Abstract:
A reusable biohazard waste container is configured such that the container can be transported without requiring any additional packaging elements. A lid is pivotally connected to the container and is movable between an open position and a closed position. A latch secures the lid to the container when in the closed position such that the container is capable of holding liquids.

Description:
RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Provisional Application No. 61/230,797, filed Aug. 3, 2009, and U.S. Provisional Application No. 61/296,623, filed Jan. 20, 2010. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention relates to a reusable biohazard waste container that is properly packaged such that the container can be transported without requiring any additional packaging elements. 
         [0003]    Biohazard waste containers are used as containment receptacles for transporting biohazard waste streams. While these containers can be used for any type of biohazard waste, one example of such a container is referred to as a “sharps” container. Biological sharps typically include, but are not limited to, items such as hypodermic needles, syringes, Pasteur pipettes, broken glassware, broken plastic-ware, lancets, glass slides, cover slips, plastic pipettes, pipette tips or any other material that is able to puncture a plastic trash bag Such items must be placed into impervious, rigid, puncture-resistant containers to avoid injury during transport. Once an item has been used, it is placed in the waste container for disposal or reuse. Once the container is full, the container is transported to a facility such that the waste can be properly disposed of or recycled for reuse. 
         [0004]    Due to the contaminated and potentially hazardous nature of the contents of the container, these containers need to be shipped within a properly packaged environment. If the container is properly sealed then it can be transported without any form of secondary packaging. Typically, most biohazard waste is double packaged either by having waste disposed within a tied-off red bag that is deposited within a container, or by depositing the waste in one container that is then placed within a separate outer container for transportation. Requiring additional containers and/or other packaging elements is expensive, and further takes up valuable cargo space. 
       SUMMARY OF THE INVENTION 
       [0005]    A reusable biohazard waste container is configured such that the container can be transported without requiring any additional packaging elements. The container includes a bottom wall, a front wall, a rear wall, and a pair of side walls that extend upwardly from the bottom wall to form a box-shaped biohazard waste container. A lid is pivotally connected to the container to be movable between an open position and a closed position. A latch secures the lid to the container when in the closed position such that the container is capable of holding liquids. 
         [0006]    In one example, the lid includes a gasket feature formed within an upper lid surface and a gasket rib structure formed within a lower lid surface. A gasket is installed on the gasket rib structure and is sealable against upper edges of the front, rear and side walls when the lid is in the closed position. The gasket feature and the gasket rib structure are configured such that the container is capable of holding liquids when the latch secures the lid to the container and such that the lid lies flat against an outer surface of the rear wall when the lid is in the fully open position without bending the gasket. 
         [0007]    In one example, the lid comprises a primary lid and the latch comprises a primary latch. The primary lid includes an opening for a secondary lid that is pivotally attached to the primary lid to provide access to an interior of the container without having to unlatch the primary latch. A secondary latch secures the secondary lid to the primary lid such that the container is capable of holding liquids when both the primary and secondary latches are latched. 
         [0008]    In one example, a recessed area is formed within a lower portion of at least one of the front, rear, or side walls. The recessed area is adapted to receive a portion of a second container to facilitate stacking of the container on top of the second container. 
         [0009]    In one example, a recessed area is formed within the container and includes a gripping surface to receive one of a universal clamp or hook. This allows the container to be picked up by an automated device and moved as needed. 
         [0010]    In one example, a plurality of vertical extension portions are located at each corner of the container. Each vertical extension portion extends outwardly from one of the front, rear, or side walls of the container to nest on corresponding nesting stop areas on an adjacent container. 
         [0011]    In one example, the lid includes at least one raised locating portion to locate a second container on top of the lid. 
         [0012]    In one example, the lid includes at least one raised stacking portion to hold a second container on top of the lid. 
         [0013]    These and other features of the present invention can be best understood from the following specification and drawings, the following of which is a brief description. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]      FIG. 1  shows an iso view of a reusable biohazard waste container including the subject invention. 
           [0015]      FIG. 2  shows a side view of the container of  FIG. 1 . 
           [0016]      FIG. 3  shows a front view of the container of  FIG. 1 . 
           [0017]      FIG. 4  shows a back view of the container of  FIG. 1 . 
           [0018]      FIG. 5  shows an enlarged back view of a hinge area of the container of  FIG. 1 . 
           [0019]      FIG. 6  shows a top view of the container of  FIG. 1 . 
           [0020]      FIG. 7  shows a bottom view of the container of  FIG. 1 . 
           [0021]      FIG. 8   a  shows an iso view of a lid of the container of  FIG. 1 . 
           [0022]      FIG. 8   b  shows a front view of the lid of  FIG. 8   a.    
           [0023]      FIG. 8   c  shows a side view of the lid of  FIG. 8   a.    
           [0024]      FIG. 8   d  shows a top view of the lid of  FIG. 8   a.    
           [0025]      FIG. 8   e  shows a bottom view of the lid of  FIG. 8   a.    
           [0026]      FIG. 9  shows an enlarged bottom view in a gasket rib area of the lid of  FIG. 8   a.    
           [0027]      FIG. 10  is an iso view of  FIG. 9  showing a gasket rib. 
           [0028]      FIG. 11  is the same as  FIG. 10  but with a gasket installed on the gasket rib. 
           [0029]      FIG. 12  is an iso view facing an internal rear portion of the container, and which shows a gasket sealing surface. 
           [0030]      FIG. 13  shows an example of an extruded gasket profile. 
           [0031]      FIG. 14  shows an iso view of the container without a lid to show gasket sealing surfaces about a perimeter of the container. 
           [0032]      FIG. 15  is a view similar to  FIG. 14  but with a gasket placed against the gasket sealing surfaces. 
           [0033]      FIG. 16  is an enlarged iso view of a recessed area in an exterior of the container for stacking purposes. 
           [0034]      FIG. 17  is an enlarged iso view showing a sharps container stacked on top of a medical waste container. 
           [0035]      FIG. 18  is an enlarged view of a latch area of the container showing a latch member of the lid latched to the container. 
           [0036]      FIG. 19  is similar to  FIG. 18  but does not show the lid. 
           [0037]      FIG. 20  is an enlarged corner area of the container which shows a bag holding device. 
           [0038]      FIG. 21  shows an iso view of another example of a reusable biohazard waste container 
           [0039]      FIG. 22  is a front view of the container of  FIG. 21 . 
           [0040]      FIG. 23  is a top view of the container of  FIG. 21 . 
           [0041]      FIG. 24  is an iso view of a lid of the container of  FIG. 21 . 
           [0042]      FIG. 25  is a top view of the lid of  FIG. 24 . 
           [0043]      FIG. 26  is a side view of the lid of  FIG. 24 . 
           [0044]      FIG. 27  is a front view of the lid of  FIG. 24 . 
           [0045]      FIG. 28  is an iso view of a sub-lid of the lid of  FIG. 24 . 
           [0046]      FIG. 29  is a front view of the sub-lid of  FIG. 28 . 
           [0047]      FIG. 30  is a rear view of the sub-lid of  FIG. 28 . 
           [0048]      FIG. 31  is a side view of the sub-lid of  FIG. 28 . 
           [0049]      FIG. 32  is a second view of the sub-lid of  FIG. 31 . 
           [0050]      FIG. 33  is a cross-section view of a gasket used in the sub-lid. 
           [0051]      FIG. 34  is a bottom view of the sub-lid of  FIG. 31 . 
           [0052]      FIG. 35  is view similar to  FIG. 24  but showing the sub-lid in an open position. 
           [0053]      FIG. 36  is a bottom view of the container of  FIG. 21 . 
           [0054]      FIG. 37  is an enlarged view of a clamp/hook feature formed within one side of the container of  FIG. 21 . 
           [0055]      FIG. 38  is a section view of  FIG. 37  showing a rotating swing clamp engaging the clamp feature. 
           [0056]      FIG. 39  is a section view of  FIG. 37  showing a hook that engages the hook feature. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0057]    A reusable biohazard waste container  10  is shown in  FIGS. 1-7 . The container  10  is used as a containment receptacle for transporting and/or collecting any type of biohazard waste stream. In one example, the container is used as a sharps container. The container includes a bottom wall  12 , a front wall  14 , a rear wall  16 , and a pair of side walls  18  that extend up from the bottom wall  12  and connect the front wall  14  to the rear wall  16  to form a box-shaped container. 
         [0058]    A lid  20  is attached to the rear wall  16  at a hinged connection  22 . The lid  20  is moveable between a closed position, shown in  FIGS. 1-2 , to an open position indicated by arrow  24  in  FIG. 2 . As shown, when in the open position, the lid  20  is rotated 270 degrees and lies flat against the rear wall  16 . A latch  26  is used to secure the lid  20  to the container  10  when in the closed position as shown in  FIGS. 1 and 3 . 
         [0059]    As shown in  FIGS. 4 and 5 , the hinged connection  22  includes a first set of hinge members  28  on the container  10  that interface with a second set of hinge members  30  on the lid  20 . The first set of hinge members  28  are spaced apart from each other by a distance that generally corresponds to a length of one hinge member  30  of the second set of hinge members  30 . The second set of hinge members  30  are spaced apart from each other by a distance that generally corresponds to a length of one hinge member  28  of the first set of hinge members. 
         [0060]    A hinge feature  32  is formed within the second set of hinge members  30 . In one example, the hinge feature  32  is permanently molded as one piece with the lid  20  and extends between adjacent hinge members  30 . The hinge feature  32  comprises a series of axially extending rod portions  34  that are exposed for connection to the first set of hinge members  28 . The first set of hinge members  28  comprise curved members with open recesses that are configured to receive the rod portions  34 . The rod portions  34  of the lid  20  are positioned 180 degrees relative to the closed position such that the rod portions  34  in the lid  20  can be snapped into the hinge members  28 . 
         [0061]      FIGS. 8   a - 8   e  show the lid  20  in greater detail. An upper surface  38  of the lid  20  is configured to have a gasket feature  40 . The gasket feature  40  is configured to have side edge portions  42  taper gradually upwardly from a flat surface near a rear portion of the lid at each side edge  44  of the lid  20  to a raised front edge portion  46  as best shown in  FIGS. 1 ,  8   a , and  8   c . The front edge portion  46  extends along a front edge  48  of the lid  20  and connects the side edge portions  42 . Thus, the gasket feature  40  comprises a raised C-shaped feature formed on the lid  20  with distal ends lying flat with the lid  20 , and leg portions that extend at an upward angle from the distal ends to a raised center portion extending along a front edge of the lid  20 . 
         [0062]    The gasket feature  40  corresponds to a gasket rib structure  50  that is formed within a lower surface  52  of the lid  20  (see  FIGS. 8   e  and  9 - 11 ). The gasket rib structure  50  receives a gasket  54  ( FIGS. 10-11 ). When installed, the gasket  54  allows the container to be considered leak proof or leak resistant and capable of holding liquids when the lid  20  is latched in the closed position. Optionally, when the container is only required to hold biohazard non-liquids, the gasket may be eliminated. The angled gasket feature  40  is required to allow the lid  20  to lie flat against the rear wall  16  when the lid  20  is in the fully open position (as indicated at  24  in  FIG. 2 ) without kinking/bending the gasket  54 . 
         [0063]    The gasket rib structure  50  includes a support rib  56  that extends about a perimeter of the lower surface  52  of the lid  20 . As shown in  FIG. 8   e , the support rib  56  includes a first portion  56   a  that extends along a rear edge of the lid  20  and along side edge portions closes to the rear of the lid  20 . The support rib  56  includes a second portion  56   b  that transitions from the first portion  56   a  and extends inwardly relative to the surface  52  to match the angled portion of the gasket feature  40 . As discussed above, the gasket support rib  56  is configured to extend into this angled portion of the lid  20  such that the lid  20  can lie flat against the rear wall  16  when opened without adversely affecting the gasket  54  itself during opening and closing movement. 
         [0064]    The gasket rib structure  50  also includes an inner protective rib  60  that is spaced inwardly relative to the support rib  56  and a split outer protective rib structure  62  that is spaced outward of the support rib  56 .  FIG. 10  shows an enlarged view of the support rib  56 , inner protective rib  60 , and the split outer protective rib structure  62 . The split outer protective rib structure  62  includes a series of ribs that are spaced apart from each other along a rear edge of the lid  20 , and which are generally aligned with the hinge members  30  of the lid  20 . The gasket  54  is pushed onto the support rib  56  such that when installed, the gasket  54  protrudes downwardly from the lower surface  52  of lid as shown in  FIG. 11 . The inner  60  and outer  62  protective ribs are positioned to prevent damage to the gasket  54 . 
         [0065]    As shown in  FIGS. 12 and 14 , the container  10  includes flat sealing surfaces  68  formed about an inner perimeter of the rear wall  16 , side walls  18 , and front wall  14 . These sealing surfaces  68  seal against corresponding flat surfaces of the gasket  54 , which is shown in greater detail in  FIG. 13 . One example extruded profile of the gasket  54  comprises a U-shaped cross-section with a base portion  70  and leg portions  72  that are spaced apart from each other by a groove  74 . The groove  74  is received over the support rib  56 . The outward facing surface of the base portion  70  is in direct abutting and sealing engagement with the sealing surfaces  68 . 
         [0066]    As shown in  FIG. 14 , the flat sealing surfaces  68  of the container are tapered to match the angle of the gasket feature  40 . A rear portion  68   a  of the sealing surface extends along an edge of the rear wall  16 , and side portions  68   b  of the sealing surface taper upwardly from the rear portion  68   a  toward a front portion  68   c . The front portion  68   c  extends along a front edge of the front wall  14 , and due to the taper, is positioned within a plane that is vertically higher than a plane defined by the rear portion  68   a .  FIG. 15  shows how the gasket  54  interfaces with the sealing surfaces  68 . The lid  20  is not shown for purposes of clarity. 
         [0067]      FIG. 16  shows an enlarged view of a bottom portion of either the rear wall  16  or front wall  14  of the container  10 . This portion includes recessed areas  80  that provide clearance for stacking purposes. For example, as shown in  FIG. 17 , the reusable biohazard waste container  10  can sit on top of another medical waste container  82 . In one example configuration, two smaller containers  10  can sit on top of one large container  82 . Due to the fact that the biohazard waste containers  10  are sealed/leak-proof and capable of holding liquids, and the fact that the containers  10  include the recessed areas  80  for stacking, the ease of the transportation of these containers is significantly improved. 
         [0068]      FIGS. 18-19  show one example of a biohazard waste container  10  that includes an additional locking feature  90 . The lid  20  includes a first latch member  92  ( FIG. 18 ) that cooperates with a second latch member  94  ( FIG. 19 ) to securely latch the lid  20  to the container  10 . In one example, the additional locking feature  90  comprises aligned openings  96  in the first  92  and second  94  latch members that allow a zip tie to be utilized if needed. 
         [0069]    In one example shown in  FIG. 20 , the container  10  includes a holding feature  100  that helps hold a red bag, i.e. a standard receptacle bag as used in the medical industry for containment, in place within the container  10 . In one example, the holding feature  100  comprises a flange portion  102  located at each upper corner  104  of the container  10  with a cut-outs  106  being located on opposing sides of the flange portion  102 . A portion of the bag is secured under the flange portion  102  via the cut-outs  106  at each corner  104 , which prevents the bag from inadvertently falling inside of the container  10 . 
         [0070]      FIGS. 21-39  show another example of a reusable biohazard waste container  200 . The container  200  includes a bottom wall  212 , a front wall  214 , a rear wall  216 , and a pair of side walls  218  that extend up from the bottom wall  212  and connect the front wall  214  to the rear wall  216  to form a box-shaped container. 
         [0071]    A primary lid  220  is attached to the rear wall  216  at a hinged connection  222 . The primary lid  220  is moveable between a closed position shown in  FIGS. 21-22  to an open position such as that shown in  FIG. 2 . When in the open position, the lid  220  is rotated 270 degrees and hangs down vertically. A latch  226  is used to secure the lid  220  to the container  200  when in the closed position. The latch  226  and hinged connection  222  are similar to those used in the container  10  shown in  FIGS. 1-20 . 
         [0072]    Further, the container  200  includes the gasket feature  40  and gasket rib structure  50  that is formed within a lower surface  52  of the primary lid  220  as shown in  FIGS. 8   e  and  9 - 11 . 
         [0073]    The container  200  includes a universal clamp or hook feature  230  (FIGS.  21  and  36 - 39 ) for automation integration. One hook feature  230  is located in the bottom wall  212  adjacent each of the side walls  218  as shown in  FIG. 36 . Each hook feature  230  comprises a recessed area  232  that extends inwardly into the associated side wall  218 . The recessed area  232  includes a flat bottom surface portion  234  that has an opening  236  that is open through to the bottom surface of the bottom wall  212  as shown in  FIGS. 37-39 . 
         [0074]      FIG. 38  shows a rotating swing clamp  238  that rotates to clamp down on the flat bottom surface portion  234  of the recessed area  232 . Once clamped, an automation device associated with the rotating swing clamp  238  can then pick up and move the container  200  as needed. 
         [0075]      FIG. 39  shows a hook member  240  that extends through the opening  236  in the recessed area  232  to catch and hold the container  200  when rotated for emptying the contents. 
         [0076]    The container  200  also includes a plurality of nesting ribs or extension portions  242  ( FIGS. 21-22 ) that facilitate stacking of adjacent containers. The nesting ribs or extension portions  242  are located at each corner of an upper portion of each of the front wall  214 , rear wall  216 , and side walls  218  to provide a total of eight extension portions  242 . The extension portions  242  extend downwardly in a linear direction from the upper portion of the respective front wall  214 , rear wall  216 , and side walls  218  toward the bottom wall  212 . The length of these extension portions  242  can be varied as needed. Further, the extension portions  242  can comprise any of various shapes that are formed as extensions of the container walls such that the extensions can be nested on corresponding nesting stop areas on an adjacent container. 
         [0077]    As shown in  FIGS. 23-24 , the primary lid  220  includes a plurality of locating ribs or raised locating portions  244  formed in an upper surface of the primary lid  220  near each corner of the primary lid  220 . The raised locating portions  244  are used to visually locate where stacked containers should sit. In one example, the raised locating portions  244  each have a curved profile that extends along a portion of a side edge  220   a  and one of a front  220   b  and rear  220   c  edge of the primary lid  220 . It should be understood that while the raised locating portions  244  are shown to have a rib-type structure, the raised locating portions  244  can take any of various shapes and sizes, and can be positioned at different locations on the primary lid  220  as needed. 
         [0078]    The primary lid  220  also includes a plurality of stacking ribs or raised stacking portions  246  that facilitate locating and fixation of containers stacked on top of the primary lid  220 . The raised stacking portions  246  extend upwardly from an upper surface of the primary lid  220  near each corner of the primary lid  220 , and in the example shown, are spaced inwardly relative to the raised locating portions  244 . In one example, the raised stacking portions  246  have a linear profile that extends generally parallel to the side edges  220   a  of the primary lid  220 ; however, it should be understood that the raised stacking portions  246  can take any of various shapes and sizes, and can be positioned at different locations on the primary lid  220  as needed. 
         [0079]    The primary lid  220  also includes a secondary lid  250  as best shown in  FIGS. 23-24 . The secondary lid  250  is a smaller lid that is pivotally attached to the primary lid  220  to provide for additional container access without having to unlatch the latch  226  of the primary lid  220 . An opening  252  ( FIG. 35 ) is formed within the primary lid  220  and a hinged connection interface  254  is formed near one edge of the opening  252  to attach the secondary lid  250  to the primary lid  220 . This hinged connection interface  254  will be discussed in further detail below. 
         [0080]    The secondary lid  250  includes a latch  256  to lock the secondary lid  250  to the primary lid  220 . A grasping portion or handle  258  is formed within the secondary lid  250  to allow someone to unlatch and open the secondary lid  250  using only one hand. The handle  258  is formed as a recessed area  260  ( FIG. 28 ) extending downwardly into the secondary lid  250  to comprise a finger receiving area. The latch  256  comprises a flexible member that is compressed by a thumb while the fingers are in the recessed area  260  to unlatch and open the secondary lid  250 . 
         [0081]    As shown in  FIGS. 28-31 , the latch  256  comprises a U-shaped member having a first portion  256   a  extending downwardly from a front edge  250   a  of the secondary lid  250 . The first portion  256   a  transitions into a second (base) portion  256   b , which then transitions into a third portion  256   c  that extends upwardly in a direction generally common to the first portion  256   a . An open area  256   d  is formed between the first  256   a  and third  256   c  portions. The third portion  256   c  is compressed toward the first portion  256   a  to unlatch the latch  256 . A lock tab  256   e  extends outwardly from the third portion  256   c  to engage a corresponding lock member  284  ( FIG. 35 ) in the primary lid  220  to secure the secondary lid  250  to the primary lid  220 . Horizontally extending gripping ribs  256   f  are also included on the third portion  256   c  to facilitate grasping. 
         [0082]    At a rear edge  250   b  of the secondary lid  250 , a plurality of C-shaped hinge members  262  are formed as one-piece with the lid  250 . The hinge members  262  are axially spaced apart from each other along the rear edge  250   b  and receive posts  264  ( FIGS. 24-25 ) that are integral to the primary lid  220  to form the hinge connection interface  254 . The primary lid  220  includes a recessed area  266  at each post  264  and hinge member  262  connection to allow the secondary lid  250  to lie flat against an upper surface of the primary lid  220  when the secondary lid  250  is open. 
         [0083]    As shown in  FIGS. 32-35 , the secondary lid  250  includes a gasket rib structure  270  that is formed within a lower surface  272  of the secondary lid  250 . The gasket rib structure  270  receives a gasket  274 . When installed, the gasket  274  allows the container to be leak proof or leak resistant and capable of holding liquids when the secondary lid  250  is latched in the closed position on the primary lid  220 . Optionally, when the container is only required to hold biohazard non-liquids, the gasket may be eliminated. 
         [0084]    The gasket rib structure  270  includes a downwardly extending support rib  276  that extends about a perimeter of the lower surface  272  of the secondary lid  250 . Open space is provided on each side of the support rib  276  such that the gasket  274  can be installed onto the secondary lid  250 . An additional inner rib  278  also extends downwardly about the perimeter of the lower surface  272  of the secondary lid  250 . The inner rib  278  extends downward to a further extent than the support rib  256  to help protect the gasket  274  and keep the gasket in place. 
         [0085]    The gasket  274  comprises a U-shaped upper portion having first and second legs  274   a  that are connected by a base portion  274   b . The first and second legs  274   a  are separated from each other by a groove  274   c . When installing the gasket  274 , the gasket  274  is pressed onto the support rib  276  such that the rib  276  is pressed into the groove  274   c  with the legs  274   a  being located on sides of the rib  276 . The base portion  274   b  further includes a bulbous seal portion  274   d  that is compressible when the secondary lid  250  is closed to provide the required level of sealing. 
         [0086]    As shown in  FIG. 35 , the gasket  274  will seal off against flat surfaces  280  formed around the perimeter of the opening  252  in the primary lid  220  when closed. As the secondary lid  250  is moved toward the closed position, the bulbous seal portion  274   d  is compressed against the flat surfaces  280  and the latch  256  is received into a recess  282  formed within the primary lid  220  such that the lock tab  256   e  grips the corresponding lock member  284  to latch the secondary lid  250  in place. 
         [0087]    The biohazard waste containers  10 ,  200  provide the required amount of leak proof protection needed to properly transport the containers, and eliminates the need to double package the container for transport by enclosing it within a separate outer container. In some applications the subject container can be disposable as well as be treated as an outer container for waste that has an inner container. When used as an outer container, further sealing is not necessary. 
         [0088]    While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.