Multiple configuration disposable sharps container system

A secure disposable container assembly for medical sharps and waste comprises the combination of a substantially rigid box-like lower housing defined by upstanding front, back, and side walls terminating with a top having an upwardly extending rectangular opening for providing access to the housing, and a top cover secured by locking tabs for permanent securement thereto, an elongated horizontally extending access opening in the top for receiving a disposable syringe or the like, and a pivotable closure for said opening pivotably mounted about said axis within said top and having a receptacle area normally exposed to said access opening in a first position for receiving a disposed article and a curved surface for covering said access opening upon pivoting from said first position to a second position for dumping said article into said housing.

BACKGROUND OF THE INVENTION 
The present invention relates to disposable containers for hospital sharps 
and infectious waste, and pertains particularly to a secure disposable 
container and alternate closure assemblies for stand alone and for insert 
containers. 
Hospitals and medical clinics use great quantities of sharps, such as 
needles, syringes, surgical blades, and the like, that are disposed of 
rather than cleaned and reused. It is necessary that the sharps be 
disposed of in a manner that prevents them being reused without 
sterilization. In particular, it is necessary to keep them from falling 
into the hands of those, such as intravenous drug users and the like, who 
are likely to use them without proper sterilization. 
Numerous containers have been developed in recent years, which are 
reasonably secure and disposable for receiving and disposing of hospital 
sharps, wastes and the like. Many of these containers are disposable 
inserts that mount into a security housing which is lockable and is 
securely mounted on a wall or other support structure. Many of these 
insert containers however have an inadequate security closure built into 
it, and are out dated so that they do not provide adequate security 
against pilfering of used syringes and the like therefrom. While improved 
containers have been developed which cannot readily be reopened and 
articles cannot be easily removed therefrom, such containers must be kept 
in a secure place or securely mounted to non-removable structure to 
prevent unauthorized removal. 
Many hospitals and clinics that have the older secure housings with insert 
type disposable containers do not wish to invest in new housings. It is 
therefore necessary to develop improved insert type disposable containers 
for these housings with improved closures for the combination. It is also 
desirable that new stand alone units be available. 
An example of a prior art disposable insert type container and mounting 
housing is disclosed in U.S. Pat. No. 4,715,498 of Hanifl dated Dec. 29, 
1987. This patent discloses a sharps container having a closure door that 
provides limited access to the interior of the container for mounting in a 
protective housing. However, an improved closure is desirable for such 
containers. 
Examples of stand alone type containers are disclosed in U.S. Pat. No. 
4,736,860, granted Apr. 12, 1988 to Bemis, and entitled SHARPS DISPOSAL 
CONTAINER, and in U.S. Pat. No. 4,828,107, granted May 9, 1989 to Spencer 
and entitled DISPOSABLE CONTAINER FOR SYRINGES. It is desirable that 
simpler more effective disposable containers be available. 
In the manufacture of multiple related or similar products, it is desirable 
that as many parts be interchangeable as possible in order to reduce 
manufacturing costs. It is also desirable that different variations of the 
product be available to meet different conditions and needs. It is, 
therefore, desirable that an improved securable disposable container 
combination be available to provide both insert and stand alone 
containers. 
SUMMARY AND OBJECTS OF THE INVENTION 
It is the primary object of the present invention to provide an improved 
securable disposable container assembly. 
In accordance with a primary aspect of the present invention, a secure 
disposable container assembly comprises a base container for receiving a 
first closure assembly for forming a stand alone unit for securely and 
detachably mounting to a support member, and a second closure assembly for 
providing a disposable insert container, both having an opening in a top 
front for receiving a disposable article and preventing access to the 
interior of the container by the human hand.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT 
Referring to FIG. 1 of the drawing, there is illustrated an exemplary 
embodiment of the invention, which comprises a generally rectangular open 
top container shell, designated generally by the numeral 10, and formed of 
the usual plastic material for such containers. The container in its 
preferred form is formed of a lower substantially rectangular box-like 
open top shell. The container has a front wall or panel 12 and a back wall 
or panel 14 (FIG. 2) defining front and back walls, and further including 
opposed side walls 16 and 18, all terminating at a top rectangular 
peripheral edge 20. The container is designed to receive alternate top 
cover or shell constructions to provide either a stand alone disposable 
container, as shown in FIG. 1, or a disposable insert for a protectable 
container as shown in FIG. 5. A generally semi-circular top shell 22 is 
mounted or attached to the top peripheral edge of the rectangular shell 10 
to provide the stand alone configuration of FIGS. 1-5. A lower profile 
more open top shell provides the insert configuration of FIGS. 5-8. 
The stand alone disposable container of FIGS. 1-4 will be described first. 
The top shell 22 and bottom are molded separately and utilize a plurality 
of snap lock tabs 24 (FIG. 5), for permanent attachment of the top to the 
top edge of the container. The snap lock tabs 24 extend slots 28 formed in 
the upper rim 20 of the container between the wall and downwardly 
extending skirt 30. The tab lock assembly includes tabs 26 on the top and 
tab sockets in the upper or top edge of the container to permanently lock 
the top 22 in the covering position, as shown in FIGS. 1 and 3. 
A pair of attachment hinge tabs 26 are provided for connecting the top 
shell to the container in spaced relation, and allowing them to pivot 
relative to one another for providing a shipping mode of the container as 
will be described. The attachment hinge tabs 26 comprise a pair of 
downwardly directed prong hooks on the top shell for extending into and 
hooking under the edge of a pair of slots formed in the rim 20 of the 
container located above a pair of mounting slots. 
The container top shell 22 and the bottom 12 are preferably separately blow 
molded of a suitable plastic, and later assembled. The container bottom 12 
is preferably formed with a slight taper from top to bottom to enable 
stacking for ease of shipment. The top shell 22 has a generally 
semi-cylindrical configuration about a horizontal axis, about which a 
pivoting closure member 24 is mounted, as more specifically disclosed and 
described in the parent application. Referring to FIG. 2, the top shell 22 
is provided with a top front opening 32 of a generally elongated 
configuration having circular or oval ends. This opening is formed in the 
upper front one side of the top extending approximately one-half the 
length of the top. This opening is designed to receive syringes and the 
like for disposal point first and includes a self-dumping closure 34 to 
secure the syringes against unauthorized retrieval. 
The opening is closed by a pivoting closure member or unit 34, as 
illustrated in FIG. 3, of a substantially unitary structure. The closure 
member 34 has a generally horizontal support face or ledge portion 36 
disposed below the opening 30, and to one side of its pivot axis defined 
by a pair of pivot pins 38 at each end of the member 34. An upwardly 
extending face portion 40 forming a continuation of the face 36 extends 
upward at approximately a forty-five degree angle to a curved surface 
portion 42. These faces together form a combination closure and receiving 
support for disposable articles, such as a syringe or the like 38 as 
illustrated. The curved surface portion 42 extending backward from the 
upper or top edge of the face portion 38 thereby forms a closure for 
extending over the opening 32 when the closure member pivots about 
horizontal axis 38 for dumping an article. 
The closure unit 34 is mounted for pivotal movement about a pair of pins, 
one at each end, which are rotatably mounted in snap in journals in the 
ends of the top shell 22. A counterweight is formed by wall portions 40 
and 42 extending outward from the axis of the pivot pins and pivot axis of 
the unit opposite to the support surface 36, and biases the closure unit 
to its normally closed article receiving position. Once the container has 
been filled, the closure is forced or rotated to its closed position by 
grasping a hand recess 44 and forcing the closure such that curved closure 
portion 42 extends over the opening 32, and lock tabs 46 on an upper 
portion of the closure panel 42 extend into and lock into lock slots or 
sockets 48 formed in a small horizontal lip at the forward edge of the top 
shell opening 32. This essentially permanently locks the container in its 
closed position for disposal. 
In normal operation, to dispose of a syringe as viewed in FIG. 1, the 
syringe is inserted into the top opening, needle first, with the needle 
extending toward the left to extend inside and underneath the top cover of 
the housing. The body of the syringe is placed on the horizontal closure 
surface 36, as seen in FIG. 3. The weight of the syringe overcomes the 
counterweight and tilts the closure member to automatically self-dump the 
syringe into the container. At the same time, the closure surface 42 moves 
forward and covers the opening 30 to prevent the insertion of a hand or 
the like for the removal of articles from the container. 
If it is desirable to remove the needle to either reuse the syringe or 
prior to disposing of the syringe, a needle removal slot 50 is formed in 
the upper portion of the top for this purpose. This needle removal slot 
has a generally tear-drop configuration converging from a larger diameter 
at one end to a smaller diameter at the other. The slot has a pair of 
opposed tapered side walls, which act as wrench surfaces for engaging the 
side of a needle hub for applying torque for unthreading the needle. 
The container is designed for ease of handling and to this end is provided 
with a retractable handle 52 that is preferably molded integrally with the 
lower edge of a peripheral rim or skirt 30. The handle 52 is pivotal 
outwardly, as shown for ease of grasping, and downward to a retracted 
position, engaging and latching to the lower ends of detent bars 54 and 
56. 
Referring to FIGS. 2 and 3, the back of the container is provided with 
means for attachment to a wall bracket to be described. The attachment 
means comprises a pair of hook slots 58 and 60 extending downwardly from 
the top back of the container. These slots are formed in an outer or 
outwardly spaced wall 62 and 64 of downwardly extending sockets formed on 
the back wall 14 of the container. The slots extend and hook over a pair 
of side walls on a mounting bracket 66, shown in FIGS. 3 and 4 as will be 
explained. 
A latching tab 68 at the lower end of the back wall 14 extends downward and 
is biased by a cam or lever outwardly at about 90 degrees into latching 
engagement with a shoulder on and at the lower edge of the wall bracket 
for latching the container in place to the wall bracket. The tab 68 
extends down at the outer edge of a cavity or recess 70 in the bottom back 
edge of the container. 
A wall mounting bracket is illustrated in FIG. 4, designated generally by 
the numeral 66, and is constructed to mount either to a vertical support 
surface or to a previously mounted bracket. The mounting bracket comprises 
a generally rectangular vertical panel, comprising a generally planar 
central panel 72 secured to and extending upwardly from a latching housing 
74 to be described. The vertical panel comprises central panel 72 and 
forwardly stepped side panels 74 and 76 connected by forwardly extending 
side walls 78 and 80. The central panel 72 has an upper edge 72a which 
extends beneath the skirt 30 on the back of the container between slots 58 
and 60. The forwardly extending walls 78 and 80 have upper edges (only 80a 
shown) which extend into and along slots 58 and 60 of the container. This 
arrangement of upper wall edges engages and supports the upper end of the 
container. 
A lower housing 74 is permanently attached to or made integral with the 
vertical panel and houses the latching and locking mechanism. The panel 72 
and the housing 74 are preferably made separately, such as by molding, and 
latched together by snap-fit latching means, not shown. The housing 74 is 
sized and shaped to form the appearance of an extension of the container 
and to cover the lower end thereof. The face of panel 72 facing the 
housing 74 is considered the front face of the panel for purposes herein. 
A latching lever or arm 82 (FIG. 4) is pivotally mounted in the housing 74 
by a shaft and includes a latching cam or finger 84 on the inner end. The 
latching cam or finger engages tab 68 and biases it under and into 
engagement with latch surface 86 for latching the container in place. 
The outer end of the arm 82 includes a lock assembly 88 that locks the 
lever 82 in the inner position. When the lever 82 is pivoted outward, cam 
or finger 84 is pulled away from shoulder 86, and the tab 68 is released 
so that the container may be lifted upward and removed from the mounting 
bracket. The lock assembly 88 is of conventional construction, having a 
key slot for receiving a key to rotate a shaft having a finger or arm, 
which in one position engages a shoulder in housing 74 for locking the arm 
in the inner position. 
The mounting bracket 66 may be mounted to a vertical support surface, such 
as a wall by screws or lag bolts extending through mounting holes 90 and 
92. It may also preferably be constructed to mount onto other mounting 
brackets. An exemplary embodiment of a typical wedge type bracket is 
illustrated in FIG. 6, of U.S. Pat. No. 4,736,860, and includes a panel 
having upper mounting holes and lower mounting holes for attachment by 
bolts or screws to a wall or the like. The panel includes a pair of 
non-parallel sides forming opposed downwardly diverging mounting rails for 
receiving a disposable container or the like. 
The bracket 72 is provided with a series of opposing fingers along each 
side that engage the rails of the aforementioned bracket. 
Referring now to FIGS. 6-10, the disposable insert version of the 
disposable container for removably mounting in a protective housing will 
be described. This version, as previously mentioned, involves essentially 
the mounting of the different top cover or shell 100 on the same container 
16 of the previous embodiment. As in the previous embodiment, the top 
cover or shell 100 contains a lower peripheral rim 102, having a plurality 
of locking tabs for permanent attachment of the top cover to the upper 
peripheral rim of the container. It also has a pair of hinge tabs 106 for 
spaced connection of the cover to the container. The top cover, as in the 
previous embodiment, also includes a pair of hinge tabs on one side, 
preferably the back side, which are elongated and permit the top cover to 
be attached to one side of the top rim of the container, and hingedly 
positioned over the container in spaced relation, substantially as shown 
in FIG. 7, for serving as a shipping container as will be subsequently 
described. 
Referring to FIG. 6, the top cover 100 comprises a generally rectangular 
top cover with rounded corners, as can be seen from the top view in FIG. 
9, having an elongated slot opening extending substantially the long or 
longitudinal length of the top cover 100. The open slot is surrounded at 
the ends or sides and back by an upwardly extending shallow wall 110, as 
shown in FIGS. 6 and 7, for cooperatively receiving an elongated pivoting 
closure member 112 as illustrated. 
The closure member 112 has a lower horizontally extending shelf or 
receptacle area 114 extending outward from one side of the axis as defined 
by a pair of pivoting pins 116 (only one shown) on the opposite ends 
thereof, and further including an upwardly extending curved portion 118 
extending to the opposite side of the pivot axis, and upward therefrom to 
an upper transverse edge having a pair of locking tabs 120. The closure 
member is assembled in the top cover member as shown in FIG. 6, with the 
pins 116 extending into bearing mounts in the ends of the slot walls for 
pivotally mounting the closure member. The closure member has a normal 
slot closed position, as shown in FIG. 7, with the receptacle area 114 
disposed horizontally for receiving a syringe or like article for 
disposal. The closure member is responsive to the positioning of a syringe 
or article on the receptacle area 114 to self dump the article, i.e., it 
is pivoted about its axis 116 downward to dump the article into the 
container, while the curved portion 118 of the closure extends or pivots 
over and closes the opening 108. 
This container combination is designed as a disposable insert for certain 
existing housings, as illustrated in FIGS. 8 and 10, wherein a rectangular 
box-like housing 122 has a front openable door 124, with locking means 126 
for opening the front of the housing for access thereto. The housing has 
an upper opening slot 128, with a curved cowling or protective shield 130 
extending over the top of the slot 128. The top 100 is designed with its 
opening to fit this opening, with closure member 116 protectively 
extending under the shield 130. In the illustrated arrangement, the 
disposable container is protectively positioned and retained within the 
protective housing 122, with the two openings in registration. 
Thus, the above described system provides a construction wherein one 
container top cover can be utilized to provide a stand alone disposable 
container, and a second closure cover top can be utilized to provide a 
disposable insert for a protective housing. As in the previous embodiment, 
when the container has become full of disposable articles, the closure is 
pivoted forward, such that the top curved portion extends over the 
opening, and the lock tabs at the forward edge thereof are extended into 
and locked into locking slots at the forward edge of the cover opening. 
The container may then be disposed of in the usual manner. 
An alternate feature of the present invention is a construction of both 
embodiments which enable the containers to be shipped in volume in a 
nested fashion, with the top cover attached by the two elongated tabs at 
the back and the top hinged over to one side (not shown). In an alternate 
arrangement, the container can serve as a shipping container, with the top 
positioned over and spaced above the top peripheral edge of the container, 
to accommodate a container 132 as illustrated in FIG. 7, and secured by a 
banding strap 134 in that manner to provide a closed shipping container. 
The carton 132 is preferably high enough to support the top 100 in spaced 
relation above the container, so that attachment tabs 104 do not extend 
into the slots. When the container reaches its destination, the customer 
removes strapping bands, the contents of the container, and then positions 
and attaches the cover directly to the upper rim of the container. This 
may be utilized, for example, for shipping a supply of syringes to a 
hospital clinic or the like. Thus, each container may serve as a shipping 
container for a quantity of syringes which would normally fill the 
container in its disposed configuration. Thus, each shipped supply or 
package of syringes is provided with its own disposable container shipped 
therewith in a compact efficient arrangement. 
While I have illustrated and described my invention by means of specific 
embodiments, it is to be understood that numerous changes and 
modifications may be made therein without departing from the spirit and 
scope of the invention as defined in the appended claims.