EARPLUG DISPENSER BOX

Abstract: An earplug-holding box is described, which can be inserted into a dispenser where the contents can be readily released. The box (30) has a bottom wall formed by a pair of flaps (50, 52). A release device (34) holds outer portions (64, 66) of the flaps together until the release device is pulled out. The outer portion of each flap includes an upstanding tab (76, 78) with a horizontal slot (82), and the release device includes a cardboard plate which is received in the slots. While the upper walls (84, figure 5) of the slots press down against the release plate, the widely spaced opposite sides (90, 92) of the release plate bear against the upper surfaces (94, 96) of the flaps to prevent the tabs (76, 78) and therefore the flaps (50, 52) from moving down.

Description: EARPLUG DISPENSER BOX BACKGROUND OF THE INVENTION: Disposable earplugs, which each have a length of about one inch and a diameter of about 0.5 inch, can be conveniently packaged in cardboard boxes that each hold several hundred. The earplugs can be transferred from the box into a dispenser. It would be desirable if the contents of the box could be transferred without spillage, and without contact with a person's hands which could dirty the earplugs. Such box would be desirable for the transfer of other small articles. SUMMARY OF THE INVENTION In accordance with one embodiment of the present invention, a container is provided which can readily release multiple small articles such as earplugs held therein, into a receiver such as a dispenser, without involving handling by human hands and without substantial danger of spillage. The container includes a box that has a bottom wall with at least one flap. The flap has an inner end pivotally mounted at the bottom of a side wall of the box, and has a free outer end portion. A release device has a forward part coupled to the outer flap portion and to another portion of the box, to support the outer portion of the flap on another portion of the box, until the release device is pulled out o release the flap and allow it to pivot down under the weight of articles in the box. The bottom wall of the box can include two flaps having inner ends pivotally connected to opposite side walls of the box, and having adjacent outer end portions. Each flap outer end portion has a slot forming a tab. The release device can be in the form of a plate whose inner portion lies in the slot to support the tabs, with widely spaced opposite sides of the plate supported on upper surfaces of the flaps. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is an isometric and partially broken-away view of an earplug dispenser, showing a box of the present invention installed thereon. Fig. 2 is an isometric view of the box of Fig. 1 in a closed configuration and also showing in phantom lines, the bottom flaps in an open configuration. Fig. 3 is a view similar to that of Fig. 2, with the release device shown in solid lines in the release position and in phantom lines in the retain position. Fig. 4 is a partial plan view of the release device and of a portion of the bottom wall flaps of Fig. 3. Fig. 5 is a view taken on the line 5 - 5 of Fig. 4. Fig. 6 is a partial isometric view of the apparatus of Fig. 4. Fig. 7 is a front elevation view of the box of Fig. 3, shown prior to unfolding of the box. Fig. 8 is a rear elevation view of a box in the configuration of Fig. 7. Figs. 9 and 10 are partial isometric views of another container. Fig. 11 is a partial isometric view of another container. Fig. 12 is a partial isometric view of another container. DESCRIPTION OF THE PREFERRED EMBODIMENTS Fig. 1 illustrates a container 10 of the present invention, which is filled with earplugs and which is shown installed on an earplug dispenser 12. The earplug dispenser has an open top 14 for receiving the container, and has a frame 16 that forms a hopper for receiving the earplugs. One of the earplugs is indicated at 18. The earplugs fall into holes 20 of a wheel 22 that turns when a crank 24 is turned, to bring each hole and a corresponding earplug therein to a location over a dispense passage 26. The earplug drops out of the hole. through the dispense passage, into a workman's hand or into a receiver 28 from which earplugs are removed. The container 10 and dispenser 12 are constructed so that a person can load the earplugs initially held in the container into the dispenser and can operate the dispenser to dispense a pair of earplugs, without having any worker's hands (which may be dirty) touch the earplugs. The container 10 shown in Fig. 1 includes a box 30 which is installed on the dispenser by pressing the box down through the open top 14 of the dispenser, until stops 32 on the box lie a small distance above the walls 14w of the open top. At that time, a release device 34 of the container will lie within an opening 36 of the dispenser, with the bottom 38 of the box lying substantially at the bottom of the dispenser opening 36. An outer or rear end 40 of the release device forms a handle that can be pulled out, which allows a bottom wall of the box to open and the earplugs to drop out into the dispenser hopper. As shown in Fig. 2, the box has four side walls 41 - 44, a top wall 46, and a bottom wall 48. The bottom wall includes first and second flaps 50, 52. As shown in Fig. 3, each flap has an inner end 54, 56 pivotally mounted on the lower edge 60, 62 of corresponding opposite side walls 41 , 42. Each flap also has an outer flap portion 64, 66. The release device 34 has a forward part 70 coupled to the outer flap portions 64, 66 to support each flap portion from moving down. When the release device handle 40 is pulled out in the rearward direction of arrow R, the flap outer portions are released to pivot down. The flaps pivot down under the weight of the articles contained in the box, and because of a tendency of the box to return to an unfolded configuration. As shown in Fig. 6, each of the flaps has a main part 72, 74 both lying in a substantially horizontal plane. Each flap outer portion includes a largely vertical tab 76, 78 which is engaged with the release device 34. Each tab has a slot 80, 82 extending forwardly from a rear edge 83, with an upper slot wall forming a downwardly-facing surface or shoulder 84. The release device is preferably in the form of a rigid plate of material such as cardboard. The release device has a middle portion 86 with locations that bear against the downwardly-facing surfaces 84 of the tabs, and has opposite sides 90, 92 that bear against upwardly-facing surfaces 94, 96 of the flap main parts 72, 74. As shown in Fig. 5, the middle portion 86 of the substantially rigid plate-like release device 34 presses up against the downwardly-facing surfaces 84 of the tabs 76, 78. At the same time, the opposite sides 90, 92 of the release device press down against the upwardly-facing surfaces 94, 96 of the flap main parts 72, 74. As the flaps 50, 52 begin to pivot downwardly, the tabs 76, 78 and the middle 86 of the release device, tend to move down much further than the opposite sides 90, 92 of the release device. As a result, the opposite sides 90, 92 of the release device are supported on the flaps, and the middle 86 of the release device supports the tabs 76, 78 and therefore the outer end portions of the flaps. Thus, the release device prevents the outer portions of the flaps from moving down by more than a small amount, to thereby prevent release of the articles in the box. When the release device 34 is pulled out, the flaps are free to move down and release the articles. Applicant prefers to construct the release device so its maximum width C (Fig. 3) where it engages the upper surfaces of the flaps, is at least 20 percent of the width D of each of the flaps, and preferably is at least 40 percent of the width of the flaps. Referring again to Fig. 6, it can be seen that the release device 34 has a rearwardly-extending slot 100 which receives the two tabs 76, 78. This prevents more than small movement of the release device, except in rearward and forward directions R, F. Figs. 7 and 8 illustrate the box at 30A in its manufactured but flat orientation. The box is formed from a single sheet of cardboard which has been bent as shown, and with the ends of the single sheet overlapping at 110 in Fig. 8. The stops 32 are formed by cuts along the corners such as at 112 where a pair of adjacent side walls meet. When the box is folded to its use position for fill up with earplugs, all of the stops 32 project and leave only small holes in the box. The release device 34 (Fig. 3) also can be formed of a sheet of cardboard. Applicant prefers to construct the release device 34 (Fig. 6) so its front end 114 substantially abuts the rearwardly facing surface 116 of the rear box side wall 44, across the width of the release device. The release device thereby couples the bottom wall flaps 50, 52 to the rear wall 44. This enables the release device to help keep the bottom of the rear wall extending parallel to the inner edges 118 of the flaps, to avoid a gap through which earplugs could escape. Applicant has constructed and successfully tested containers which were largely of the configuration shown in Figs. 1 - 8. Each box, designed to hold 200 earplugs, was of cardboard of 2.5mm thickness. Each flap (Fig. 3) had a width D of 5.6cm and length of 12.2cm. The release device had a width C of 7.6cm. The width W of the box was 11.2cm, the length L was 12.7cm, and the height was 18.5cm. Fig. 9 and 10 illustrate a portion of another container 140 which includes a box 141 with a pair of flaps 142, 144 forming much of its bottom wall. A release device 146 has a middle 148 which lies under flap outer locations 149, and has opposite outer ends 150, 152 that lie over the inner flap locations 153. A handle 154 can be used to pull out the release device. Each of the flaps has a slot 155, 156 extending forwardly from a forward side 157 of each flap. The release device has a pair of slots 158, 159 extending from its forward edge 161. An important advantage of this container is that the flaps 142, 144 do not have upstanding tabs, on which one or two earplugs might remain when the flaps pivot down. Fig. 11 illustrates a portion of another container 120 which includes a pair of flaps 122, 124 forming much of its bottom wall. However, instead of forming the flaps with upstanding tabs as extensions of the outer edges of the flaps, the tabs are in the form of separate rigid tabs 126, 128 having inner parts 130 fastened as by adhesive or staples to the corresponding flaps 122, 124. Each tab also has an upstanding portion 132 slightly spaced from an upper surface 134 of a corresponding flap to receive an inner portion 136 of a release device 140. The tab upstanding portion 132 may be considered as a location on the flap. The particular tabs 126, 128 can be formed of rigid plastic. The release device will act in the same manner as for the embodiment of Figs. 1 - 8 to prevent the flaps from pivoting down until the release device is pulled out. Fig. 12 illustrates a portion of another container 160 which includes a pair of tabs 162, 164 lying below the bottom surfaces of the flaps 166, 168. A release device 170 in the form of a plate lies under the flaps. The release device has an inner end with opposite sides 172, 174 captured in the tabs and abutting vertically-facing shoulders 176 of the tabs. The middle 180 of the release device abuts the outer flap portions 182, 184. The upwardly- facing shoulders 176 may be considered to be locations on the upper surfaces of the flaps. Although applicant prefers to use two separate flaps, it is possible to use a single flap whose outer end is held by a release device to the side wall. The release device lies substantially no lower than the bottoms (60, 62 in Fig. 3) of the box side walls, to avoid a gap under the box frontmost side wall 43 (Fig. 1) through which earplugs can fall out of the dispenser. That is, the release device should not extend below the side wall bottoms by more than 10 percent of the width or the length of the box. The release device handle 40 should project at least 5mm beyond the box frontmost side wall, to project forward of the dispenser front (or side) wall and to be grasped by fingers. The release device should be removable by sliding it horizontally. Applicant has tried several techniques to enable a box to be installed in a dispenser and earplugs in the box then to be released. One approach was to use a thin plastic sheet covering the bottom of the box, and upstanding blades on the dispenser to cut three sides of the sheet as the box was installed. However, the sharp-pointed blades were dangerous. Another technique was to use a pair of flaps at the bottom of the box, and to use a piece of folded-over tape which could be pulled to peel the tape from outer portions of the flaps and allow them to pivot down. Applicants present approach has been found to assure reliable release of the flaps and closure of the box in a low cost construction. While terms such as "horizontal", "vertical", etc. are used herein to describe the invention, it should be understood that the box can be transported in any orientation with respect to gravity. Although applicant has developed the container to hold earplugs, it is possible for the container to be used to hold other articles of the same order of magnitude as the earplugs (which each have a length of about 2.5cm). Thus, the invention provides a container which can hold multiple small articles, especially earplugs, and which can be inserted into an open top of a dispenser or other receiver, where the box can be readily released to allow the articles to fall out. The box has a bottom wall forming at least one flap, and a release device is provided which has an inner end which holds an outer portion of the flap to another portion of the box. When the release device is moved to a release position, as by pulling it, the flap is released to pivot down. The bottom wall preferably includes two flaps. The release device has a middle portion which lies under locations at outer ends of the two flaps, and has widely spaced opposite sides which bear against upper surface locations of the flaps.

Claims: IN THE CLAIMS: 1. A container which can hold multiple earplugs and which can be inserted into an open top portion of an earplug dispenser where the container can be readily opened to allow the earplugs to fall into the dispenser, where the container includes a box having side walls and a bottom wall, with a first of said side walls having a lower edge, said bottom wall including at least a first flap having an inner end pivotably mounted on said lower edge of said first side wall and having an outer flap portion, characterized by: a release device having a forward part coupled to said outer flap portion and to another part of said box to support said outer flap portion from moving down, said release device having a rear release part forming a handle which can be pulled rearwardly to decouple said forward part of said release device from said outer flap portion and allow said flap to pivot down. 2. The container described in claim 1 wherein: a second of said side walls lies opposite said first side wall and has a lower edge; said bottom wall includes a second flap having an inner end pivotally mounted on said second side wall lower edge and having an outer second flap portion forming said another part of said box; said release device forward part being coupled to said outer flap portions to prevent said flap outer portions from separating and therefore prevent their downward pivoting, until said release device is pulled. 3. The container described in claim 2 wherein: said release device has a middle which lies under locations on said outer flap portions to support said outer flap portions, said release device including a pair of opposite ends that lie on top of inner flap locations that lie inward of said outer flap portions so said flaps support said release device. 4. The container described in claim 2 wherein: said flaps each have a main part lying in a substantially horizontal plane and said outer portions each have a largely vertical tab, and each tab has a slot with an upper slot wall forming a largely downwardly-facing surface; said release device forward part lies under and against said tab downwardly-facing surfaces, and said release device is slidably received in said slots, so as said release device handle is pulled rearwardly said release device moves out of said slots. 5. The container described in claim 4 wherein: said tabs form downwardly facing surfaces at the upper ends of said slots; said release device is in the form of a rigid plate having a width that is at least 20 per cent of the width of each of said flaps, said plate having opposite sides that bear against upper surfaces of said flaps, and said plate having a middle that bears against said downwardly facing surfaces of said tabs. 6. The container described in claim 4 wherein: said box side walls include a frontmost side wall lying opposite said release device handle and having a rearwardly facing surface, and said flaps have upper surfaces and have inner edges lying adjacent to said frontmost side wall; said release device comprises a rigid plate having opposite sides bearing against said upper surfaces of said flaps and a middle engaged with said flap outer portions; said plate having a forward end which substantially abuts said frontmost side wall to keep its rearwardly facing surface substantially parallel to said flap inner edges. 7. The container described in claim 1 wherein: said box side walls have lower ends and said side walls include a frontmost side wall; said release device lies substantially no lower than the lower ends of said box side walls, and said handle of said release device extends at least 5mm rearward of said frontmost side wall. 8. The container described in claim 1 including: an earplug dispenser which has a frame with a box-receiving open upper part constructed with walls that closely receive said box, said walls including a first wall with an opening through which said handle projects to a position outside said frame, to enable grasping and pulling of said handle. 9. A container which can hold multiple earplugs and which can be rapidly opened, comprising: a box having side walls and a bottom wall, said side walls including largely opposite first and second side walls having lower edges, and said bottom wall including first and second flaps each having an inner end pivotally mounted on a corresponding one of said side wall edges and each having adjacent outer end portions, and each having upwardly and downwardly facing surfaces; a release device having a forward portion with a middle that engages said downwardly facing surfaces of said flaps at said outer end portions thereof, said release device having opposite sides that each engages one of said upper surfaces of said flaps at locations spaced from said flap outer end portions, said release device being horizontally slidable to remove said forward portion from said flaps to allow said flaps to pivot down. 10. The container described in claim 9 wherein: each of said flap outer end portions has an upstanding tab with a horizontal slot having a downwardly-facing shoulder forming a portion of a corresponding downwardly-facing surface, said release device middle lying in the slots of said tabs and under and against said shoulders. 11. The container described in claim 9 wherein: each of said flaps has a slot extending from a forward side of said flap and only part of the way toward the rear side of the flap; said release device comprises a plate with a pair of slots extending rearwardly from its forward end, to be aligned with said flap slots. 12. A method for holding and then releasing earplugs into a dispenser that has an open top, comprising: forming a box with side walls and a bottom wall, including forming said bottom wall with a pair of flaps that have upwardly-facing and downwardly- facing flap surfaces, that each have inner ends pivotally mounted on opposite side walls and adjacent outer ends, including forming each flap outer end portion with a rearwardly-extending slot; inserting a plate into said slots so a middle plate portion lies under said flap outer portions between said slots, and outer plate portions lie on top said flaps outward of said slots, to prevent said flaps from pivoting down until said plate is removed.

Inventors: LEIGHT HOWARD S, LEIGHT, HOWARD, S.
Applicants: LEIGHT HOWARD S, LEIGHT, HOWARD, S.
Application year: 1993
Main classification: G07F11
IPC codes: A47F1, A61F11, A61F15, B65D5, G07F11