Abstract:
An emergency eyewash station and dispensing structure therefore is disclosed. The emergency eyewash station includes a main body configured and arranged to hold and dispense eyewash fluid therefrom, an actuator arm assembly movable from a closed position to an open position, and a dispensing structure having an eyepiece sealed by a membrane. The eyepiece is in fluid connection with the eyewash fluid contained in the main body. The dispensing structure is removably coupled to the actuator arm assembly such that when the actuator arm assembly is moved from the closed position to the open position, the membrane is unsealed and the eyewash fluid dispenses from the eyepiece.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The present application claims priority to earlier filed U.S. Provisional Patent Application Ser. No. 60/743,484, filed Mar. 15, 2006, the contents of which are incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to emergency eyewash stations and more particularly to an emergency eyewash station having a mechanism to remove a plug from a sealed end of a fluid dispensing hose connected to a source of “sterile” eyewash fluid. 
     2. Background of the Related Art 
     Government and employers are increasingly aware of the need for protecting the health and safety of workers. For this reason, it is common to find eye wash fountains at industrial work sites, laboratories, and other locations where workers are exposed to gaseous fumes, liquids or solid materials which can irritate or injure eyes upon contact therewith. The Occupational Safety and Health Administration (OSHA) has made eye wash fountains mandatory for particular industrial work stations. 
     Early installations of eye wash fountains employed sprays of regular tap water fed from regular plant plumbing connections. These devices were adequate for a period of time, but suffered from the drawbacks of using the regular water supply. For example, there could be contaminants and bacteria in regular plumbed water. Furthermore, the pressure of regular running water is inconsistent creating an uneven water flow, or in the event of a major facility accident, the water may not be running at all. 
     Later devices, such as the eye wash fountains disclosed in U.S. Pat. No. 4,012,798 to Liautaud and U.S. Pat. No. 4,363,146 to Liautaud, were self-contained, gravity-fed, and independent of any plumbing connections. These self-contained eye wash fountains typically included a reservoir (or bottles) of wash fluid spaced above two opposed liquid spray nozzles. Upon activating the fluid flow, the wash fluid from the reservoir is fed solely by gravity to the nozzles to cause a gravity-induced spray of wash fluid from the nozzles. These stations provided improved safety in terms of the quality of the water utilized but suffered from low and/or inconsistent water pressure to properly flush the eyes. 
     In an effort to encourage more suitable eye wash facilities, the American National Standards Institute (ANSI) promulgated voluntary standards for portable eye wash fountains relating to flushing periods and the rate of flow of wash fluid. These standards dictate that portable eye wash fountains should deliver no less than 0.4 gallons per minute (1.5 liters per minute) of eye wash fluid for a time period of minutes. Responsive to the new ANSI standard, several designs emerged that included means for maintaining a constant eye wash flow rate without any powered pumping mechanisms. For example, U.S. Pat. No. 5,566,406, U.S. Pat. No. 5,695,124 and U.S. Pat. No. 5,850,641 all issued to Demeny et al, disclose an emergency eyewash station having a gravity assist mechanism that acts on a flexible reservoir contained in a disposable paperboard box. The self-contained emergency eye wash station generally comprises a housing, a reservoir, and a platen. The housing includes a shelf that supports a pair of flexible containers arranged in side-by-side relation. The flexible containers are of the type generally referred to as “bag-in-a-box” packaging, having an inner flexible plastic bag containing the eyewash fluid, and an outer cardboard box structure, which supports the flexible bag in a predetermined shape. The housing further supports a delivery platform including a nozzle, which is in fluid communication with the flexible container. The nozzle selectively dispenses the eye wash fluid from the flexible container when activated. The housing further includes a drain that captures the eye wash fluid dispensed from the nozzle and directs the eye wash fluid into the reservoir. The reservoir is slidably mounted to the housing and the platen is connected to the reservoir. As the reservoir fills, the platen presses downward on the flexible container with a downward force proportional to a weight of the eye wash fluid collected in the reservoir. The transfer of the weight of the eye wash fluid collected in the reservoir to the platen maintains a constant flow of eye wash fluid dispensed from the nozzle. 
     The above-noted gravity assist configuration has been very successful in the marketplace and is still in widespread use today. Because the 6 gallons of fluid is divided into two smaller containers, the flexible reservoirs are relatively small and easily replaced by service personnel. In addition, the bag-in-a-box packaging technology is well established, and the costs for producing, maintaining and replacing the disposable cartridges at established intervals of time has heretofore been relatively inexpensive. The costs for this type of system are such that the manufacturer could cost effectively provide a pre-assembled delivery tube and nozzle assembly with each of the disposable cartridges, making installation and replacement that much easier. 
     However, new ANSI and OSHA regulations have created new issues that will need to be addressed, and will require improvements to the existing designs to maintain compliance. In particular, upcoming OSHA regulations will soon require the use of “sterile” eye wash fluids. The regulatory and production requirements for “sterile” eyewash fluids are far greater than the previous “non-sterile” standards and will make the production of the existing cartridges cost prohibitive. 
     Accordingly, there is a need in the industry for an improved cartridge assembly which can be filled with a sterile fluid, maintained in a sterile condition for the required shelf-life of the product, provide for safe shipment, handling and storage of the product, and provide for simple installation and replacement, and finally provide a reliable dispensing arrangement for emergency use. Furthermore, there is a need for an improved delivery system which can accommodate the different requirements of the new “sterile” cartridge assemblies, while reducing costs and maintaining simple installation and upkeep of the system. 
     SUMMARY OF THE INVENTION 
     The emergency eyewash station of the present invention addresses the problems of the prior art by uniquely providing an emergency eyewash station including an improved cartridge assembly having a sterile “bag” or bladder with a fluid hose having a sealed eyepiece on a dispensing structure at one end, and an actuation mechanism to tear the seal free from the eyepiece upon actuation of the unit. 
     In particular, the emergency eyewash station of the present invention has a dispensing unit with a pivoting actuator arm assembly having a pair of spring-biased locking members. The actuator arm assembly is configured to pivot between an upright closed position and an open activated position. The locking members are configured and arranged to securely receive the dispensing structure, and may be configured to be selectively releasable therefrom. The seal on the eyepiece of the dispensing structure is secured to the dispensing unit and is configured to peel or tear away from the eyepiece as the actuator arm assembly is pivoted to the open position from the closed position. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description, appended claims, and accompanying drawings where: 
         FIG. 1  is a front perspective view of the preferred embodiment of the emergency eyewash station of the present invention; 
         FIG. 2A  is front perspective view of the cartridge for the preferred embodiment of the emergency eyewash station of the present invention; 
         FIG. 2B  is an exploded view of the cartridge of the preferred embodiment of the emergency eyewash station of the present invention; 
         FIG. 3A  is a front perspective view of the dispensing structure and clip body unfolded; 
         FIG. 3B  is a rear perspective view of the dispensing structure and clip body unfolded; 
         FIG. 3C  is a rear perspective view of the dispensing structure and clip body folded and ready for use in the emergency eyewash station of the present invention; 
         FIG. 4  is a perspective view of the preferred embodiment of the emergency eyewash station of the present invention with the actuator arm assembly deployed to the open position and the headrest pulled forward; 
         FIG. 5  is a front perspective view of the dispensing structure connected to the projection of the emergency eyewash station of the present invention; 
         FIG. 6  is a side cross-section through line  6 - 6  of  FIG. 1 ; 
         FIG. 7  is a top perspective view of the actuator arm assembly of the emergency eyewash station of the present invention; 
         FIG. 8  is a top perspective view of the emergency eyewash station of the present invention with the actuator arm assembly being activated, which illustrates the membrane being peeled free from the eyepiece of the dispensing structure; and 
         FIG. 9  is a front perspective view of the emergency eyewash station of the present invention with the actuator arm assembly in the fully open position. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to  FIG. 1 , the emergency eyewash station of the present invention is shown generally at  10 . As will be described in greater detail below, the emergency eyewash station  10  of the present invention includes an eyewash cartridge assembly  12  and a dispensing structure  22  (best seen in  FIG. 2A ), which is operable for dispensing eyewash fluid from the cartridge assembly  12  upon activation of a pivoting actuator arm assembly  36 . 
     As shown in  FIGS. 2A and 2B , the cartridge assembly  12  generally comprises a rigid plastic, outer housing  16  and a disposable flexible inner bladder  14  or bag containing a sterilized eyewash fluid therein. 
     The housing  16  is formed from two symmetrically identical housing sections  16   a ,  16   b , each having interfitting mating formations that permit the housing sections  16   a ,  16   b  to be snap-fit together and maintained in assembled relation. 
     The flexible bag  14  comprises a flexible plastic material configured for optimal displacement and capacity within the housing  16 . The flexible bag  14  is filled using a proprietary filling system through a filling port  18  that maintains sterility of the inside of the bag  14  and the fluid during the filling process. Also connected to the flexible bag  14  is a hose  20  with a dispensing structure  22  at the opposite end. 
     Referring to  FIGS. 3A ,  3 B and  3 C, the dispensing structure  22  has an eyepiece  23  extending from a forward facing portion of the dispensing structure  22  and a hose connector  24  extending from a rear facing portion of the dispensing structure  22 . The eyepiece  23  is in fluid connection with the hose connector  24 , hose and flexible bag  14  as shown in  FIGS. 2A and 2B . However, for ease of illustration,  FIGS. 3A ,  3 B, and  3 C, illustrate the dispensing structure  22  is shown disconnected from the hose  20  and flexible bag  14 . 
     The eyepiece  23  is sealed closed by a membrane  26  with a tab  27  extending from one end. The tab  27  of the membrane  26  is trapped between two halves of a clip body  28   a ,  28   b  that fold closed and snap-fit together to securely hold the tab  27  of the membrane  26  to the clip body  28   a ,  28   b . Once snapped closed, the clip body  28   a ,  28   b  is folded over onto the dispensing structure  22 . 
     The retaining structures  30   a ,  30   b ,  30   c  on the outboard edges of the clip body  28   b  attach to the outer edges of the dispensing structure  22  and hold the clip body  28   a ,  28   b  onto the dispensing structure  22 , which is shown in  FIG. 3C . On the opposite side of the clip body  28   a  is a cantilevered spring arm  32  for attaching the clip body  28   a ,  28   b  to the eyewash station  10 , which will be further described below. Extending from a rear facing portion of the dispensing structure  22  is a pair of opposing and outwardly facing hooks  34   a ,  34   b  for connecting the dispensing structure  22  to the pivoting actuator arm assembly  36 , which will also be more fully described below. Each hook  34   a ,  34   b  has a sloped surface thereon. 
     Referring to  FIG. 4 , the main body of the eyewash station  10  includes a pivoting actuator arm assembly  36 . The actuator arm assembly  36  can be pivoted from an upright closed position (as seen in  FIG. 1 ) to an activated or open prone position (as seen in  FIGS. 4 and 9 ). When in the closed position, the actuator arm assembly  36  conforms to the main body portion to present a uniform appearance and prevent accidental discharge of the eyewash station  10 . Although it is preferred that the actuator arm assembly  36  pivot downwardly, one-skilled in the art would appreciate that the actuator arm assembly  36  could be configured and arranged to slide or pivot in another direction as desired with equally effective results. 
     The actuator arm assembly  36  also includes a headrest  38  to help the user of the eyewash station  10  properly align his or her eyes with the eyepiece  23  of the dispensing structure  22 . As shown in  FIG. 4 , the headrest  38  conveniently folds forward and out of the way to allow the eyewash station  10  of the present invention to be easily armed and inspected. In particular, the user may fold the headrest  38  out of the way to be able obtain access to the interior of the device through an access port to be able to feed the dispensing hose  20  therethrough. During use, the headrest  38  is folded rearward, as shown in  FIG. 9 . The headrest  38  also has a central channel for the hose  20  to nestle in during and prior to actuation of the emergency eyewash station  10 . 
     Referring now to  FIGS. 4-6 , within the main dispensing unit and behind the actuator arm assembly  36  (while in the upright closed position) there is a projection  40  with a front face  42  and a slot  44  on a top edge of the projection  40 . To arm the eyewash station  10 , the dispensing structure  22  is connected to the projection  40  by sliding the spring arm  32  of the clip body  28   a ,  28   b  into the slot  44 , as shown in  FIGS. 5-6 . The clip body  28   a ,  28   b  is held against the front face  42  of the projection  40  by the spring arm  32 . 
     Referring now to  FIG. 7 , on the actuator arm assembly  36  is a pair of inwardly spring-biased locking members  46   a ,  46   b . The spring-biased locking members  46   a ,  46   b  may be forced apart by depressing a release button  48  on the front of the actuator arm assembly  36 , best viewed in  FIG. 1 . Referring back to  FIG. 7  now, the release button  48  has a wedged-shaped projection that forces the locking members  46   a ,  46   b  apart when the release button  48  is depressed. The release button  48  allows for convenient inspection of the eyewash station  10 , without discharging the station accidentally. 
     When the actuator arm assembly  36  is pivoted to the upright and closed position, the locking members  46   a ,  46   b  couple to the hooks  34   a ,  34   b  on the dispensing structure  22 . In particular, the sloped surfaces of the hooks  34   a ,  34   b  force the locking members  46   a ,  46   b  apart and to allow the locking members  34   a ,  34   b  to pass over and couple to the hooks  46   a ,  46   b . With the spring arm  32  secured to the projection  40  and the locking members  46   a ,  46   b  secured to the hooks  34   a ,  34   b  on the dispensing structure  22 , the emergency eyewash station  10  is now armed and ready for use. 
     Referring to  FIGS. 8-9 , pulling on the actuator arm assembly  36  causes the dispensing structure  22  to separate from the clip body  28   a ,  28   b , thereby freeing the membrane  26  from the eyepiece  23 . Specifically, as shown in  FIG. 8 , as the actuator arm assembly  36  pivots, the clip body  28   a ,  38   b  remains secured to the projection  40  by the spring arm  32 . Because the tab  27  of the membrane  26  is securely held within the to portions of the clip body  28   a ,  28   b  and the dispensing structure  22  is securely held in the actuator arm assembly  36  by the locking members  46   a ,  46   b , the membrane  26  is peeled away from the eyepiece  23  of the dispensing structure  22  as the actuator arm assembly  36  pivots downwardly to the open position. As seen in  FIG. 9 , once the actuator arm assembly  36  is pivoted to the open position, the membrane  26  has been completely separated from the eyepiece  23  of the dispensing structure  22  and the eyewash fluid may dispense freely therefrom. 
     Therefore, it can be seen that the present invention provides a unique solution to the problems of the prior art by providing an emergency eyewash station that uniquely providing an emergency eyewash station including an improved cartridge assembly having a sterile “bag” or bladder with a fluid hose having a sealed eyepiece on a dispensing structure at one end, and an actuation mechanism to tear the seal free from the eyepiece upon actuation of the unit. 
     It would be appreciated by those skilled in the art that various changes and modifications can be made to the illustrated embodiments without departing from the spirit of the present invention. All such modifications and changes are intended to be within the scope of the present invention except as limited by the appended claims.