Patent Publication Number: US-2023149110-A1

Title: Sharps container

Description:
RELATED APPLICATIONS 
     The present invention is a continuation of U.S. patent application Ser. No. 16/845,842 filed Apr. 10, 2020, now U.S. Pat. No. 11,559,369 issued Jan. 24, 2023, which is a continuation of U.S. patent application Ser. No. 16/436,920 filed Jun. 11, 2019, now U.S. Pat. No. 10,617,485 issued Apr. 14, 2020, which is a continuation of U.S. patent application Ser. No. 14/921,586 filed Oct. 23, 2015, now U.S. Pat. No. 10,321,968 issued Jun. 18, 2019, which applications are incorporated herein by reference in their entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to containers for disposal of medical waste, and in particular to the disposal of contaminated items. The present invention may be a disposal system for use in a hospital or similar environment where contaminated items must be collected and disposed of without creating a hazard for patients or hospital personnel. 
     BACKGROUND OF THE INVENTION 
     In hospitals, clinics and similar institutions, contamination is of utmost concern. Disposable, single use patient-care products, which used to be the exception, are now the norm. Such hospital waste products might include surgical sharps, such as needles, syringes, scalpel blades, or the like, or might include gauzes, bandages, or sponges. 
     Various types of containers for hospital use have been developed for receiving medical waste in a surgical operating room, pre-op or post-op room, or a patient&#39;s room. These containers are particularly designed to protect the user of such containers, such as doctors, nurses, or other hospital personnel, from the hospital waste products that may be disposed therein. 
     The proximal disposal of sharps in patient rooms has spawned a host of specialized sharps disposal containers. These containers are primarily designed to allow for the easy disposal of sharps in a manner that does not require excess effort, exposure to the sharp portion of a device and in which the disposed of sharp cannot be subsequently accessed. In most instances, the disposal system consists of a non-disposable cabinet or support that is more or less permanently affixed to a room surface (usually affixed to the wall with some type of anchor) and a disposable container that fits within or is attached to the cabinet or support. Typically, the disposable container utilizes some type of door that prevents unobstructed access to the interior of the container, but allows relatively easy disposal of the sharp. 
     It is important to prevent the user of a sharps container from being accidentally cut or punctured by its contents. Furthermore, it is important to prevent access to the contents of the container during disposal thereof. 
     Sharps containers have commonly been provided with a relatively large circular opening through which sharps may be dropped in a vertical orientation for haphazard collection within the container. As the container fills, the user runs the risk of a previously inserted sharp protruding from the opening where it can stab the hand of the next operator inserting something into the container. Side walls may be constructed of relatively soft or thin-walled material which could be pierced by any one of the haphazardly arranged needles within the container thereby possibly exposing to infectious disease the next person brushing against the container. Other known sharps containers have a mailbox-like structure having a tilt pan which tips outwardly for receiving a sharp and which tips inwardly for depositing the sharp in the container. In this manner, the interior of the container is never completely open to the room and the sharp can be disposed of with one simple motion. 
     However, previous designs have been subject to jamming, improper function and manufacturing difficulties. For example, previous designs included lids with multiple distinct parts. In some examples, these parts may be ultrasonically welded together. This creates extra manufacturing steps as well as unnecessarily using more plastic. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG.  1    is a side perspective view of a sharps disposal system including a permanent exterior cabinet and disposable interior container; 
         FIG.  2    is a side perspective view of the disposable interior container with the closure flap in a closed position; 
         FIG.  3    is a front perspective view of the disposable interior container with the closure flap in an opened position; 
         FIG.  4    is a side cut-away view of the interior of the disposable container with the closure flap in a closed and locked position; 
         FIG.  5    is a side cut-away view of the interior of the disposable container with the closure flap in a partially open position; 
         FIG.  6    is a side cut-away view of the interior of the disposable container with the closure flap in a closed and permanently locked position; 
         FIG.  7    is a side cut-away view of the interior of the disposable container with the closure flap in a completely open position; 
         FIG.  8    is a partially exploded side perspective view of the lid of the disposable container; 
         FIG.  9    is an exploded side perspective view of the lid and component parts of the disposable container; 
         FIG.  10    is a cross-sectional view of the axial hub of the closure flap; 
         FIG.  11    is a perspective view of a lid of a disposable interior container; 
         FIG.  12    is a perspective view of a sharps disposal system including a permanent exterior cabinet and disposable interior container; 
         FIG.  13    is partial perspective view of an underside of a closure flap of the container. 
     
    
    
     DETAILED DESCRIPTION 
     With reference to  FIGS.  1 - 2   , the disposal system  2  of the present invention includes a locking exterior cabinet  4  that may be wall mounted and a disposable container  6  that is placed within the cabinet  4 . For example, as shown in  FIG.  1   , the cabinet  4  includes a bottom wall, rear wall  110 , opposite upstanding side walls  104  and a front wall  102 . The front wall  102  may be hinged to the side wall  104  or to the bottom wall such that the front wall can be swung open to remove the disposable container  6  from the cabinet  4 . The front wall  102  or corresponding side wall  104  may include a locking mechanism (not shown) for securely locking a disposable container  6  into the cabinet  4 . The locking mechanism may comprise a locking tab or latch, or it may include a keyed lock. 
     The cabinet  4  may be secured to a wall, desk, table or other surface. The securing mechanism may consist of screws or other fasteners inserted through the cabinet into the surface that are only accessible when the cabinet  4  is opened and the container  6  is removed. In this way, the cabinet could only be removed from the surface by someone with access to a cabinet key. Alternatively, an exterior frame, locking tabs or other mechanism may be provided to attach the cabinet to the surface. 
     As further shown in  FIG.  1   , embodiments of the cabinet  4  may not include a top wall. Rather, the cabinet side walls  104  and rear wall  110  may extend to and generally parallel to or below a top surface  16  of the container  6 . Alternatively, the cabinet may include a top wall that is dimensioned so as not to interfere with movement of a closure flap  12  of the container  6 . The front wall  102  of the cabinet  4  may have an angled or sloped portion  108 . The sloped portion  108  may be angled such that the top end portion  112  of the sloped portion  108  aligns generally with an upper portion  62  of the closure flap  12  when the closure flap  12  is in a closed and locked position, and the bottom end portion  114  of the sloped portion  108  aligns below an upper portion  62  of the closure flap  12  when the closure flap is in an open position. 
     As show in  FIGS.  2 - 4   , the disposable container  6  is preferably formed of four component parts including an open topped receptacle  8  for receiving medical waste, a snap fit lid  10 , a pivotal closure flap  12  and a plurality of snap fit covers  14 . The front portions of the lid side wall  18  may include a sloped portion  208  that generally corresponds with the sloped portion  108  of the cabinet front wall  102 . Similarly, the sloped portion  208  may be angled such that the top portion  212  of the sloped portion  208  aligns generally with an upper portion  62  of the closure flap  12  when the closure flap  12  is in a closed and locked position, and the bottom end portion  214  of the sloped portion  208  aligns below an upper portion  62  of the closure flap  12  when the closure flap  12  is in an open position. The front shelf  22  provides a deck upon which the closure flap  12  may rest when in the open position. 
     As shown in  FIGS.  3 - 4   , the lid  10  includes an upper wall  16 , side walls  18 , a front wall  20 , a front shelf  22 , a rear wall  24 , and a skirt  26  extending around the lower portions of the lid  10  side and rear walls  18 ,  24 . Located in spaced relation between the front shelf  22 , the front portion  16   a  of the upper wall  16  and front portion of the side walls  18 , an elongated opening  28  is provided for receiving the closure flap  12  which is pivotally operable between a normal closed position, a fully opened position and a permanently closed and locked position. The closure flap is sized such that when is in the normal closed position, the lower portion  60  of the closure flap  12  extends into the receptacle  8  in spaced relation with the bottom wall (not shown) of the receptacle  8  and the upper portion  62  of the closure flap  12  extends above the lid upper wall  16 . Still further, the closure flap is sized such that when in the open position, the lower portion  60  of the closure flap  12  sweeps immediately adjacent to the interior rear wall  24  of the lid  10  and the detent  72  of the upper portion of the closure flap approximately corresponds with the portion of the lid  10  where the front wall  20  and the front shelf  22  meet. 
     The upper wall  16  of the lid  10  may have a generally planar and smooth surface as illustrated in  FIG.  3   . Alternatively, as shown in  FIG.  11   , embodiments of the lid  10  may include an upper wall  16  that incorporates one or more decorative or structural features. For example, the upper wall  16  may incorporate ribs  92  that increase the structural rigidity of the upper wall. These ribs may be formed in a cross-hatch pattern  94  or a circular pattern  95 , or some combination of these or other patterns as may be appropriate to enhance the structure and/or aesthetics of the upper wall. Additionally, the lid  10  may incorporate ribs  96  that bridge the gap between the side wall  18  and the lid skirt  26  in order to provide additional structural integrity to the lid. 
     As shown in  FIG.  4   , the skirt  26  may include a horizontal portion  25  that extends from the lid side  18  and rear walls  24 . The skirt may also include a vertical portion  27  that extends below a flange  52  of the receptacle  8 . In some embodiments, as illustrated in  FIG.  4   , the skirt  26  may not include a horizontal portion adjacent to the front wall  20 . And the skirt  26  may generally vertically from the edge of the front shelf  22  to a lower edge  29  of the skirt. Alternatively, as illustrated in  FIGS.  11 - 12   , embodiments of the lid  10  may include a skirt horizontal portion  25  that extends adjacent to the front wall  20  in addition to the side walls  18  and rear wall. This horizontal portion  25  may be positioned such that it accommodates the geometry of the front wall  104  of the cabinet  4 . For example, a top edge of the cabinet front wall  104  may include a lip that extends partially over the horizontal portion of the skirt  26 . 
     Turning to the interior surfaces of the lid  10 , a plurality of features are provided to protect the user from accidental exposure to medical waste located within the receptacle  8 . As shown in  FIGS.  4 - 7    the front portion  16   a  of upper wall  16  interior, in spaced relation with the opening  28 , includes a downward projection  30 . As shown in  FIGS.  4  and  5   , the rear wall  24  interior includes a fixed cowl  32  which extends downwardly into the receptacle  8  to assist in guiding horizontally disposed sharps placed on the closure flap  12  into the receptacle  8 . The projection  30  and the cowl  32  restrict access into the interior of the container  6  when the closure flap  12  is in a fully open position by constricting access within the area that is the opening  28 . The relative spacing of the front shelf  22 , the downward projection  30  and the cowl  32  define a limited opening  28  which restricts access to the interior of the container  6 . The relative spacing of these features are dimensioned so that access to the interior of the container  6  is inhibited to the extent that it is difficult or impossible for an adult human hand to pass through the opening  28 . Still further, once the closure flap  12  is locked in a fully closed position, if the closure flap  12  is pried away from the front portion  16   a  of the lid upper wall  16  in an attempt to gain access to the interior of the container  6 , the projection  30  offers a further safety feature by restricting access to the interior of the container. 
     The front shelf  22  includes a front portion that aligns with the front wall  20  and a rear portion that includes a projection  220 , which is directed downward into the interior of the receptacle  8 . When the closure flap  12  is in a closed position, the medial portion of the closure flap rests against the downward projection  220 . As with other lid interior features, downward projection  220  assists in restricting access into the interior of the contain 6 by providing structural support to the front shelf  22 , as well as offers a further safety feature by restricting access to the interior of the container  6  in the event an attempt to pry open the closure flap  12  is made in an attempt to gain access to the interior of the container 
     Additionally, in spaced relation with the interior upper wall  16  the interior side walls  18  are provided a plurality of slots  34  through which hooks  36  of the closure flap  12  are inserted to provide permanent closure of the container  6  for transport and disposal. Once the hooks  36  pass through the slots  34 , movement of the closure flap  12  is blocked so that force applied against the closure flap  12  will not move the closure flap  12  from a closed position to an open position. 
     As shown in  FIG.  8   , the lid  10  may also include an opening  38  through which an axial hub  42  of the closure flap  12  may be inserted. In addition, the lid may include openings  40  through which locking tabs  44  of the snap fit cover  14  extend, as discussed in greater detail below. 
     The receptacle  8  includes a bottom wall, front wall  46 , rear wall  48  and side walls  50 . As shown in  FIG.  4   , the upper portions of the receptacle  8  front, rear and side walls,  46 ,  48 ,  50  include a flange  52  that extends outwardly and downwardly from the top edge of the side walls. The flange is adapted to receive corresponding inwardly extending locking fingers  54  of the lid skirt  26  to provide a permanent snap fit connection between the lid  10  and receptacle  8 . 
     As shown in  FIGS.  8 - 9   , the upper edges of the receptacle  8  side walls  48  may include locking fingers  56  that are inserted into through openings  58  located on the lid  10  side wall skirt  26  permanent provide a snap fit connection between the receptacle  8  and lid  10 . 
     Additional embodiments of the disposal system may include viewing ports in the one or more of the front  102  and side  104  walls of the cabinet  4 . These view ports correspond to view ports  230 ,  232  ( FIG.  3   ) that may be located in the front  46  and side  50  walls of the receptacle  8 . The viewing ports permit a user to view the contents of the system and determine empty/full status prior to attempted use. 
       FIGS.  4 - 7    illustrate the relative positions of the closure flap  12  in the assembled container  6 . During use, the closure flap  12  is pivotally movable between a normal closed, unlocked position (not shown), and a fully opened position as shown in  FIG.  7   . As shown in  FIG.  4   , the closure flap  12  may be permanently closed and locked for transport and disposal. In the normal closed position, the upper portion  62  of the closure flap does not touch the upper wall  16  of the lid  10 ; the container is never fully closed and locked until the hooks  36  are inserted into through slots  34  at which point the container  6  is locked for transport and disposal. When in the locked position, the upper portion  62  of the closure flap  12  rests against the front portion  16   a  of the upper wall  16  of the lid  10  and the closure flap detent  72  rests against the interior downward projection  30 . 
     The closure flap  12  includes a lower portion  60 , an upper portion  62 , and side portions/walls  64  as well as interior  66  and exterior  68  surfaces. The upper portion  62  of the closure flap  12  includes a central tab  70 , which is operable by a user to displace the closure flap  12  between normal closed and open positions. When the tab  70  is pivotally directed downward toward the front shelf  22 , the closure flap  12  opens. When released, the closure flap  12  returns to its normal closed position. A detent  72  is provided is provided adjacent to the upper flap portion  62 , which when the closure flap  12  is in a permanently locked position rests against the downward projection  30  of an interior upper wall  16  of the lid  10 . With respect to the interior surface  66  of the closure flap, the detent  72  provides an inclined surface  74  which works with gravity to direct sharps into the container  6  when the closure flap  12  is moved from an open position to a normal closed position. 
     The pivotal operation of the closure flap  12  is provided by a plurality of annular axial hubs  42  located at the side edges  64  of the flap in spaced relation with the upper portion  62  of the closure flap  12  such that the mass of lower portion  60  of the closure flap  12  exceeds the mass of the upper portion  62  with the result that the closure flap  12  is gravitationally biased to its normal closed position when released. 
     As shown in  FIG.  13   , the closure flap  12  may include various ribs that provide structural rigidity to the closure flap. For example, the flap may include one or more ribs  122  extending across the flap  12  between hubs  42 . The flap may also include additional ribs arranged in various appropriate patterns on other portions of the flap.  FIG.  13    illustrates, for example, ribs  124  arranged in a generally rectangular pattern across an underside of the lower portion  60  of the flap. In addition, the flap  12  may include a rib  126  that extends from the hub  42  along an edge of the upper portion  62 . This rib  126  may include a notch  128  that aids in the installation of the flap  12  into the lid. 
     As illustrated in  FIGS.  8 - 10   , axial hubs  42  are inserted through openings  38  in the lid  10 . The axial hubs  42  include a bearing surface  87  and a flange  88 . The flange has a larger diameter than the bearing surface  87 . The openings  38  include a circular portion  39  at an upper end of the opening and a generally rectangular lower portion  41 . The lower opening portion  41  may extend through the side wall  18  as well as the skirt  26  adjacent the side wall. In this manner, the hub  42  can be inserted through the lower opening  41  and slid upward such that the hub bearing surface  87  engages with the circular opening  39 . The circular opening  39  has a diameter that is less that the hub flange  88  so that the flange engages an outside surface of wall  18  adjacent to the semicircular opening  39 . The semicircular opening  39  may extend over an arc of 90 degrees, an arc of 180 degrees or an arc of greater than 180 degrees so as to have a snap fit the hub bearing surface  87 . 
     Snap fit covers  14  are provided to maintain the axial hubs  42  in position once inserted through the through openings  38  of the lid  10 . The covers  14  include an exterior wall  76 , an interior wall  78 , side walls  80  and lower wall  82 . Locking tabs  44  extending from the side walls  78  in spaced relation with the lower wall  82  and an annular bushing  84  extends from the interior wall  78 . After the axial hubs  42  of the closure flap  12  are inserted into the through openings  38  from the interior of the lid  10 , the annular bushings  84  of the covers  14  are aligned with the annular opening  86  of the axial hubs  42  and the locking tabs  44  are aligned with the through openings  40  of the lid  10 . The diameter of the annular bushing  84  is sized for insertion into the annular opening  86  of the axial hub  42 . Once aligned and snapped in place, the cover  14  provides the structural support for the pivotal rotation of the closure flap  12 .