Abstract:
Overpack drum assemblies are disclosed. The overpack drum assemblies include a container base and a lid that may be securely closed on the base within a range of acceptable closure positions that may be visually indicated. The lid may include at least one leverage bracket for receiving a bar or other leverage tool that facilitates tightening and loosening of the lid. The container base may include at least one indented anti-rotation notch to help secure the container base against rotation during tightening or loosening of the lid. An anti-rotation fixture may be used to resist rotation of the container base.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/054,015 filed Sep. 23, 2014, which is incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to overpack drum assemblies including a container base and a lid that may be tightened securely to the base. 
       BACKGROUND INFORMATION 
       [0003]    The U.S. Department of Transportation (“USDOT”) has established regulations for removable head salvage drums, e.g., 49 CFR §1.173(c), which are also known in the art as overpack salvage drums. Overpack salvage drums are used in a variety of applications, including for the containment of packages that have been damaged, have otherwise become defective, or have been found to be leaking and/or for the containment of potentially hazardous solid materials while they are being transported. 
       SUMMARY OF THE INVENTION 
       [0004]    Overpack drum assemblies are provided. The overpack drum assemblies include a container base and a lid that may be securely closed on the base within a range of acceptable closure positions that may be visually indicated. The lid may include at least one leverage bracket for receiving a bar or other leverage tool that facilitates tightening of the lid. The container base may include at least one indented anti-rotation notch to help secure the container base against rotation during tightening or loosening of the lid. An anti-rotation fixture may be used to resist rotation of the container base. 
         [0005]    Certain embodiments of the present invention provide a closure zone indicator that indicates proper sealing and closure of containers to ensure that potential hazardous contents are secured for safe transportation. For example, to visually indicate that an overpack drum is properly closed, a visual indicator on a lid may be aligned within a closure zone on the container base, such as a group of holes and accompanying tabs on a radially extending rim that encircles the drum base. A user may thread the lid completely onto the base and then exert further force until the indicator is within the base tabs. Such alignment indicates a properly closed container and will be considered safe for transportation, e.g., as long as the contents fall within the specified container ratings. 
         [0006]    Overpack drums are often used as part of spill kits that contain absorbent materials and other items for responding to liquid spills. Such liquid spill kits are important parts of spill response contingency plans. Ensuring that the spill response contents of those kits are there when needed becomes critical. In the past, the contents of unsecured kits have sometimes been pilfered and used for non-spill response events. Those used contents are sometimes not refilled, leaving the kit unprepared for a true emergency event. Tamper evident features of the present invention allow such kits to be secured with a security device such as a tamper tag. In the event someone uses the kit, the security device must be removed to access the contents of the kit and cannot be reattached. The absence or damage of a security device provides visual evidence that the kit has been opened and requires an inspection to ensure readiness. A new security device can be attached to indicate a new state of readiness. 
         [0007]    An aspect of the present invention is to provide an overpack drum lid comprising a generally circular top surface, a lower rim, a generally cylindrical threaded sidewall extending between the top surface and the lower rim, and a pair of opposing leverage brackets circumferentially spaced from each other on the lid extending upward from the top surface, wherein each leverage bracket comprises an at least partially enclosed leverage hole structured and arranged to receive a leverage bar therethrough. 
         [0008]    Another aspect of the present invention is to provide an overpack drum container base comprising a bottom surface, an upper opening, a generally cylindrical sidewall extending between the bottom surface and the upper opening, and at least one anti-rotation notch adjacent the bottom surface extending radially inward from the sidewall a distance less than a radius of the sidewall. 
         [0009]    A further aspect of the present invention is to provide an anti-rotation fixture for resisting rotational movement of an overpack drum container base when a lid is secured to or removed from the container base. The anti-rotation fixture comprises a base, and two anti-rotation pegs located adjacent to opposite edges of the base and extending upward from the base, wherein the anti-rotation pegs are structured and arranged to be at least partially received within anti-rotation notches in a bottom of the overpack drum container base. 
         [0010]    Another aspect of the present invention is to provide an overpack drum assembly comprising a container base comprising an upper opening and a radially extending rim adjacent to the upper opening comprising a plurality of closure indicator tabs circumferentially spaced on a portion of the radially extending rim, and a lid threadingly engageable with the container base comprising at least one closure security hole rotatingly alignable with at least one of the closure indicator tabs when the lid is in a secured closed position on the container base. 
         [0011]    These and other aspects of the present invention will be more apparent from the following description. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  is an exploded isometric view of a container base and lid of an overpack drum assembly in accordance with an embodiment of the present invention. 
           [0013]      FIG. 2  is a bottom isometric view of the overpack drum assembly of  FIG. 1 . 
           [0014]      FIG. 3  is a magnified portion of  FIG. 2  showing a closure indicating assembly in accordance with an embodiment of the present invention. 
           [0015]      FIG. 4  is a broken away isometric sectional view, and  FIG. 5  is a broken away side sectional view showing a closure indicating assembly in accordance with an embodiment of the present invention. 
           [0016]      FIG. 6  is an isometric view of a lid of an overpack drum assembly in accordance with an embodiment of the present invention. 
           [0017]      FIG. 7  is a bottom isometric view of an overpack drum assembly in accordance with an embodiment of the present invention. 
           [0018]      FIG. 8  is an isometric view of an anti-rotation fixture in accordance with an embodiment of the present invention. 
           [0019]      FIG. 9  is an isometric view of the anti-rotation fixture of  FIG. 8  showing a portion of a container base placed thereon. 
       
    
    
     DETAILED DESCRIPTION 
       [0020]      FIG. 1  illustrates an overpack drum assembly  10  in accordance with an embodiment of the present invention. As used herein, the term “overpack drum” means a container including a container base and a lid that may be securely closed on the container base. In certain embodiments, the overpack drums comprise overpack salvage drums that meet government regulations such as USDOT regulations. In other embodiments, the overpack drums may be used as part of spill kits to contain liquid spill response materials. The overpack drum assembly  10  includes a container base  12  having a bottom surface  13 , sidewall  14  and upper opening  15 . External threads  16  are provided near the top of the sidewall  14  below the upper opening  15 . In the embodiment shown, the sidewall  14  includes an upper shoulder  17  having a diameter that is larger than the diameter of the lower portion of the sidewall. A radially extending rim  18  extends from the upper shoulder  17  below the external threads  16 . The internal volume and dimensions of the container base  12  may be varied depending on the intended use of the overpack drum  10 . For example, the capacity of each overpack drum may typically range from 5 gallons to 100 gallons or more. The outer diameter of each overpack drum  10  may typically range from 6 inches to 3 feet, e.g., from 10 to 25 inches. The overall height of each overpack drum may typically range from 6 inches to 4 feet, e.g., from 12 to 42 inches. 
         [0021]    As shown in  FIGS. 1-3 , the overpack drum assembly  10  includes a lid  30  that may be removably secured to the container base  12 . A closure indicating assembly  20  provides a closure zone indicator to ensure that the lid  30  is sufficiently tightened and secured to the container base  10  when the assembly is closed. As shown in  FIGS. 2-5 , the closure indicating assembly  20  includes indicator tabs  21  formed in the radially extending rim  18  of the container base  12 . Each indicator tab  21  includes a hole  22  through which a security device  38  may pass, as more fully described below. Radially indented notches  23  are provided in the radially extending rim  18  circumferentially between adjacent indicator tabs  21 . As shown in  FIG. 3 , the indicator tabs  21  have an arc length measured around a portion of the circumference of the radially extending rim  18 , which is designated as the tab arc A T . In the embodiment shown, the indicator tabs  21  are integrally formed with the radially extending rim  18 , and the circumferentially spaced radially indented notches  23  define spaces between adjacent indicator tabs  21 . However, any other suitable shape and arrangement of indicator tabs may be used, e.g., each indicator tab may extend radially outward from the outer diameter of the rim, and/or the indented notches may be of different shapes or may be eliminated. In the embodiment shown, there are five indicator tabs  21 , but any other suitable number of indicator tabs may be used. For example, there may be two, three, four or more indicator tabs. In accordance with embodiments of the present invention, the multiple indicator tabs  21  are provided in order to allow for alignment of the lid  30  at different circumferential positions with respect to the container base  12  at which the lid  30  is sufficiently tightened and secured to the base  12 , as more fully described below. 
         [0022]    As shown in  FIGS. 1-5 , the lid  30  includes a top surface  31 , sidewall  32  and lower rim  33 . Internal threads  34  are provided on the inside of the generally cylindrical sidewall  32  above the lower rim  33 . Raised vertical ribs  35  may be provided on the exterior of the sidewall  32  in order to help strengthen the lid  30  and/or provide additional gripping surfaces when the lid  30  is opened or closed. A gasket  29  is seated in a channel of the lid  30 , as shown in  FIGS. 4 and 5 . The gasket  29  may be made of any suitable type of compressible elastomeric material such as closed cell foam or other polymeric material. A closure security hole  36  is provided through the sidewall  32  of the lid  30 . The closure security hole  36  is intended to be substantially aligned with one of the holes  22  of the indicator tabs  21  of the base  12  when the lid  30  is secured thereto. This arrangement provides an acceptable range of closure positions as long as the closure security hole  36  is aligned vertically above at least one of the tabs  21 . As the lid  30  is tightened to its various closure positions, the gasket  29  is increasingly compressed to provide a seal between the lid  30  and the upper rim of the container base  12 . In certain embodiments, the tab arc A T , which represents the arc distance the tabbed region extends circumferentially around the rim  18 , may range from 1° to 60°, for example, from 5° to 50° or from 10° to 40°. The use of multiple indicator tabs  21  and a closure security hole  36  in accordance with embodiments of the present invention provides for secure closure of the lid  30  at a desired position on the container base  12  without the necessity of additional mechanical fasteners such as clips or brackets fastened between the lid  30  and container base  12 . 
         [0023]    As shown in  FIGS. 2-4 , a closure alignment indicia  37  is provided on the sidewall  32  above the closure security hole  36  in order to provide a visual indication of whether the lid  30  is in a desired secured location with respect to the container base  12  when tightened thereon. Although the closure alignment indicia  37  shown in the figures comprises a downward facing triangular arrow, any other suitable indicia may be used, including other directional symbols, alphanumeric symbols, words, or the like. 
         [0024]    When the lid  30  is sufficiently tightened on the container base  12  to a desired secure position, the closure security hole  36  and closure alignment indicia  37  may be substantially lined up with a corresponding indicator tab  21  and hole  22  of the container base  12 . In this position, a security device  38  may be inserted through the closure security hole  36  and tab hole  22  in order to provide an indication of whether the lid  30  has subsequently been moved from its tightened secured position. In the embodiment shown, the security member  38  includes a wire loop with its ends secured together by a security tag  39 . The wire security devices  38  and security tag  39  may provide a tamper-evident function in which any attempt to remove or significantly loosen the lid  30  from the container base  12  will result in breakage of the security tag  39 , breakage of the security device  38  and/or removal of an end of the security device  38  from the security tag  39 . Although the security device  38  shown in the  FIG. 5  is provided in the form of a flexible wire, it is to be understood that any other suitable security device such as a strap, rod, cable or the like may be used. In addition, the security device may be provided in the form of a lock such as a combination lock or a key lock. 
         [0025]    Additional features of the lid  30  are shown in  FIG. 6 . An annular channel  40  extends circumferentially around the upper surface of the lid  30  near the peripheral outer edge of the lid  30 . The annular channel  40  includes an exterior cylindrical sidewall  41 , an interior cylindrical sidewall  42  and a floor  43 . In the embodiment shown, the floor  43  of the annular channel  40  lies in the same plane as the top surface  31  of the lid  30 . As further shown in  FIG. 6 , multiple radial channels  45  are provided across the upper portion of the lid  30 . Each radial channel  45  includes sidewalls  46  and a floor  47 . In the embodiment shown, the floor  47  lies in the same plane as the top surface  31  of the lid  30 . 
         [0026]    As also shown in  FIG. 6 , multiple retaining channels  50  are provided around the circumference of the lid  30  in locations where the annular channel  40  intersects the radial channels  45 . Each retaining channel  50  includes raised sidewalls  51 , a radial inner wall  53 , a radial outer wall  54  and a floor  52 . In the embodiment shown, the floor  52  lies in the same plane as the top surface  31  of the lid  30 . Each radial inner wall  53  corresponds to a portion of the interior cylindrical wall  42  of the annular channel  40 . Each radial outer wall  54  corresponds to a portion of the exterior cylindrical sidewall  41  of the annular channel  40 . However, the radial outer wall  54  of the retaining channel  50  is notched such that it does not extend the full axial distance of the exterior cylindrical sidewall  41  of the annular channel  40 . 
         [0027]    In accordance with certain embodiments, the various sidewall heights and other dimensions of the annular channel  40 , radial channels  45  and radial retaining channels  50  are selected in order to allow a leverage bar (not shown), such as a wooden 2×4 stud or a metal bar or rod, to be positioned in a selected radial channel  45  in order to provide rotational leverage when closing or opening the lid  30 . The exterior cylindrical sidewall  41  of the annular channel  40  has a height H ES , and the interior cylindrical sidewall  42  has a height H S . The exterior sidewall height H ES  is greater than the interior sidewall height H IS , e.g., at least 10 or 20 percent higher. For example, the ratio of H ES :H IS  may be from 1.2:1 to 5:1, for example, from 1.5:1 to 3:1. Each raised sidewall  51  of the radial retaining channels  50  has a height H S , and each radial outer wall  54  has a height H O . Each radial inner wall  53  has a height H I . In the embodiment shown, the raised sidewall height H S  is equal to the height H ES  of the exterior cylindrical sidewall  41 . Furthermore, in the embodiment shown, the height H I  of the radial inner wall  53  is equal to the height H IS  of the interior cylindrical sidewall  42 . Similarly, the height H O  of the radial outer wall  54  is equal to the height H IS  of the interior cylindrical sidewall  42 . 
         [0028]    In accordance with embodiments of the invention, the lid  30  may include leverage brackets  60 , as most clearly shown in  FIGS. 6 and 7 . A leverage hole  61  is provided through each leverage bracket  60 . A leverage bar  65  may be inserted through the leverage holes  61 . The leverage holes  61  are fully or partially enclosed to prevent the leverage bar  65  from being removed in an upward direction from the holes  61 , i.e., the leverage bar  65  must be inserted axially through the holes  61 . In the embodiment shown, the leverage brackets  60  comprise an axial extension of the exterior cylindrical sidewall  41 . Although the leverage holes  61  illustrated in the figures are provided in the form of fully enclosed circular openings, it is to be understood that non-enclosed or non-360° holes or notches may be used, e.g., a non-enclosed hole of greater than 220° or 270° to 360° may be provided through the exterior sidewall  41  of the annular channel  40 . 
         [0029]    As shown in  FIG. 7 , the container base  12  of the overpack drum assembly  10  may include at least one anti-rotation notch  70  extending radially inward a slight distance at the bottom surface  13  adjacent to the lower portion of the sidewall  14 . Each anti-rotation notch  70  has a height H N , width W N  and depth D N  selected to allow an operator to insert an object such as the toe portion of a boot or shoe into the notch  70  when the lid  30  is being tightened or loosened from the container base  12 . For example, the radial depth D N  of each anti-rotation notch  70  may range from 0.5 to 4 inches, or from 1 to 3 inches, or from 1.2 to 2 inches. As shown in  FIG. 7 , each anti-rotation notch  70  does not extend to the radial center of the bottom surface  13  of the container base  12 . Such partial extension of the anti-rotation notches  70  minimizes the amount of volume that is lost from the interior of the container base  12 , and maintains a flat support surface over most of the bottom surface  13 . The height H N  and width W N  of each anti-rotation notch  70  are also selected to allow partial insertion of a user&#39;s boot or shoe, or another similarly sized object that may be used to prevent unwanted rotation of the container base  12 . In certain embodiments, the notch height H N  may be from about 2 to 4 inches, and the notch width W N  may be from 3 to 5 inches. In the embodiment shown, two anti-rotation notches  70  are illustrated. However, any other suitable number of anti-rotation notches may be used, e.g., one, two, three, four, etc. Although the anti-rotation notches  70  shown in the figures have open bottoms, the bottom of each notch  70  may be closed, e.g., the bottom surface  13  of the container base  12  may extend under each notch  70  to form a pocket. 
         [0030]    The anti-rotation notches  70  allow a single person to easily secure the lid  30  on the container base  12 . When screwing lids on conventional large containers, the containers tend to spin and do not permit the lid to be secured tightly. This results in the need for a second person to secure the base container from rotating, which is still difficult without a tool to oppose container rotation. The anti-rotation notches  70  of the present invention provide depressions in the base container that allow for a foot or other means to be secured and oppose the rotation force created when the lid is screwed onto the base. The anti-rotation notches  70  also provide for the added possibility that one person can complete the lid closing task. 
         [0031]      FIGS. 8 and 9  illustrate an anti-rotation fixture  80  in accordance with an embodiment of the present invention. The anti-rotation fixture  80  includes a base  81  with anti-rotation pegs  82  extending upwardly therefrom on two opposite sides of the base  81 . The anti-rotation pegs  82  are sized to at least partially fit within the anti-rotation notches  70  of the container base  12 , as shown in  FIG. 9 . For example, each anti-rotation peg  82  may have a height and width equal to, or slightly less than, the height H N  and width W N  of the anti-rotation notches  70 . In the embodiment shown, the length of each anti-rotation peg  82  is greater than the depth D N  of the anti-rotation notches  70 , such that a portion of the anti-rotation peg  82  extends radially outward from the bottom of the container base  12  when placed on the fixture  80 . Any suitable length of the anti-rotation peg  82  may be used, e.g., its length may be equal to the notch depth D N  of the anti-rotation notches  70  or may be up to ten times or more greater than the notch depth D N . Although the anti-rotation fixture base  81  shown in  FIGS. 8-9  is rectangular with a width approximating the width of a container base  12  placed thereon, any other suitable shape and dimensions may be used. For example, the width of the base  81  may be smaller than shown in  FIGS. 8 and 9 , e.g., its width may be approximately the same as the widths of the anti-rotation pegs  82 . 
         [0032]    The container base  12  and lid  30  may be made of any suitable materials such as plastics, metals and the like. For example, the container base  12  and lid  30  may be made of polyethylene with UV inhibitors. The anti-rotation fixture  80  may be made of any suitable materials such as metal, wood, plastic and the like. 
         [0033]    Whereas particular embodiments of this invention have been described above for purposes of illustration, it will be evident to those skilled in the art that numerous variations of the details of the present invention may be made without departing from the invention as defined in the appended claims.