly and then downwardly from the upper edge of the container  310 ′. A lid  430  includes a plurality of integrally molded hinge portions  436  that are received between the hinge receiver portions  432  and hingeably connected thereto by an inserted metal rod  434 . The opposite edge of the lid  430  is fitted (prior to insertion of the rod  434 ) onto the lip  446  of the container  310 ′. The lid  430  includes a peripheral lip portion  442  protruding outwardly and then downwardly from the upper edge of the lid  430 . A hook portion  444  then protrudes inwardly and upwardly from the lip  442 . The peripheral lip  446  of the container  310  is received between the hook  444  and the lip  442  of the lid  430  as shown in  FIG. 43 . The lid  430  includes a threaded opening  448  therethrough into which is removably screwed a cap  440 . The lid  430  in particular is useful for smaller items such as pharmaceutical items. Note that the lid  430  could also be provided as a rim-type design that snaps to the container  310  as described in previous embodiments. 
         [0079]    In accordance with the provisions of the patent statutes and jurisprudence, exemplary configurations described above are considered to represent a preferred embodiment of the invention. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.