Abstract:
A refuse container has a lid that is hinged thereto without the use of mechanical fasteners. The container has short shafts extending therefrom. The lid has arms that pivotally receive and are captured on the container shafts. The shafts are formed with sectors, and the lid arms have recesses that receive the sectors. The lid arms recesses define stepped surfaces located at predetermined locations relative to the container sectors so as to positively stop the lid at a desired open position. The lid arms may be formed with dual radius recesses connected by a flat surface. The container sectors and the recess surfaces are dimensioned to enable the lid to be freely pivoted to an intermediate open position approximately 90° from a closed position and subsequently in a controlled manner to a third open position approximately 270° from the first position. The mold for making the container and lid has a flat parting surface.

Description:
This is a divisional of copending application Ser. No. 07/506,330 filed on Apr. 9, 1990. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention pertains to waste handling, and more particularly to apparatus for temporarily storing waste materials. 
     2. Background of the Invention 
     Various types of receptacles have been developed to temporarily store and transport waste products. For example, receptacles that include a wheeled container for holding the refuse and a lid pivotally connected to the container are well known. Some types of receptacles are designed to be handled and emptied by automatic equipment. Typical examples of prior receptacles are shown in U.S. Pat. Nos. 4,450,976 and 4,749,101. 
     The receptacle lids may be retained on the containers by various means, such as mechanical fasteners. On the other hand, the lid may be hinged directly to a handle that is an integral part of the container. In some designs, the lid is pivotable from a closed position overlying the top of the container through approximately 100° to an open position whereat it is generally vertical and above the hinge. In other receptacles, the lid is pivotable from the closed position through approximately 270° to an open position whereat the lid is generally vertical and below the handle. Ideally, a single lid is selectively openable to both the 100° and the 270° positions. 
     However, prior receptacles employ rather makeshift designs for enabling the lids to have 100° and 270° stop positions. In some cases, the 100° stop is achieved by manually moving the lid pivot point such that the lid strikes the container handle to provide the stop. In prior receptacles, swinging the lid from the 100° position to the 270° position is uncontrolled, and the rapidly rotating lid tends to strike the bottom of the container and tip the container over as the lid approaches its lowermost position. 
     An additional disadvantage of prior receptacles is that it is difficult to satisfactorily convert a container and lid having a 100° lid opening to one with a 270° opening. Consequently, a user must order and stock two entirely different receptacles if he has applications requiring both openings. 
     Thus, a need exists for improvements in refuse receptacles. 
     SUMMARY OF THE INVENTION 
     In accordance with the present invention, a refuse receptacle is provided in which a lid is controllably pivotable about a container. This is accomplished by apparatus that includes cooperating stops and cams incorporated into a hinge connecting the container and lid. 
     The container is manufactured from a rather flexible plastic material. The container has front, back, and side walls and a generally horizontal open top into which waste materials are deposited. An elongated horizontal handle is formed integrally with the container back wall adjacent the top thereof. The ends of the handle terminate in oppositely extending shafts. The free end of each shaft is formed with a mushroom-shaped surface; the two mushroom-shaped surfaces diverge toward each other. Each shaft has a circumferential groove adjacent the base of the corresponding mushroom-shaped surface. 
     The lid is designed with a cover portion that fits snugly over the container walls adjacent the tops thereof. Like the container, the lid is made of rather flexible plastic material. The lid includes two arms that extend from the cover portion. The arms have respective inwardly facing surfaces that are spaced apart a distance slightly greater than the distance between the opposite ends of the container handle. The arms are formed with recesses in their respective inwardly facing surfaces. At the bottom of each recess is a circular opening that extends through a middle wall and into a clearance chamber. The clearance chamber may be partially bounded by an outside wall of the arm. 
     The lid is hinged to the container by means of the container shafts and lid arms. The opening in an arm middle wall is aligned axially with a shaft mushroom-shaped surface. The lid arm is then pushed over the container shaft to force the shaft mushroom-shaped surface through the lid opening such that the shaft circumferential groove (or neck portion) is received in the lid opening to capture the lid in the groove. Then the lid is flexed to align the opening in the middle wall of the second lid arm with the shaft on the second end of the container handle, and the lid is pushed onto and captured by the circumferential groove in the handle second end. The result is a receptacle having a hinge between the container and lid that does not require any mechanical fasteners and that is completely hidden so as to provide an attractive appearance. 
     The receptacle of the present invention is designed to enable the lid to pivot between a horizontal first position whereat it is snugly snapped over the container open top and a generally vertical second position whereat the lid is in an open position approximately 100° from the first position. To positively locate the lid at the second position, the receptacle hinge is fabricated with cooperating stops. In the preferred embodiment, the hinge stops comprise a radially extending sector formed on each container shaft and a stepped surface on each lid arm. Each container sector is joined to the shaft adjacent the circumferential groove opposite the mushroom-shaped surface. Each sector has a radius slightly less than the radius of the arm recess and a radial end face. The sector is received in the arm recess. 
     To positively locate the lid at the second position, the stepped surface of the lid stop forms a boundary of the recess of each lid arm. The stepped surface extends radially of the arm middle wall opening. When the lid is in the horizontal first position, the stepped surfaces of the two lid arms are approximately 100° from the end faces of the corresponding container sectors. The lid is thus pivotable about the container shafts for approximately 100° until the lid stepped surfaces strike the sector end faces. As a consequence, the lid is positively located at the open second position, where it remains until it is intentionally closed. 
     Further in accordance with the present invention, the receptacle hinge may be designed such that the lid is freely pivotable between the first closed position and an intermediate position and is controllably pivotable from the intermediate position to a third position approximately 270° from the first position. For that purpose, the receptacle hinge includes friction cams acting between the container and the lid. The hinge cams may utilize the same sectors on the container shafts as are used with the positive 100° stops described previously. To provide controlled camming action with the container sectors, each lid arm recess is formed with two arcuate surfaces and an interconnecting flat surface. The first arcuate surface has a radius slightly greater than the radius of the container sector. The arm second arcuate surface has a radius that is slightly less than the sector radius. The interconnecting flat surface extends tangentially from the second arcuate surface to intersect the first arcuate surface. When the lid is in the horizontal first position on the container, the container sectors fit inside the first arcuate surfaces of the corresponding arm recesses, and the intersection of the recess tangential surface and the recess first arcuate surface is approximately 75° from the container sector end face. The cam dimensions thus enable the lid to be rotated freely through approximately 90°. Further lid rotation past the 90° causes the arm tangential surfaces to contact the associated container sectors in a gradual camming action. Additional lid rotation is possible until the lid has undergone 270° of rotation from the first position. However, for approximately 180° of rotation, the second arcuate surfaces of the arm recesses are in frictional contact with the container sectors. As a consequence, lid rotation is slow and controlled, and the danger of a rapidly dropping lid overturning the receptacle when the lid reaches the 270° position is eliminated. 
     Other advantages, benefits, and features of the invention will become apparent to those skilled in the art upon reading the detailed description of the invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a side view of the receptacle of the present invention. 
     FIG. 2 is a back view of the present invention. 
     FIG. 3 is a top view of FIG. 1. 
     FIG. 4 is an enlarged view taken along lines 4--4 of FIG. 3. 
     FIG. 5 is a cross-sectional view taken along lines 5--5 of FIG. 4. 
     FIG. 6 is a cross-sectional view taken along lines 6--6 of FIG. 5. 
     FIG. 7 is a view similar to FIG. 6, but showing a modified embodiment of the present invention. 
     FIG. 8 is a view similar to FIG. 7, but showing the lid at an open third position. 
     FIG. 9 is a view similar to FIGS. 7 and 8, but showing the lid at a position intermediate the first and third positions. 
     FIG. 10 is a top view of the receptacle as molded. 
     FIG. 11 is a partial side view of FIG. 10. 
     FIG. 12 is a partial cross-sectional view taken along lines 12--12 of FIG. 10. 
     FIG. 13 is a partial cross-sectional view taken along lines 13--13 of FIG. 11. 
     FIG. 14 is a partial cross-sectional view taken along lines 14--14 of FIG. 11. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to FIGS. 1-3, a receptacle 1 is illustrated that includes the present invention. The receptacle is particularly useful for temporarily storing and transporting waste materials, but it will be understood that the invention is not limited to refuse handling applications. 
     The receptacle 1 comprises a large container 3, which may have a capacity of approximately 90-100 gallons. The container 3 is fabricated with a front wall 5, back wall 7, two opposed side walls 9, and a floor 11. The side walls 9 may have respective cut-outs 12 to accommodate wheels 13 that are rotatably mounted to respective axles 15. In turn, the axles 15 are secured to the container to enable the container to be rolled along the ground 17. The back wall 7 is provided with an arc shaped toe rest 7a to make it easier to tip the container. 
     Integral with the container back wall 7 near the top 16 thereof is an elongated handle 18. The handle 18 may be formed as a horizontal bar 21 connected to the top end 16 of the back wall by two inner supports 23 and two outer supports 24 so as to form three grabbing areas 25. In that manner, a person may use one or both hands to easily manipulate the container 3. The base areas 23a of supports 24 and 23 (FIG. 10) are curved to provide added strength to the handle 18. 
     The container 3 has an open top that is selectively coverable by a lid 19. The lid 19 has a cover portion 20, which, when the lid is in the closed position of FIGS. 1-3, fits over the top ends of the container front, back, and side walls 5, 7, and 9, respectively. Preferably, a tight snap fit exists between the lid cover portion 20 and the rolled top edge 3a (FIG. 8) of the container so as to prevent insects and rodents from reaching the inside of the container. 
     In accordance with the present invention, the lid 19 is hinged to the container 3 in manner that does not require any mechanical fasteners and that also is aesthetically pleasing. Turning to FIGS. 4 and 5, an outwardly extending shaft 27 is joined to each handle outer support 24. Each shaft 27 terminates in a neck portion 33 (or groove) having a tapered mushroomshaped head 29 formed thereon to provide a shoulder 33a therebetween. 
     To mate with the container shafts 27, the lid 19 is provided with a pair of arms 35 that project backwardly from the cover portion 20. Each arm 35 has an inwardly facing surface 36 with a recess 37 partially bounded by a middle wall 39. Each arm is further formed with a chamber 41 defined partially by the middle wall 39 and by an outer wall 43. The arm middle wall 39 has an opening 45 therethrough. The opening 45 has a diameter slightly greater than the diameter of the container neck 33 but smaller than the diameter of the container shaft 27. The diameter of head 29 is slightly greater than the diameter of opening 45. 
     Both the container 3 and the lid 19 are manufactured from a relatively flexible thermosetting plastic material. The four container walls 5, 7, and 9, as well as the floor 11, may be approximately 0.02&#34; thick. The lid cover portion 20 may also have a thickness of 0.02&#34;. Consequently, the container and lid are slightly flexible. 
     To assemble the lid 19 to the container 3, one of the lid arms 35 is placed adjacent the corresponding container shaft 27 such that the shaft is aligned with the arm opening 45. The mushroom-shaped head 29 is placed against the arm opening. Then a tap with a mallet on the arm outer wall 43 forces the arm opening over the head 29 and into engagement with the neck 33. The arm is thus captured on the container shaft by shoulder 33A. 
     Then the lid 19 is flexed to bring the opening 45 of the other arm 35 into alignment with the second container shaft 27. Another tap with the mallet forces the arm opening over the head 29 of the second container shaft. In that manner, the container shafts 27 and lid arms cooperate to form a hinge between the container 3 and lid 19 that requires no additional fasteners and that is neatly hidden from sight. 
     Further in accordance with the present invention, the receptacle hinge includes stops that limit lid pivoting between a first position whereat the lid 19 is generally horizontal and in engagement with the container 3 and a second position whereat it is approximately 100° from the first position. Looking also at FIG. 6, each container shaft 27 is formed with a radially extending sector 47 that may subtend an angle of approximately 90°. Preferably, the sector 47 spans the distance between the shaft groove 33 and the handle support 24. The sector 47 has a radius that is slightly less than the radius of the lid arm recess 37. The sector has a first end face 49 and a second end face 51. In the particular construction illustrated, the sector first end face 49 is generally vertical and the second end face 51 is generally horizontal, but those orientations are not required. 
     To limit the pivoting of the lid 19 on the container shaft 27, the lid stop is composed of a stepped surface 53 formed as part of the arm recess 37. The stepped surface 53 extends radially of the axis 31 and between the inner radius of the recess 37 and an arcuate surface 55. The arcuate surface 55 has a radius that is slightly greater than the radius of the container shaft 27. The arcuate surface 55 may subtend an angle of approximately 165°, and it terminates in a second stepped surface 57 similar to the stepped surface 55. 
     When the lid 19 is in the first position, which is generally horizontal and snapped in place on the container 3 as shown by the solid lines of FIGS. 1, 4, and 6, the lid stepped surface 53 is approximately 100° from the container sector end face 49, and the lid stepped surface 57 is proximate the sector second end face 51. Accordingly, the lid may be pivoted clockwise with respect to FIGS. 1, 4, and 6 through approximately 100° until the lid stepped surface 53 abuts the sector end face 49. At that point, the lid is in the position 19&#39; shown in phantom lines in FIGS. 1 and 6. The lid is retained in the second position by gravity until it is intentionally reclosed. 
     It is a feature of the present invention that the receptacle lid may be opened to a third position approximately 270° from the first position in a controlled and safe manner. For that purpose, the hinge between the container and lid is modified from the positive stop design shown in FIGS. 4 and 6 to a frictional cam design illustrated in FIGS. 7-9. In the frictional cam hinge, the container shaft 27, including the neck 33 and the sector 47, remain the same as with the stop design described previously. In FIGS. 7-9, the lid 58 has two arms 60 with respective recesses 62. Each recess 62 is partially defined by a first arcuate surface 59 that has a radius that is slightly greater than the radius of the container sector 47. A radial stepped surface 61 extends between the first arcuate surface 59 and a second arcuate surface 63. The second arcuate surface 63 has a radius slightly less than the radius of the sector 47. The second arcuate surface preferably subtends an angle of approximately 155° from the stepped surface 61 to a point 65 at which the arcuate surface 63 blends into a flat surface 67 that is tangential to the arcuate surface 63. The tangential surface 67 intersects the first arcuate surface at point 69. 
     When the lid 58 is in the first, horizontal position closed over the container 3, FIG. 7, the intersection point 69 between the first arcuate surface 59 and the tangential surface 67 is approximately 75° from the first end face 49 of the container sector 47. From the first position, the lid is freely pivotable about the container shafts 27 in a clockwise direction with respect to FIG. 7 toward the position of FIG. 9. The lid tangential surface 67 is dimensioned such that it contacts the corner 71 between the sector periphery 73 and the first end face 49 when the plane of the lid is in a generally vertical attitude, FIG. 9. 
     From the position of FIG. 9, the lid 58 is further pivotable in a clockwise direction to the third position of FIG. 8. However, lid pivoting between the intermediate position of FIG. 9 and the third position of FIG. 8 is in a controlled manner that allows smooth and safe descent. Lid control is achieved by the frictional contact of the peripheries 73 of the container sectors 47 initially with the lid tangential surfaces 67 and subsequently with the arcuate surfaces 63. Initial controlled lid pivoting from the intermediate position of FIG. 9 clockwise through an angle of approximately 30° is the result of a gradually increasing camming contact between the sector peripheries 73 and the lid tangential surfaces 67. After the lid has pivoted approximately 120° from the first position thereof, the lid tangential points 65 between the respective tangential surfaces and the arcuate surfaces 63 are proximate the sector corners 71. Further lid pivoting from that position is in a uniformly resisted manner with frictional contact between the sector peripheries and the constant radius arcuate surfaces 63. Untimately, the lid reaches the third position of FIG. 8 after rotating through approximately 270° from the first position. Because of the frictional resistance between the container and lid, the lid descends slowly and safely to the third position, eliminating the usual tendency of the centrifugal force of the lid to tip the container backwards. 
     An outstanding advantage of the present invention is that a single container 3 is interchangeable with both lid 19 for 100° rotation of the lid and with lid 58 for 270° rotation. The same shaft 27 and sector 47 are used with both lids. Accordingly, a user can purchase and assemble either lid to a container, and, at a future time should the need arise, replace the initial lid with the other lid without having to replace the container. 
     As shown in FIG. 8, the top of container 3 has a rolled lip 3a which cooperates with a rolled lip 19a on cover 19 (FIG. 1) to provide a tight seal between container and cover when the cover is in closed position. 
     In carrying out the present invention, provision is made for improving the process by which the receptacle 1 is manufactured. Looking at FIGS. 10 and 11, the receptacle is molded as a single piece, with the lid 19 or 58 on top of the container 3, and with the lid arms 35 or 60 reversed 180° from the container handle 18. To remove the receptacle from the mold, the parting line 75 must pass through the centers of the container shafts 27 and the lid openings 45 (FIGS. 5 and 6). An S-shaped container lip 77 allows this by enabling the parting line 75 to be at or below the top of the container 3, FIGS. 13 and 14. This advantage of the manufacturing process of the present invention is that the S-shaped container lip (FIGS. 13 and 14) allows the parting line 75 to be in a single plane to thus facilitate removal of the molded receptacle from the mold. 
     Thus, it is apparent that there has been provided, in accordance with the invention, a refuse container with snap-on cover that fully satisfies the aims and advantages set forth above. While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations as fall within the spirit and broad scope of the appended claims.