Abstract:
A sharps container includes a sub-lid that normally defines an opening into the container that is too small for a hand. Upon closure of the sub-lid, the opening is enlarged so that larger objects can be placed in the container while the closure of the sub-lid continues to prevent a hand from reaching into the container interior. Other embodiments are also disclosed.

Description:
[0001]    This application claims priority to U.S. Provisional Applications Ser. Nos. 61/385,539, filed Sep. 22, 2010; 61/422,776, filed Dec. 14, 2010; and 61/513,378, filed Jul. 29, 2011. 
     
    
     BACKGROUND 
       [0002]    Sharps containers are used in hospitals, doctor offices and other areas for the safe disposal of needles and other sharp objects. Some sharps containers inhibit the ability of a person to reach a hand into the container where the hand could come into contact with the sharps. 
         [0003]    Some sharps containers may simply include an opening too small for a hand; however these sharps containers cannot accommodate the occasional large object. 
       SUMMARY 
       [0004]    Several different embodiments of sharps containers are disclosed herein. In a first embodiment, the sharps container includes a sub-lid that normally defines an opening into the container that is too small for a hand. Upon closure of the sub-lid, the opening is enlarged so that larger objects can be placed in the container while the closure of the sub-lid continues to prevent a hand from reaching into the container interior. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0005]      FIG. 1  is an exploded view of a sharps container according to a first embodiment. 
           [0006]      FIG. 2  is a rear perspective view of the assembled container of  FIG. 1 . 
           [0007]      FIG. 3  is a top view of the body portion of the container of  FIG. 1 . 
           [0008]      FIG. 4  is a perspective view of the container of  FIG. 2  in the open, use position. 
           [0009]      FIG. 5  is a perspective view of the assembly of  FIG. 4 , with the insert  26  and sub-lid  24  removed from the body portion 
           [0010]      FIG. 6  shows the sub-lid  24  and insert  26  snap-fit into the body portion 
           [0011]      FIG. 7  shows the connection of the lid  20  to the insert 
           [0012]      FIG. 8  is a section view of the container  10  of  FIG. 7   
           [0013]      FIG. 9  shows the container of  FIG. 8  with the sub-lid rotated forward. 
           [0014]      FIG. 10  shows the container of  FIG. 8  with the sub-lid rotated forward to a locked position. 
           [0015]      FIG. 11  shows the container of  FIG. 10  with the lid closed. 
           [0016]      FIG. 12  is a perspective view of a container according to a second embodiment in a closed position. 
           [0017]      FIG. 13  is a perspective, exploded view of the container of  FIG. 12 . 
           [0018]      FIG. 14  is a bottom perspective view of the exploded container of  FIG. 13 . 
           [0019]      FIG. 15  shows the container of  FIG. 12  with the sub-lid pivoted to an open position. 
           [0020]      FIG. 16  is a section view through the container of  FIG. 15 . 
           [0021]      FIG. 17  shows the container of  FIG. 12  with the lid assembly pivoted to an open position. 
           [0022]      FIG. 18  shows the container of  FIG. 12  stacked with an identical container. 
           [0023]      FIG. 19  shows the container of  FIG. 12  nested with an identical container. 
           [0024]      FIG. 20  is a perspective view of a container according to a third embodiment. 
           [0025]      FIG. 21  is an exploded view of the container of  FIG. 20 . 
           [0026]      FIG. 22  is a section view through the container of  FIG. 20  in the open position. 
           [0027]      FIG. 23  shows the container of  FIG. 20  with the sub-lid rotated to the closed position. 
           [0028]      FIG. 24  shows the container of  FIG. 23  with the lock arm rotated down to the locked position. 
           [0029]      FIG. 25  is a perspective view of a container according to a fourth embodiment in the closed position. 
           [0030]      FIG. 26  shows the container of  FIG. 25  in the open position. 
           [0031]      FIG. 27  is an exploded view of the container of  FIG. 25 . 
           [0032]      FIG. 28  is a section view through the container of  FIG. 26 . 
           [0033]      FIG. 29  shows the container of  FIG. 25  with the lid assembly pivoted to the open position for cleaning. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0034]    An exploded view of a sharps container  10  according to one embodiment of the present invention is shown in  FIG. 1 . The sharps container  10  includes a body portion  12  having a side wall  14  extending upwardly from the perimeter of a base wall  16 . A lip  15  protrudes outwardly and then downwardly from an upper edge of the side wall  14 . The container  10  further includes a lid assembly  18  selectively enclosing the opening to the body portion  12 . The lid assembly  18  includes a lid  20 , a sub-lid  24  and an insert  26 . 
         [0035]    The sub-lid  24  includes a concave upper wall  28  and a rear wall  29  between two side walls  30  having pivot pins  32  projecting outwardly therefrom. Crenulated or corrugated handle portions  34  project outwardly from a front edge of the side walls  30 . A flange  36  projects forward from the concave upper wall  28 . 
         [0036]    The insert  26  includes a peripheral wall  40  and a lip  42  projecting outwardly from an upper edge of the peripheral wall  40 . Recesses  44  are formed on the interior of the insert  26  for pivotably receiving the pivot pins  32  of the sub-lid  24 . Brackets  46  project upwardly from lateral edges of the insert  26  toward the rear of the insert  26 . Each bracket  46  includes a guide track  48  having a narrow portion spaced away from an open end. Connectors  50  project downwardly at each lateral end of the insert  26  for connecting the insert  26  to the body portion  12 . 
         [0037]    The body portion  12  includes complementary recessed connectors  54  for receiving the connectors  50  of the insert  26 . The body portion  12  may optionally be molded from a translucent polymer so that it can be determined whether the container  10  is full. Indentations  70  are formed in each lateral portion of the side wall  14  of the body portion  12  so that the body portion  12  can be locked to a counter top. 
         [0038]    A handle  56  may be integrally molded with the lid  20 . Hinge pins  76  are formed along a rearward edge of the lid  20  for connection to the body portion  12 . 
         [0039]      FIG. 2  is a rear perspective view of the assembled container  10  in a closed position. Hinge pin receivers  72  are formed along a rearward side of the lip  15  for hingeably connecting the hinge pins  76  of the lid  20  to the body portion  12 . A bracket  78  across the rear of the body portion  12  can be used to lock the container  10  to a wall mount. 
         [0040]      FIG. 3  is a top view of the body portion  12 . As shown, the base  16  includes a plurality of soft bumps  86  that keep waste from sticking to the base  16 . 
         [0041]      FIG. 4  shows the assembled container  10  in the open position. The insert  26  includes an apron  80  angling downwardly from an upper front edge of the insert  26 . The apron  80  has upwardly angled side edges  82 . The handles  34  and side walls  30  of the sub-lid  24  are disposed outwardly of the side edges  82  of the apron  80  of the insert  26 . The pivot pins  32  of the sub-lid  24  are received in the recesses  44  of the insert  26  so that the sub-lid  24  is pivotably mounted in the insert  26 . The front edge of the lid  20  includes a pair of latch openings  60  for interlocking with tabs  62  on the lip  15  of the body portion  12  to lock the lid  20  to the body portion  12 . A gasket (not shown) may optionally be secured to the lid  20  to seal liquids within the container  10 . 
         [0042]      FIG. 5  is a perspective view of the assembly of  FIG. 4 , with the insert  26  and sub-lid  24  removed from the body portion  12 . The sub-lid  24  is shown in a closed position, with the angled side edges  82  of the apron  80  of the insert  26  received in recesses in the front flange  36  of the sub-lid  24 . 
         [0043]      FIG. 6  shows the sub-lid  24  and insert  26  snap-fit into the body portion  12  (via connectors  50 ,  54  ( FIG. 1 )). In  FIG. 6 , the sub-lid  24  is in the closed position. The lid  20  is pivoted rearward. Brackets  73  project downwardly from a lower surface of a top wall of the lid  20 . Pivot pins  74  project inwardly from the brackets  73 . The pivot pins  74  align with the tracks  48 . 
         [0044]      FIG. 7  shows the connection of the lid  20  to the insert  26 . The pivot pins  74  snap-fit into an upper portion of the guide tracks  48  formed in the brackets  46  of the insert  26 . The upper portion of the guide track  48  retains the pivot pins  74  in the upper portion until sufficient force is applied to the lid  20  to force the pivot pins  74  past the upper portion of the guide track  48  into the remainder of the guide track  48 . In this manner, the lid  20  will remain in the open position during use until intentionally closed for transport when full. 
         [0045]      FIG. 8  is a section view of the container  10  of  FIG. 7 . As shown, the hinge pins  74  snap-fit into the upper portion of the guide tracks  48  above the narrow portion formed in the brackets  46  of the insert  26 . In  FIG. 8 , the sub-lid  24  is pivoted to the open position and the lid  20  is in the open position. In this position, a user can place an object (e.g. a sharp) on the apron  80  of the insert  26  and it will slide or roll toward the rear of the container  10 , fall between the rearward edge of the apron  80  and the concave wall  28  of the sub-lid  24  onto the rear wall  29  of the sub-lid and then slide or roll forward into the container body portion  12 . 
         [0046]    The space between the rearward edge of the apron  80  and the concave wall  28  of the sub-lid  24  is shown as distance A in  FIG. 8 . This is the narrowest point in the path into the container  10  when the sub-lid  24  is open. In the example shown, the distance A is about 1.05″, but other distances could be used. The distance A may be chosen small enough to prevent a user&#39;s hand from reaching into the container  10  when the sub-lid  24  is open, but large enough to let most objects fall into the body portion  12  without requiring the user to touch the container  10 . 
         [0047]    If a larger object is placed on the apron  80 , it may be larger than the distance A and therefore may stop at the rearward edge of the apron  80 . In that case, the sub-lid  24  can be rotated forward as shown in  FIG. 9 . Because of the location of the pivot axis P (corresponding to pivot pins  32 , more precisely identified in  FIG. 1 ) of the sub-lid  24  and the shape of the sub-lid  24 , the concave wall  28  and rear wall  29  move upward and rearward, thus enlarging the distance between the rearward edge of the apron  80  and the rear wall  29  to a distance B ( FIG. 10 , in this case about 1.58″). As the sub-lid  24  is pivoted forward, the larger object can drop into the body portion  12  of the container  10 , but only as the sub-lid  24  is being closed, which prevents hand access into the body portion  12  of the container  10 . When the sub-lid  24  is released, the weight of the rear wall  29  and concave wall  28  pivot the sub-lid  24  back to the open position. 
         [0048]    As shown in  FIG. 10 , when the container  10  is full, the sub-lid  24  can be pivoted forward firmly, forcing a locking protrusion  88  on a rear surface of the sub-lid  24  past a flange  90  on the insert  26 . This keeps the sub-lid  24  in the closed position. The lid  20  is then pivoted downward, forcing the pivot pins  74  into the tracks  48 , until the lid  20  is closed, as shown in  FIG. 11 . When the lid  20  is closed, the tabs  62  on the lip  15  of the body portion  12  snap into the latch openings  60  on the lid  20  to keep the lid  20  in a closed position (tabs  62  and latch openings  60  shown in  FIG. 4 ). 
         [0049]    The closed container  10  can then be shipped to an appropriate facility for removing and disposing of the sharps, cleaning the container  10  and returning it to use. 
         [0050]    A container  110  according to a second embodiment of the present invention is shown in  FIGS. 12-19 . Referring to  FIG. 12 , the container  110  includes a body portion  112  having a side wall  114  extending upwardly from a periphery of a base wall  116 . A lip extends outwardly and then downwardly from an upper most edge of the side wall  114 . A lid assembly  118  includes a lid portion  120  and a sub-lid  124 . The lid portion  120  includes a hood  138  generally over a rearward half (approximately) of the opening to the container body portion  112 . The hood  138  extends upwardly from rear and side portions of a lip portion  132  of the lid portion  120 . The upper wall of the hood  138  includes a pair of openings  137 . The sub-lid  124  includes a concave wall  148  having a pair of raised rail portions  158  along an exterior surface thereof, including an enlarged portion  160 . The rail portions  158  are aligned with and received in the openings  137  of the hood  138 . 
         [0051]      FIGS. 13 and 14  are exploded views of the container  110 . The lid portion includes a pair of slots  134  formed in a front portion of the lip  132 . An upper wall  139  of the lid portion  120  extends rearwardly and downwardly from a front portion of the lip  132 . The lid portion  120  further includes a pair of arms  136  extending downwardly adjacent the upper wall  139  to form pivot pin receiving portions. Concave ribs  164  are formed on a rear wall and the upper wall of the hood  138  of the lid portion  120 . 
         [0052]    The sub-lid  124  includes a concave wall  148 , which in the embodiment shown is semi-cylindrical, although greater than or less than 180° could also be used. The sub-lid  124  also includes opposed side walls  146  from which hinge pins  147  protrude for pivotably connecting to the lid portion  120 . 
         [0053]    Hinge portions  128  are formed on a rear portion of the lip  115 . 
         [0054]    The front portion of the lip  115  includes a protruding latch portion  130 , which snap-fit connects to a latch portion  162  formed integrally with the lid portion  120 . The raised rail portions  158  provide more stable support for stacking another container on them when the sub-lid  124  is closed. Complementary recesses  166  in the bottom wall  116  of the body portion  112  receive the rail portions  158  when stacked thereon. 
         [0055]      FIGS. 15 and 16  show the sub-lid  124  pivoted to the open position. As shown in  FIG. 16 , the flange  152  of the sub-lid  124  contacts the hood  138  of the lid portion  120  in the open position. The concave wall  148  of the sub-lid  124  together with the upper wall  139  of the lid portion  120  provide a tortuous path into the body portion  112  of the container  110 . Objects can be dropped through the opening between the hood  138  and the upper wall  139  of the lid portion  120 . If the object does not fall into the body portion  112  after rolling off the concave wall  148 , the object will drop into the body portion  112  when the sub-lid  124  is rotated back to the closed position. 
         [0056]    When full, the container  110  is shipped to a disposal facility in the closed position as shown in  FIG. 12  with the locking tabs  140  snap-fit into the slots  134  in the lid portion  120  ( FIGS. 13 and 14 ). At the disposal facility, the lid portion  120  is released from the body portion  112  by unlatching the latch portions  130 ,  162  and pivoting the lid assembly  118  to the open position, as shown in  FIG. 17 . The container is then emptied and washed before being returned for reuse. 
         [0057]    As shown in  FIG. 18 , the containers  110  can be stacked on one another in the closed position. As shown in  FIG. 19 , the containers  110  can be nested within one another with the lid assemblies  118  in the open position. 
         [0058]    A sharps container  210  according to a third embodiment of the present invention is shown in  FIGS. 20-24 . Referring to  FIG. 20 , the container  210  includes a body portion  212  having a side wall  214  extending upwardly from the perimeter of a base wall  216 . A lip  215  protrudes outwardly and then downwardly from an upper edge of the side wall  214 . The container  210  further includes a lid assembly  218  selectively enclosing the opening to the body portion  212 . The lid assembly  218  includes a lid portion  220 , a lock arm  222  and a sub-lid  224 . The lid portion  220  is connected to the lip  215  of the body portion  212 . The lock arm  222  and the sub-lid  224  are pivotably connected to the lid  20 . 
         [0059]    An exploded view of the container  210  is shown in  FIG. 21 . The body portion  212  includes hinge members  228  at a rear of the body portion  212  extending from the lip  215 . A lock  230  is secured to the lip portion  215  at the front of the body portion  212 . 
         [0060]    The lid portion  220  includes a perimeter lip portion  232  having a pair of slots  234  formed through a front portion thereof. Pivot recesses  236  are formed in side portions of the lid portion  220 . The rear half (approximately) of the lid portion  220  includes a hood  38  extending upwardly from the perimeter lip  232  and forwardly to about a midpoint of the lid portion  220 . An upper wall  239  of the lid portion  220  extends from a front portion of the lip  232  and slopes downwardly to an approximate midpoint of the lid portion  220 . Thus, an opening is defined between the rearward edge of the upper wall  239  and the back wall of the hood  238 . 
         [0061]    The lock arm  222  includes a pair of locking tabs  240  extending downwardly from a front wall  242 . The front wall  242  is defined between a pair of arms  244 , which pivotably connect to the lid portion  220  as shown in  FIG. 20 . 
         [0062]    The sub-lid  224  includes side walls  246  having pivot pins  247  extending therefrom. A concave upper wall  248  joins the two side walls  246  and is connected to a flat lower wall  250 . A flange  252  protrudes outwardly from an upper portion of the side walls  246  and the upper edge of the upper wall  248 . 
         [0063]      FIG. 22  is a section view through the container  210  of  FIG. 20 . In the open position, objects, such as hazardous, sharp medical objects can be deposited through the opening defined between the upper wall  248  of the sub-lid  224  and the upper wall  239  of the lid portion  220 . The lower wall  250  of the sub-lid  224  together with the upper wall  239  of the lid portion  220  define a tortuous path that permits small objects to drop into the body portion  212 , but prevents a hand from reaching into the body portion  212 . The sub-lid  224  remains in the open position due to weight balance and the hinge location. This also causes the sub-lid  224  to automatically rotate down into the closed position if the container  210  falls and rotates up-side-down. 
         [0064]    As shown in  FIG. 23 , the sub-lid  224  can be rotated downward to the closed position. The upper wall  248  of the sub-lid  224  covers the opening between the hood  238  and the upper wall  239  of the lid portion  220  ( FIG. 22 ). The sub-lid  224  can be repeatedly opened and closed in order to place more objects into the body portion  212  of the container  210 . When the container  210  is full, the lock arm  222  is rotated downward over the flange  252  of the sub-lid  224 , as shown in  FIG. 24 . The locking tabs  240  snap into the slots  234  in the lip  232  of the lid portion  220 , thereby more permanently closing the container  210 . The locking arm  222  and sub-lid  224  cannot be opened again without special tools inserted into the small openings  256  formed at the front of the lip  232  of the lid portion  220 , in order to release the locking tabs  240 . The container  210  loaded with objects would be shipped as shown in  FIG. 24  and would be opened at the disposal facility for disposing of the objects therein, possibly washing the container  210  and returning the container  210  for reuse. 
         [0065]      FIGS. 25-28  illustrate a container  310  according to a third embodiment of the present invention. The container  310  includes a body portion  312  having a side wall  314  extending upwardly from the periphery of a base wall  316 . A lip  315  protrudes outwardly and then downwardly from an upper most edge of the side wall  314 . A lid assembly  318  is secured over an opening to the body portion  312 . The lid assembly  318  includes a lid portion  320  having a peripheral lip  332 , which is selectively latched to the lip  315  of the body portion  312  by a sliding latch member  330 , which can be released by sliding the latch member  330  to a release position  333  on the lid portion  320 . 
         [0066]      FIG. 26  shows the container  310  in the open position, with the lid portion  320  pivoted upwardly about an axis at its rearward edge. The lid portion  320  includes side walls  336  projecting downwardly into the container  310 . A dump tray  324  is pivotably mounted in the mouth of the body portion  312 . A guard  370  is also mounted in the mouth of the body portion  312 . 
         [0067]      FIG. 27  is an exploded view of the container  310 . The tray  324  includes a lower wall portion  348  and a pair of opposed pivot pins  347  about which the tray  324  can pivot. 
         [0068]    The guard  370  includes a peripheral wall portion  372  having a lip about the periphery thereof. The guard  370  further includes a rear wall  374  extending downwardly and inwardly at an angle. In the embodiment shown, the rear wall  374  is concave. 
         [0069]    Referring to  FIG. 28 , when the lid portion  320  is opened, an opening is defined between the front edge of the lid portion  320  and the tray  324 . An object placed on the lower wall  348  of the tray  324  will cause the tray  324  to tip downwardly, thereby dumping the object into the body portion  312  of the container  310 . The wall  348  of the tray  324  together with the rear wall  374  of the guard  370  provide a tortuous path into the body portion  312 , thereby preventing a hand from entering the body portion  312 . An angled wall  378  extends downwardly from the lower wall  348  of the tray  324  to retain objects in the body portion  312 . The guard  370  includes a front wall angled inwardly to provide a stop for the tray  324 . 
         [0070]    As shown in  FIG. 29 , the entire lid assembly  318  can be pivoted to the open position as shown, to empty the contents of the container  310  and permit washing. 
         [0071]    In accordance with the provisions of the patent statutes and jurisprudence, exemplary configurations described above are considered to represent a preferred embodiment of the invention. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.