Patent Description:
So called 'beanbags' as an article of furniture are generally known in the art of interior design and furnishing. The cover of a conventional beanbag may typically be made out of an expandable material, such as polyvinylchloride, leather or any other suitable fabric and the bag is typically filled with small pellets (e.g. <NUM> - <NUM> diameter) made from polymer material (e.g. polystyrene) suitable to "flow" easily within the flexible container and, thus, enabling the bag to conform to a user's body.

<FIG> illustrates (a) an example of a typical beanbag <NUM> filed with polystyrene pellets <NUM> that are filled or refilled via a zip access <NUM> (see <FIG> shows a typical use of a common beanbag <NUM> as furnishing for a user.

In recent years such beanbags have been found very useful when applied as a safety pod, i.e. a beanbag that is a specially designed for use in industries that carry out physical interventions (e.g. restraint), such as, for example, in the police sector, the prison sector, the healthcare sector etc..

These safety pods have shown great potential when used within secure mental health facilities, where the need for the safety pod was due to an extremely high use of ground related restrain. Here, ground related restraint generally involves a large amount of risk from as low as minor bruising to as much as death of the restrained person. When the safety pods were then introduced into health care services along with a new approach to this area of care, an unprecedented reduction of ground related restraint was witnessed with some areas achieving up to <NUM>% reduction in ground restraint by using safety pods within practices.

It is understood that, due to the generally high impact use, these safety pods have to be purpose-built and specially constructed, as well as, medically reviewed. Thus, the safety pod is now widely considered as a piece of equipment that comes with associated training for handling and use.

For example, part of the essential requirements involves regular maintenance, such as, regular cleaning and the occasional top up of filler material (e.g. polymer pellets) may be required due to reduction of volume over time (use related). In particular, a safety pod may be filled with EPS (Expanded Polystyrene) and each individual particle of EPS has the ability to reduce to a third of its original size from compression over time. Though, for a safety pod to be considered 'fit for purpose' in accordance with it manual of guidance, it needs to maintain a certain amount of volume to operate properly, so that, on average, a regularly used safety pod may need to be refilled at least once a year.

Typically, with currently available safety pods or common beanbags, when a top up or refill of filler is required, the safety pod is accessed, for example, via an exposed zip or a zip that is concealed under a Velcro strip (more secure).

However, typical zip or Velcro closures are usually not strong enough to withstand higher pressures (e.g. from high impact forces during use with a patient) and there is a risk of these closures to burst open. In addition, in extremely high-risk environments, there is a real risk that people/patients may gain entry into the pods by simply picking at the Velcro and/or unzipping the zip closure, potentially endangering themselves or other people. As a result, the currently known solution is to simply stitch up the whole safety pod or beanbag, thus, leaving the safety pod without an access point for refilling.

In one example, and as described in the document <CIT>, a deformable ball-like object is filled with a composite filler mixture, such as, solid (PVC), non-hollow, uniform-size, spherical, independent particles that are thinly coated with a liquid lubricant and closed up via a knot. A knot hider is then used to hide the knot closing the opening. Alternatively, an elongated stem may be used to close a fluid passage of a neck.

Therefore, it is an object of the present invention to provide an improved and tamper-proof closure assembly for flexible containers, such as, pellet-filled safety pods or beanbags.

According to a first embodiment of the invention there is provided a closure assembly for a flexible container, comprising:.

This provides the advantage of an easy access point coupleable to standard filling tubes, but which is securely lockable tamper-proof by only allowing access with a suitable tool that is adapted to operably engage with the plug member.

Advantageously, said locking members may comprise L-shaped locking members, each one protruding axially away from said distal end portion and circumferentially about said third central axis towards a first direction, so as to form a bayonet mount with said internal support member during use.

Advantageously, said female connector member may be configured to telescopically and rotatingly coaxially receive said male connector member and said male connector member is configured to telescopically and rotatingly coaxially receive said plug member.

Advantageously, said support member may comprise at last one internally threaded through bore extending parallel to said third centre axis and configured to threadingly engage with a screw fastener.

Preferably, said plug member may further comprise at least one counterbore axially recessed from said third proximal end portion towards said third distal end portion, configured to receive a screw fastener and abuttingly engage and axially align with said at least one internally threaded through bore. Even more preferably, said at least one counterbore may have a predetermined diameter and length adapted to prevent the insertion of a human digit.

This provides the advantage that a user or patient is unable to open the closure without a suitable tool, i.e. it is impossible to accidentally engage the securing / locking screw fasteners with a human digit (finger or toe), therefore, preventing accidental or intentional access and potential harm to the user.

Advantageously, said support member may comprise two of said at least one internally threaded through bore that are symmetrical to and equidistantly spaced apart from said third centre axis.

Advantageously, said plug member may comprise two of said at least one counterbore, each one arranged so as to axially align with a respective one of said two internally threaded through bores.

Advantageously, said support member may comprise a substantially planar grid structure arranged normal to said second central axis, configured to allow fluid flow through said connector assembly, during use.

Advantageously, said first tubular body of said male connector member may comprise an external thread portion and said second tubular body of said female connector member may comprise an internal thread portion adapted to threadingly engage with said external thread portion during use. Preferably, said external thread portion may be provided at said first proximal end portion adjacent to said first flange portion and said internal thread portion may be provided at said second proximal end portion adjacent to said second flange portion.

Advantageously, said second tubular body may be frustoconically shaped towards said second distal end portion.

Advantageously, said second tubular body may comprise a plurality of axially and circumferentially equidistantly arranged reinforcing external ribs.

Advantageously, said plug member may further comprise a third flange portion protruding radially outwards at said third proximal end portion. Preferably, each one of said first, second and third flange portion may have a frustoconical profile configured to matingly engage with a respective other one of said first, second and third flange portion.

Advantageously, said connector assembly may be adapted to operably receive a filling tube.

Advantageously, any one of said male connector member, said female connector member and said plug member may be made from a polymer or polymer compound using suitable polymer manufacturing processes (thermoforming, injection moulding, extrusion), but also 3D printing manufacturing processes.

According to another aspect of the present invention, there is provided a flexible container comprising a closure assembly according to the first embodiment of the present invention.

Embodiment(s) of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:.

The described example embodiment relates to a closure assembly suitable for flexible containers, such as safety pods and beanbags. Although the invention is described with respect to flexible containers, it is not restricted to flexible containers altogether, but may also be used in other containers requiring tamper-proof and sealingly lockable access ports.

Certain terminology is used in the following description for convenience only and is not limiting. The words 'right', 'left', 'lower', 'upper', 'front', 'rear', 'upward', 'down' and 'downward', 'top' and 'bottom' designate directions in the drawings to which reference is made and are with respect to the described component when assembled and mounted. The words 'inner', 'inwardly' and 'outer', 'outwardly' refer to directions toward and away from, respectively, a designated centreline or a geometric centre of an element being described (e.g. central axis), the particular meaning being readily apparent from the context of the description.

Further, relative positional terms, such as, 'distal', 'proximal', 'lateral' and 'medial' are understood in their normal meaning and in relation to a specific element being described. In particular, these terms designate directions in relation to the normal use of the closure assembly by the user, e.g. proximal is in a direction towards the user end of the closure assembly (during normal use), wherein distal refers to the direction away from the user end of the closure assembly.

Referring now to <FIG>, <FIG> and <FIG>, an example embodiment of the closure assembly <NUM> of the present invention comprises a connector assembly <NUM> and a plug <NUM>. The connector assembly <NUM> includes a female connector member <NUM> and a male connector member <NUM> adapted to interlockingly engage with the female connector member <NUM>.

The female connector member <NUM> has a substantially tubular body <NUM> extending along a central axis <NUM> (see <FIG>) between a proximal end <NUM> and a distal end <NUM>. A first flange <NUM> extends from the proximal end <NUM> in a direction radially away from an outer surface of the tubular body <NUM>, so as to form a frustoconical profile tapered towards the proximal end <NUM> of the tubular body <NUM>. An inner thread portion <NUM> is provided on the inner surface of the tubular body <NUM> extending from the proximal end <NUM> towards the distal end <NUM>. A substantially planar support structure <NUM> is provided inside the tubular body <NUM> in a region closer to the distal end portion <NUM> extending through the tubular body <NUM> in a direction normal to the central axis <NUM>. The support structure <NUM> comprises a mesh or grid structure configured to allow fluid flow through the female connector member <NUM> (i.e. the spacing of the grid structure is suitable to allow beanbag pellets to pass through). The grid structure has at least a first central crosspiece <NUM> and a second central crosspiece <NUM>, orthogonal to the first central crosspiece <NUM>. The first central crosspiece <NUM> further comprises two axially embedded screw nuts 122a, 122b, each one arranged equidistantly from the central axis <NUM>. A plurality of ribs <NUM> are provided circumferentially equidistantly on an external surface of the tubular body <NUM>.

The male connector member <NUM> also has a substantially tubular body <NUM>, extending along a central axis <NUM> (the same central axis when fully assembled, see <FIG>) between a proximal end <NUM> and a distal end <NUM>, sized (or dimensioned), so as to matingly fit into the tubular body <NUM> of the female connector member <NUM>. An external thread portion <NUM> is provided on an outer surface of the tubular body <NUM> extending from the proximal end <NUM> towards the distal end <NUM>, and which is adapted to threadingly engage with the inner thread portion <NUM> of the female connector member <NUM> during assembly. The tubular body <NUM> of the male connector member <NUM> may be frustoconically tapered towards the distal end <NUM>. Further, the distal end may be provided with a plurality of partial axial cuts <NUM> circumferentially equidistantly arranged so as to allow for flexure, e.g. when engaging with a filling tube (not shown). Also, the tubular body <NUM> may have a plurality of axial guide ribs <NUM> circumferentially equidistantly arranged on the inner surface (e.g. providing for a press fit with the filling tube). A second flange <NUM> extends from the proximal end <NUM> in a direction radially away from an outer surface of the tubular body <NUM>, so as to form a frustoconical profile tapered towards the proximal end <NUM> of the tubular body <NUM> and dimensioned, so as to matingly engage with a top surface of the first frustoconically profiled flange <NUM> of the female connector member <NUM>.

The plug <NUM> comprises a cylindrical body <NUM>, extending along a central axis <NUM> (the same central axis <NUM> when fully assembled, see <FIG> and <FIG>) between a proximal end <NUM> and a distal end <NUM>, sized (or dimensioned) so as to matingly fit into the tubular body <NUM> of the male connector member <NUM>. A third flange <NUM> extends from the proximal end <NUM> in a direction radially away from an outer surface of the cylindrical body <NUM> that is frustoconically tapered towards the distal end <NUM> of the cylindrical body <NUM> and dimensioned so as to matingly engage with a top surface of the second flange <NUM> of the male connector member <NUM>. The plug <NUM> is further adapted to countersink into the frustoconical second flange <NUM> of the male connector member <NUM>. Two radially opposing L-shaped locking members 148a, 148b extend axially away from the distal end <NUM> of the cylindrical body <NUM>, wherein the end portion 150a, 150b of each one of the L-shaped locking members 148a, 148b bends circumferentially about the central axis <NUM> towards a first direction (e.g. anti-clockwise when viewed from the proximal end <NUM>). The end portions 150a, 150b are spaced apart from the distal end <NUM> of the cylindrical body <NUM> by a predetermined distance, i.e. a distance suitable to allow the locking members 148a, 148b to lockingly engage with the support structure <NUM> (i.e. the end portions 150a, 150b are configured to slide underneath the support structure <NUM> during locking engagement, similar to a bayonet mount). Two diametrically arranged bores 152a, 152b extend through the cylindrical body <NUM> of the plug <NUM> in a direction parallel to the central axis <NUM> so as to provide two recessed counterbores 154a, 154b equidistantly spaced apart from the central axis <NUM> along a diameter of the cylindrical body <NUM> (see <FIG>). The counterbores 154a, 154b are set "deep" into the cylindrical body <NUM>, wherein the diameter and depth of the bores 152a, 152b are suitably configured to receive a screw fastener 300a, 300b and respective tool (not shown), but they are also dimensioned such as to prevent the insertion of a human digit (finger, toe) to reach and tamper with the inserted screw fastener 300a, 300b. The position of the bores 152a, 152b and recessed counterbores 154a, 154b is such that each one of the counterbores 154a, 154b coaxially aligns with a respective one of the two axially embedded screw nuts 122a, 122b of the female connector member <NUM>, so as to allow a screw fastener 300a, 300b inserted into the counterbores 154a, 154b to threadingly engage with a respective one of the screw nuts 122a, 122b.

It is understood by the person skilled in the art that each one of the closure assembly components, plug <NUM>, female connector member <NUM> and male connector member <NUM>, may be made from a polymer material by suitable manufacturing processes, such as for example injection moulding, but also 3D printing or any other suitable method. Further, each one of the plug <NUM>, female connector member <NUM> and male connector member <NUM> may be made from the same or a different material. The material used for each one of the components, plug <NUM>, female connector member <NUM> and male connector member <NUM>, may be a one-component material (<NUM>) or a combination (e.g. <NUM>) of materials. When using a polymer base material for injection moulding, the polymer may be a compound material including other material components (e.g. metal, graphene, fibres, ceramic or the like).

<FIG> shows different perspective views of the closure assembly <NUM> at different stages during assembly, e.g. (a) fully assembled (but without engagement with the flexible container), (b) plug <NUM>, male connector member <NUM> and female connector member <NUM> slightly separated, (c) the connector assembly <NUM>, (d) the male connector from the bottom, (e) the plug member <NUM>, and (f) the plug member <NUM> from the bottom.

Referring now to <FIG>, in use, a flexible container <NUM> or safety pod is provided with a substantially circular opening <NUM> having a diameter that is suitable to receive the tubular body <NUM> of the male connector member <NUM>, but prevent the first and second flanges <NUM>, <NUM> from passing through. At this stage, the flexible container <NUM> or safety pod still has an external open stitch located on the base (i.e. a bottom panel of the pod) through which the female connector member <NUM> is moved inside the flexible container <NUM> or safety pod and located at the opening <NUM> by abuttingly engage the top surface of the first flange member <NUM> with a peripheral inside surface of the circular opening <NUM> of the flexible container <NUM>. The tubular body <NUM> of the male connector member <NUM> is now moved into the tubular body <NUM> of the female member <NUM> and the inner and outer thread portions <NUM>, <NUM> are screwed together until the peripheral edge portion of the circular opening <NUM> is clamped between the two engaging first and second flanges <NUM>, <NUM>. A silicone seal, glue or any other adhesive may be used to securely join or bond the peripheral edge portion of the opening <NUM> of the flexible container <NUM> with the clamping first and second flanges <NUM>, <NUM>.

At this stage, the connector assembly <NUM> is fully fitted to the flexible container <NUM> or safety pod and the external open stitch (located at the base) may be permanently closed. The flexible container <NUM> or safety pod is now ready for filling with suitable pellets <NUM> via a filling tube (not shown) that is operably connected to the male connector member <NUM> (e.g. press fit promoted by the axial cuts <NUM> and guide ribs <NUM>). Once the container <NUM> is filled, the plug <NUM> is simply inserted into the male connector member <NUM> and axially rotated about its central axis <NUM> (e.g. one-quarter turn) until the end portions 150a, 150b of the L-shaped locking members 148a, 148b lockingly slide "under" the support structure <NUM> (e.g. first or second central crosspiece <NUM>, <NUM>) and the L-shaped locking members 148a, 148b abuttingly engage with one of the first and second crosspieces <NUM>, <NUM>, coaxially aligning the counterbores 154a, 154b with respective screw nuts 122a, 122b. Screw fasteners 300a, 300b can now be inserted into the bores 152a, 152b and through the counterbores 154a, 154b to screw into the screw nuts 122a, 122b and securely fasten the plug <NUM> to the female connector member <NUM>.

Once secured, it will not be possible to accidentally open the closure assembly <NUM> by tampering with the plug <NUM> or any other component, because the user or patient will not be able to reach the screw fasteners 300a, 300b securely embedded into the bores 152a, 152b. A suitable tool (not shown) will be needed to access and loosen the screw fasteners 300a, 300b before the plug <NUM> can be rotated out of locking engagement with the connector assembly <NUM> to open the closure assembly <NUM>.

Figure <NUM> shows a partial bottom view of the closure assembly <NUM> of the present invention comprising an alternative plug <NUM>. The alternative plug <NUM> is formed similar to the plug <NUM>, but without the two radially opposing L-shaped locking members 148a, 148b extending axially away from the from the distal end <NUM> of the cylindrical body <NUM> (see <FIG>). Instead, the distal end <NUM> of plug <NUM> comprises two radially opposing locking members 648a, 648b, each one extending axially away from the cylindrical body <NUM>, so as to fit into the opposing gaps 150a, 150b flush with the support structure <NUM> of the female connector member <NUM> (the distal end <NUM> of the plug <NUM> is aligned with the outer surface of the support structure <NUM>), i.e. between the first and second crosspiece <NUM>, <NUM>, coaxially aligning the counterbores 654a, 654b with respective screw nuts 122a, 122b of the support structure <NUM>.

The engaged locking members 648a,b also prevent the plug <NUM> from rotating with respect to the female connector member <NUM>.

Claim 1:
A closure assembly (<NUM>) for a flexible container, comprising:
a connector assembly (<NUM>), mountable at an opening of the flexible container, configured to provide a fluid path through the opening of the flexible container, comprising:
a male connector member (<NUM>), comprising a first tubular body (<NUM>) having a first proximal end portion (<NUM>) and a first distal end portion (<NUM>) along a first central axis (<NUM>), and a first flange portion (<NUM>) protruding radially outwards at said first proximal end portion (<NUM>), and
a female connector member (<NUM>), comprising a second tubular body (<NUM>) having a second proximal end portion and a second distal end portion (<NUM>) along a second central axis (<NUM>), a second flange portion (<NUM>) protruding radially outwards at said second proximal end portion and at least one diametrically traversing internal support member (<NUM>) at said second distal end portion (<NUM>), said female connector member (<NUM>) being configured to coaxially matingly and interlockingly engage with said male connector member (<NUM>), so as to securingly clamp at least a peripheral edge portion of the opening of the flexible container between said first and second flange portion (<NUM>, <NUM>);
a plug member (<NUM>), comprising a third cylindrical body (<NUM>) having a third proximal end portion (<NUM>) and a third distal end portion (<NUM>) along a third central axis (<NUM>), at least two radially opposed locking members (148a, 148b), each one protruding axially away from said distal end portion (<NUM>) so as to lockingly engage with said internal support member (<NUM>) during use, said plug member (<NUM>) being configured to matingly and sealingly engage with said male connector member (<NUM>) and lockingly engage with said female connector member (<NUM>) during use.