US20060219718A1 - Integral tortuous path receptacle cover - Google Patents

Abstract

A cover for a medical waste disposal receptacle and a method of manufacturing a cover for a medical waste disposal receptacle. The cover generally comprises a body portion configured to substantially close an open end of the receptacle and a lid portion hingedly interconnected to the body portion via an integrally formed hinge extending between the lid portion and a portion of the body portion. The body portion includes a covering surface with an access opening therethrough and at least a first, fixed sloped slide surface depending from the covering surface configured to provide a fixed tortuous path extending from the access opening.

Description

BACKGROUND OF THE INVENTION
• The present invention relates to a cover for a medical waste disposal receptacle and a method of manufacturing a cover for a medical waste disposal receptacle. More specifically, the present invention relates to medical waste disposal receptacles having a flexibly pivoted top closure lid and, more particularly, to a receptacle cover having an integral pivoted lid portion and a body portion having an integral tortuous path access opening.
• 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, a patient's room, or in other clinical or non-clinical settings in which medical waste is generated. 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. Such hospital waste products might include surgical sharps, such as needles, syringes, scalpel blades, or the like, or might include gauzes, bandages, or sponges. It is important to prevent the user of a sharps container from being accidentally cut or punctured by its contents.
• Examples of such containers include those shown in U.S. Pat. No. 5,058,764, entitled “Mounting Bracket Having A Hidden Lock For A Sharps Collection System”; U.S. Pat. No. 5,080,251, entitled “Tortuous Path In-Patient Room Medical Waste Disposal Container”; and U.S. Pat. No. 5,494,186, entitled “Wall Mounted Medical Waste Disposal Container With Pivoted Top Closure Lid.”
• While the prior art containers provide a desired level of protection, they generally require various components to be formed separately and thereafter assembled. These additional steps add cost and complexity to the manufacturing process.
SUMMARY OF THE INVENTION
• In at least one embodiment, the cover comprises a body portion configured to substantially close an open end of the receptacle. The body portion has a given perimeter and defines a tortuous path access opening. A lid portion configured to selectively close the access opening is hingedly interconnected to the body portion via an integrally formed hinge extending between the lid portion and a portion of the body portion given perimeter.
• In at least one embodiment, the cover comprises a body portion including a covering surface configured to substantially close the receptacle open end. The body portion further includes first and second slide surfaces depending from the covering surface. The first and second slide surfaces are axially spaced in non-overlapping relation to define a tortuous path access opening through the covering surface.
• In at least one embodiment, the receptacle includes an open end and a receptacle body having an axis extending from the open end in a given direction and the cover comprises a body portion configured to substantially close the open end of the receptacle. The body portion defines a tortuous path access opening having opposed, axially spaced, first and second lateral edges. The body portion includes at least a first integral slide surface that defines the first lateral edge. The first and second lateral edges are configured such that a plane extending through the first and second lateral edges is at an angle of between 0 degrees and about 20 degrees relative to a plane parallel to the given direction and extending through the second lateral edge.
• The method, according to one exemplary embodiment, comprises the steps of disposing a moldable material in a linearly separable mold assembly having one or more cavities configured to define the tortuous path receptacle cover, and removing the integrally formed cover from the mold assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
• The invention is best understood from the following detailed description when read in connection with the accompanying drawings. It is emphasized that, according to common practice, the various features of the drawings are not to scale. On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity. Included in the drawings are the following figures:
• FIG. 1 is a top, front isometric view of a cover that is a first embodiment of the present invention positioned on an illustrative receptacle.
• FIG. 2 is a top plan view of the cover ofFIG. 1.
• FIG. 3 is a cross-sectional view along theline3—3 inFIG. 2.
• FIG. 4 is a detailed view of a lock portion of the cover as denoted inFIG. 3.
• FIG. 5 is a detailed view of a hinge portion of the cover as denoted inFIG. 3.
• FIG. 6 is a bottom, front isometric view of the cover ofFIG. 1FIG. 7 is a cross-sectional view similar toFIG. 3 showing a lid portion in a closed position.
• FIG. 8 is an isometric view of a first portion of an embodiment of a mold assembly utilized to manufactured the cover ofFIG. 1.
• FIG. 9. is an isometric view of a second portion of the mold assembly utilized to manufactured the cover ofFIG. 1.
• FIG. 10 is a cross-sectional side view showing the first and second mold portions ofFIGS. 8 and 9 in an assembled configuration.
• FIG. 11 is a detailed view of the cavity portions of the mold assembly ofFIG. 10.
• FIG. 12 is a top, front isometric view of a cover that is a second embodiment of the present invention.
• FIG. 13 is a top plan view of the cover ofFIG. 12.
• FIG. 14 is a cross-sectional side view along theline14—14 inFIG. 13.
• FIG. 15 is a top plan view of a cover that is a third embodiment of the present invention.
• FIG. 16 is a cross-sectional side view along theline16—16 inFIG. 15.
• FIG. 17 is a cross-sectional side view similar toFIG. 16 showing the lid portion in an operable position.
DETAILED DESCRIPTION OF THE INVENTION
• This invention will now be described with reference to several embodiments selected for illustration in the drawings. It will be appreciated that the scope and spirit of the invention are not limited to the illustrated embodiments. It will further be appreciated that the drawings are not rendered to any particular proportion or scale. Also, any dimensions referred to in the description of the illustrated embodiments are provided merely for the purpose of illustration. The invention is not limited to any particular dimensions, materials, or other details of the illustrated embodiments.
• Referring toFIGS. 1-7, acover10 that is a first embodiment of the present invention will be described. Thecover10 is configured to be positioned on a medicalwaste disposal receptacle2. Thereceptacle2 generally includes a body defined by afront wall4, a pair ofside walls3, and arear wall5 extending from abase6. Thewalls3,3,4 and5 define a generallyopen end7 opposite thebase6. Theopen end7 defines arim8 about its perimeter. Therim8 may have various configurations. As shown inFIG. 3, the edges of thewalls3,3,4 and5 are curled over to define therim8, however, a curl is not required and other configurations may be utilized.
• Thewalls3,3,4 and5 are generally planar surfaces, but may have various configurations. For example, thefront wall4 in the present embodiment defines a chevron shape. In the present embodiment, therear wall5 is a substantially planar surface which allows the receptacle to be positioned against a wall or the like. Thereceptacle2 has a central axis CA extending from thebase6 to theopen end7. Thereceptacle2 is typically positioned in use in a vertical position with the central axis CA extending vertically. In this typical arrangement, theopen end7 extends along a horizontal plane. Other configurations of thereceptacle2 and other mounting arrangements may also be utilized.
• Thecover10 generally comprises abody portion12 and alid portion50. Thebody portion12 includes a coveringsurface14 configured to substantially cover and thereby close the receptacleopen end7. The coveringsurface14 generally has a configuration that complements the configuration of thereceptacle rim8. As such, in the present embodiment, the coveringsurface14 has a front portion with a chevron shape and a rear portion that is shaped to correspond to the planarrear wall5.
• Aflange16 depends from at least a portion of the coveringsurface14. Theflange16 is configured to fit about the receptacleopen end rim8. Theflange16 may be continuous about the perimeter of the receptacle rim8 (as in the embodiment ofcover10 illustrated inFIGS. 1-7), or may be segmented and provided at various positions about thereceptacle rim8. Thebody portion12 is preferably provided with means for securing thecover10 to thereceptacle2. In the present embodiment, lockingtabs17 configured to engage thereceptacle rim8 are provided at various locations about theflange16, as shown inFIG. 5. Alternatively, thebody portion12 may have a friction fit with respect to thereceptacle2, clips (not shown) may extend between thebody portion12 and thereceptacle2, thereceptacle rim8 may be provided with projections which engage theflange16, or thebody portion12 may be provided with projections which extend through bores provided in thereceptacle rim8. Other securing means may also be utilized. Thebody portion12 may further includeinternal ribs13 configured to engage thereceptacle2 to further support thecover10 relative to thereceptacle2.
• Thebody portion12 has an access opening20 through the coveringsurface14. Theaccess opening20 is positioned within an inlet area that is defined by a rearlateral edge19, a frontlateral edge21 and opposed side edges23 and25 extending between the rear andfront edges19,21. Afront wall22 is provided along the frontlateral edge21 andopposed side walls26,28 extend along the side edges23,25, respectively. Thelid portion50 extends proximate to therear edge19 as will be described in greater detail hereinafter.
• As shown inFIGS. 3 and 7, theside walls26,28 may extend beyond theaccess opening edges23,25 to the location of ahinge54 of thelid portion50. In use, thereceptacle2 is secured to a wall surface or the like with thelid portion50 pivoted to a substantially vertical or upwardly-angled position in which thelid portion50 rests against the wall surface. Thelid portion50 may have instructions inscribed on an internal surface that will be directed to a user when thelid portion50 is in this use position. For example, thelid portion50 optionally includes directions such as “DROP SHARP HORIZONTALLY IN OPENING,” other information, or other indicia for communication to a user of thecover10.
• In this use position, thelid portion50, the openingfront wall22 and theopening side walls26,28 effectively define a funnel into theaccess opening20. Any sharp or other device positioned within this funnel area will thereby be directed to theaccess opening20. Referring toFIG. 1, the coveringsurface14 slopes downward from the openingfront wall21 and theopening side walls26,28 to the perimeter P. As such, the sloped coveringsurface14 is not configured to accommodate a sharp or other device. This configuration discourages a user from intentionally or inadvertently leaving a sharp or the like on the coveringsurface14 which may pose a danger to that user or a later user.
• Referring toFIG. 3, a substantially fixed tortuous path extends from the inlet area defined by the rearlateral edge19, the frontlateral edge21 and the opposed side edges23 and25 and through the access opening20 to provide a tortuous entry passage into the receptacle cavity. The tortuous entry passage allows for the unrestricted passage of medical instruments and/or waste past stationary surfaces while making hand insertion into the receptacle difficult, if not impossible. In the present embodiment, the tortuous path is defined by afront slide30 extending from the frontlateral edge21 and arear slide40 extending from the rearlateral edge19. The front andrear slides30,40 are formed integrally with the coveringsurface14. Preferred methods of manufacture are described in more detail hereinafter.
• Thefront slide30 includes a slopedfront slide surface32 terminating along alateral edge34. Thefront slide surface32 extends laterally between theopposed side walls26,28 and has a generally planar configuration, although other configurations are possible. Therear slide40 includes a slopedrear slide surface42 terminating along alateral edge44. Therear slide surface42 has a curved surface that reduces in slope toward thelateral edge44. Other configurations are also possible. Therear slide surface42 extends laterally between rear slide surface edges41 and43 as shown inFIG. 2. Eachside wall26,28 includes or extends to an extendingwall portion27,29, respectively, extending from theside wall26,28 to the respectiveslide surface edge41,43. The extendingwall portions27,29 extend between therear edge19 and the front slide surfacelateral edge34, but may extend farther.
• The extendingwall portions27,29 retain deposited materials within the lateral extents of therear slide surface42 and also provide support for therear slide surface42 ofrear slide40. A substantially rectangular lower opening is therefore defined by thelateral edge44 of therear slide surface42 and the forward edges of the extendingwall portions27,29. This lower opening is oriented in a plane that is substantially vertical or at an angle to a vertical plane, as will be described later in greater detail. Supportingribs46 or the like may be provided along a rear surface of therear slide40, on or oppositerear slide surface42, at various locations between the side edges41,43 to provide additional support.
• The perimeter edge of the access opening20 is therefore defined by the rearlateral edge19, the frontlateral edge34 and upper edges of the extendingwall portions27,29. Thus, a substantially rectangular access opening20 (in the embodiment illustrated inFIGS. 1-7) is oriented along a plane that is sloped toward the rear of thecover10.
• Medical waste introduced into the tortuous path through the inlet area of thecover10 follows a circuitous path into the interior of thereceptacle2. More specifically, medical waste is deposited within the interior of thereceptacle2 after it passes into the inlet area defined by the rearlateral edge19, frontlateral edge21 and opposed side edges23 and25; travels through the access opening20 defined by the rearlateral edge19, the frontlateral edge34 and upper edges of the extendingwall portions27,29; and passes through the lower opening defined by thelateral edge44 of therear slide surface42 and the forward edges of the extendingwall portions27,29.
• Thefront slide30 and therear slide40 are configured such that thefront slide surface32 is horizontally axially spaced from therear slide surface42 in non-overlapping relation. More specifically, a plane S1 parallel to the central axis CA and extending through the frontlateral edge34 of thefront slide surface32 is horizontally axially spaced a distance d from a plane S3 parallel to the central axis CA and extending through thelateral edge44 of therear slide surface42. The distance d is from 0 inches to approximately 1 inch, with a preferred range from greater than zero inches to about7/8 inch, and a more preferred range from about1/8 inch to about5/8 inch, and a more preferred range from about1/4 inch to about1/2 inch. Additionally, a plane S2 extending through the frontlateral edge34 of thefront slide surface32 and thelateral edge44 of the rear slide surface42 (i.e., the plane of the lower opening defined by thelateral edge44 of therear slide surface42 and the forward edges of the extendingwall portions27,29) is at an angle α relative to the plane S1. The angle α is from 0 degrees to approximately 25 degrees, with a preferred range from greater than 0 degrees to about 20 degrees, and a more preferred range from about 2 degrees to about 15 degrees, and a more preferred range from about 5 degrees to about 10 degrees. The distance d and the angle α are selected to provide a tortuous path entry passage having a desired waste clearance and a desired user inaccessibility.
• The substantially fixed tortuous path allows a user to dispose of an item into thereceptacle2 by dropping the item into the funnel area leading to theaccess opening20. Gravity causes the item to pass by the front andrear slides30,40 and into thereceptacle2. The user does not have to actuate thecover10 to cause disposal or even contact thecover10 in any manner during disposal. The disposed item passes freely into thereceptacle2, however, the tortuous path reduces or eliminates the possibility of an individual reaching into thereceptacle2.
• While the present embodiment is described with afront slide30 and arear slide40, both may not be necessary. For example, thefront slide30 may be eliminated while therear slide surface42 is extended axially in a forward direction. With thefront slide30 eliminated, the plane S1 would extend through theopening front edge21. If so modified, the spatial relationship between the planes S1 and S3 and the angular relationship between planes S2 and S1 provided in thecover10 would still be maintained to provide a desired tortuous path.
• Additionally, while the present embodiment is described with therear slide surface42 having a larger axial length than thefront slide surface32, such configuration can be reversed. For example, thefront slide surface32 may be configured with a larger axial length and extending at a steeper angle such that the frontlateral edge34 of thefront slide surface32 is lower than thelateral edge44 of therear slide surface42. Other configurations may also be utilized.
• To close the access opening20 once the receptacle is filled to a desired level, thecover10 includes alid portion50 configured to cover and close the inlet area andaccess opening20. In the present embodiment, thelid portion50 is integrally hinged to thebody portion12 along arear edge15 of the outer perimeter P of thebody portion12. The outer perimeter P is defined by the outer extent of the coveringsurface14 and theflange16. The perimeter P may be defined by both the coveringsurface14 and theflange16 if, for example, theflange16 extends radially outward of the coveringsurface14 along a portion of the perimeter, but is inward of the coveringsurface14 along other portions of the perimeter. At the locations where theflange16 is outward, theflange16 will define that portion of the perimeter P and at locations where the coveringsurface14 is outward, the coveringsurface14 will define that portion of the perimeter P.15 Thelid portion50 includes alid surface52 configured to complement the shape of the inlet area and/or theaccess opening20. In the present embodiment, thelid surface52 has a substantially rectangular configuration, but other configurations are also possible. An integral hinge54 (e.g., a living hinge) extends between thelid surface52 and therear perimeter edge15 of thebody portion12. Thehinge54 of the present embodiment extends substantially along the entire length of thelid surface52, however, thehinge54 may be formed as one or more segments that extend less than the length of thelid surface52. As illustrated inFIG. 5, thehinge54 is optionally formed by providing a section of reduced material thickness. Such reduced thickness provides thehinge54 with greater flexibility than the neighboringlid portion50 orcover portion10. Thehinge54 therefore has sufficient flexibility to allow thelid portion50 to be pivoted from the open position shown inFIG. 3 to the closed position shown inFIG. 5, to be described in greater detail later.
• To lock thelid portion50 in the closed position, thelid portion50 includes one ormore locking tabs56 extending from thelid surface52. A locking bore36 corresponding to each lockingtab56 is provided adjacent the opening front edge21 (FIG. 4). In the present embodiment, the locking bores36 are provided through thefront slide surface32 and each locking bore36 defines a lockingshoulder38 below thefront wall22, as shown inFIG. 4. To close the inlet area and access opening20, thelid surface52 is pivoted about thehinge54 until each lockingtab56 engages arespective locking shoulder38, as shown inFIG. 7. The engagement of the lockingtabs56 with the locking shoulders38 preferably permanently locks thelid portion50 in the closed position, prevents unauthorized opening of thelid portion50, and / or inhibits unintended opening of thelid portion50. Each lockingtab56 preferably has asupport rib55 having a width equal to the width of the locking bore36 to prevent prying of the lockingtabs56 from the locking bores36 (seeFIGS. 1-3 and7).
• Having generally described the components of thecover10 and the operation thereof, a method of manufacturing thecover10 that is a first embodiment of the inventive method will be described with reference toFIGS. 3, 5 and8-11. The first embodiment of the inventive method utilizes amold assembly300 including first andsecond mold portions302,304 that are linearly moveable relative to each other in a direction parallel to the mold axis MA. Themold assembly300 is configured for use in an injection molding process in which plastic material is injected into a cavity defined bymold portions302,304 to form thecover10. In use, themold portions302,304 are moved with respect to one another along the mold axis MA between an open position in which the mold portions are spaced from one another (e.g., for removal for a completed cover10) and a closed position in which the mold portions contact one another to define the cavity.
• Themold portions302 and304 have a control assembly for controlling the alignment and movement of themold portions302 and304 relative to one another. For example, onemold portion304 may be provided withposts308 that are received in correspondingbores306 in theother mold portion302 to align and control linear motion of themold portions302 and304. Other assemblies may also be utilized.
• Themold assembly300 has one ormore injection ports330 or the like configured to dispose moldable material incavity portions318,320,322,324,326 formed between themold portions302 and304. Themold portions302 and304 andcavity portions318,320,322,324,326 are configured such that all of the components of thecover10 may be formed as a unitary structure while allowing simple linear separation of themold portions302 and304 in a direction parallel to the mold axis MA, as indicated by arrows A inFIG. 11. In other words, all of the surfaces of the moldcavity forming cover10 are provided, according to one exemplary aspect of this invention, by two mold portions movable along a common axis. Thus, simplified and cost effective mold tooling and processes are optionally employed, thereby reducing the effort and cost associated with the manufacture of thecover10. Known mold assemblies, in contradistinction, have required additional mold components, for example, cross sliding components to make complex, unitary structures.
• Referring toFIGS. 8-11, bothmold portions302,304 include male and female mold surfaces310,311,312,313,315,317,319,321,323,325,327,329,331,333,335 configured and positioned to define thecavity portions318,320,322,324,326 when themold portions302 and304 are positioned relative to one another. For example, acavity portion324 configured to form therear slide40 of thecover10 is defined bymold surfaces311,312 and313 whilecavity portion322 configured to form thefront slide30 of thecover10 is defined bymold surfaces310,315 and317.
• As shown inFIGS. 10 and 11, the mold surfaces310 and312 mate along the plane S2, which is the plane that extends through the frontlateral edge34 of thefront slide surface32 and thelateral edge44 of therear slide surface42 of the cover10 (i.e., the plane of the lower opening defined by thelateral edge44 of therear slide surface42 and the forward edges of the extendingwall portions27,29). The plane S1 (the plane parallel to the central axis CA and extending through the frontlateral edge34 of thefront slide surface32 of the cover10) is configured to be substantially parallel to the mold axis MA. The angle α of the mating plane S2 relative to the plane S1 allows the mold surfaces310 and312 to adequately seal between the twocavities322 and324. Additionally, the angle α of the mating plane S2 allows the twomold portions302 and304 to be moved apart in a direction parallel to the mold axis MA, as indicated by arrows A, without interfering with either of the molded slide surfaces32 or42 that are formed in thecavity portions322 and324, respectively. As indicated previously, the angle α according to one embodiment is between 0 degrees and approximately 20 degrees, with a preferred range from about 2 degrees to about 15 degrees, and a more preferred range from about 5 degrees to about 10 degrees.
• Additional mold surfaces325 may be provided adjacent thesurface313 to assist in forming the lockingtabs17 along the rear portion of therim16. As illustrated inFIG. 5, the mold surfaces325leave apertures18 through the coveringsurface14; however, theapertures18 are sufficiently small that they do not allow access within thecover10 and are also covered by thelid portion50 when thelid portion50 is closed as illustrated inFIG. 7. Similarly, mold surfaces335 may be providedadjacent mold surface317 to define the locking bores36 illustrated inFIG. 4. The mold surfaces335 cooperate with themold surface319 to define the locking shoulders38.
• Mold surface319 also cooperates withmold surfaces321 and323 to definecavity portion320 configured to form thebody portion12. Mold surfaces327 and329 cooperate to definecavity portion326 configured to form thelid surface52. Mold surfaces327 and329 further cooperate withmold surface325 to definecavity portion318 configured to form thehinge54 between thelid surface52 and thebody portion12. Themold surface329 is preferably configured to form theflange16 with an inward draft angle, as indicated inFIG. 5 by the angle θ between planes E and F. The inward draft angle assists in defining thehinge cavity portion318 and the separation of themold portions302 and304. Mold surfaces327,331 and333 cooperate to define a cavity portions configured to form the lockingtabs56.
• As illustrated inFIG. 11, the mold surfaces are preferably configured such that thecavity portion326 that forms thelid portion50 is at an approximate right angle with respect to the mold axis MA to facilitate separation of themold portions302 and304 in the direction of arrows A. However, other angles may also be utilized.
• To form theintegral cover10, moldable material is supplied to the cavity portions, for example, throughinjection ports330. Themold portions302 are thereafter separated in the direction of arrows A inFIG. 11 and theintegral cover10 is removed. Thecover10 is substantially ready for use and does not require any substantial secondary operations to assemble thecover10.
• Referring toFIGS. 12-14, acover110 that is alternate embodiment of the present invention will be described. Thecover110 is similar to cover10 in that it has a one-piece construction that is capable of being formed using a cost effective molding process. As will be describe in detail below, however, thecover110 differs fromcover10 in the manner in which the lid is coupled to the body portion and in other ways.
• Thecover110 includes abody portion112 and alid portion150. Thebody portion112 includes acovering surface114 configured to substantially cover and thereby close a receptacleopen end7. The coveringsurface114 generally has a configuration that complements the configuration of thereceptacle rim8. In the present embodiment, the coveringsurface114 has a chevron shape in both the front and rear portions.
• Aflange116 depends from at least a portion of the coveringsurface114. Thebody portion112 ofcover110 is preferably provided with means for securing thecover110 to areceptacle2. In the present embodiment, lockingtabs117 configured to engage thereceptacle rim8 are provided at various locations about theflange116, as shown inFIG. 14. Other securing means may also be utilized.
• Thebody portion112 has an access opening120 through the coveringsurface114. Theaccess opening120 is defined by a rearlateral edge119, a frontlateral edge121 and opposed side edges123 and125 extending between the rear andfront edges119,121. Referring toFIG. 14, a substantially fixed tortuous path extends from the access opening120 to provide a tortuous entry passage into the receptacle cavity from the access opening120 which allows for the unrestricted passage of medical instruments and/or waste past stationary surfaces while making hand insertion into the receptacle difficult, if not impossible. In the present embodiment, the tortuous path is defined by arear slide130 extending from the opening rearlateral edge119 and afront slide140 extending from the opening frontlateral edge121. The rear and front slides130,140 are formed integrally with the coveringsurface114.
• Therear slide130 includes a slopedrear slide surface132 terminating along alateral edge134. Therear slide surface132 extends laterally betweenopposed side walls127 and has a generally planar configuration, although other configurations are possible. Thefront slide140 includes a stepped front slide surface terminating along alateral edge144. The stepped slide surface includes a firstsloped portion142 followed by a substantiallyhorizontal step146 followed by a secondsloped portion148 that terminates at thelateral edge144. The first and second slide surfaces142 and148 are substantially planar surfaces, but other configurations are also possible.
• The perimeter edge of the access opening120 is therefore defined by the rearlateral edge119, the frontlateral edge121 and upper edges of theside walls127. Thus, a substantially rectangular access opening120 (in the embodiment illustrated inFIGS. 12-14) is oriented along a plane that is substantially horizontal but that may be sloped such as toward the rear of thecover110.
• Thehorizontal step146 of thefront slide140 includes a plurality of locking bores136 configured to receive lockingtabs156 on thelid portion150 as will be described hereinafter. The front slide extends laterally betweenside walls127. The rear and front slides130,140 and the side walls1.27 effectively define a funnel-shaped path into the receptacle. A substantially rectangular lower opening is therefore defined by thelateral edge144 of thefront slide surface142 and the lower edges of theside walls127. This lower opening is oriented in a plane that is substantially vertical or at an angle to a vertical plane, as will be described later in greater detail.
• Medical waste introduced into the tortuous path through the inlet area of thecover110 follows a circuitous path into the interior of thereceptacle2. More specifically, medical waste is deposited within the interior of thereceptacle2 after it passes into the inlet area; travels through the access opening120 defined by the rearlateral edge119, the frontlateral edge121 and upper edges of theside walls127; and passes through the lower opening defined by thelateral edge144 of thefront slide surface142 and the lower edges of theside walls127.
• Therear slide130 and thefront slide140 are configured such that therear slide surface132 is axially spaced from the frontsecond slide surface148 in non-overlapping relation. A plane SI parallel to the central axis CA and extending through the rearlateral edge134 is axially spaced a distance d from a plane53 parallel to the central axis CA and extending through the frontlateral edge144. The distance d is from 0 inches to approximately 1 inch, with a preferred range from greater than zero inches to about7/8 inch, and a more preferred range from about1/8 inch to about5/8 inch, and a more preferred range from about1/4 inch to about1/2 inch. Additionally, a plane S2 extending through the rearlateral edge134 and the frontlateral edge144 is at an angle a relative to the plane S1. The angle α is from 0 degrees to approximately 25 degrees, with a preferred range from greater than 0 degrees to about 20 degrees, and a more preferred range from about 2 degrees to about 15 degrees, and a more preferred range from about 5 degrees to about 10 degrees. The distance d and the angle α are selected to provide a tortuous path entry passage having a desired waste clearance and a desired user inaccessibility.
• To close the access opening120 once the receptacle is filled to a desired level, thecover110 includes alid portion150 configured to cover and close theaccess opening120. In the present embodiment, thelid portion150 is integrally hinged to thebody portion112 along the outer perimeter P of thebody portion112 viastraps153. Thelid portion150 includes alid surface152 configured to complement the shape of theaccess opening120. In the present embodiment, thelid surface152 has a rectangular configuration, but other configurations are also possible.
• Eachstrap153 extends between thelid surface152 and a respectiveintegral hinge154 extending along the perimeter P of thebody portion112. To lock thelid portion150 in the closed position, thelid portion150 includes one ormore locking tabs156 extending from thelid surface152. To close the access opening120, thelid surface152 is pivoted about thehinges154 until eachlocking tab156 engages in a respective locking bore136. As illustrated in phantom inFIG. 13, the locking bores136' may alternatively be provided along the coveringsurface114.
• Thecover110 is configured such that it can be manufactured utilizing the method described above with respect to cover10. The mold surfaces will be arranged to provide cavity portions corresponding to the various components ofcover110. Again, the components are configured such that the mold portions may be linearly separated to remove the integrally formedcover110.
• Referring toFIGS. 15-17, acover210 that is alternate embodiment of the present invention will be described. Thecover210 is similar to cover10 andcover110 in that it has a one-piece construction that is capable of being formed using a cost effective molding process. As will be described in detail below, however, thecover210 differs fromcover10 andcover110 in the manner in which the lid is coupled to the body portion and in other ways.
• Thecover210 includes abody portion212 and alid portion250. Thebody portion212 includes acovering surface214 configured to substantially cover and thereby close a receptacleopen end7. The coveringsurface214 has a substantially domed configuration, thereby providing a more pronounced profile as compared to that ofcovers10 and110. Such a profile is optionally provided in order to maximize the capacity of thereceptacle2, to provide steeper slopes at the front and side portions of the cover, and/or to permit a deeper extension of the surfaces defining the covers tortuous path.
• The coveringsurface214 generally has a configuration that complements the configuration of thereceptacle rim8. In the present embodiment, the coveringsurface214 has a chevron shape in both the front and rear portions. The coveringsurface214 of the present embodiment has a relatively steep slope such that thebody portion212 is deeper than that of the previous embodiments, as mentioned previously.
• Aflange216 depends from at least a portion of the coveringsurface214. Thebody portion212 is preferably provided with means for securing thecover210 to areceptacle2, for example, locking tabs or the like configured to engage thereceptacle rim8. Other securing means may also be utilized.
• Thebody portion212 has an access opening220 through the coveringsurface214. Theaccess opening220 is defined by a rearlateral edge219, a frontlateral edge221 and opposed side edges223 and225 extending between the rear andfront edges219,221. Afront wall222 is provided along the opening frontlateral edge221.
• Referring toFIG. 15, a substantially fixed tortuous path extends from the access opening220 to provide a tortuous entry passage into the receptacle cavity from the access opening220 which allows for the unrestricted passage of medical instruments and/or waste past stationary surfaces while making hand insertion into the receptacle difficult, if not impossible. In the present embodiment, the tortuous path is defined by arear slide230 extending from the opening rearlateral edge219 and afront slide240 extending from the opening frontlateral edge221. The rear and front slides230,240 are formed integrally with the coveringsurface214.
• Therear slide230 includes a slopedrear slide surface232 terminating along alateral edge234. Thefront slide240 includes afront slide surface242 terminating along alateral edge244. Thefront slide surface242 depends a distance Y from the coveringsurface214. The distance Y is preferably less than the depth D of thebody portion212 in order to maintain theslide surface242 above the interior of thereceptacle2. The rear and front slide surfaces232 and242 are substantially planar surfaces, but other configurations are also possible.
• Therear slide230 and thefront slide240 are configured such that therear slide surface232 is axially spaced from thefront slide surface242 in non-overlapping relation. A plane S1 parallel to the central axis CA and extending through the rearlateral edge234 is axially spaced a distance d from a plane S3 parallel to the central axis CA and extending through the frontlateral edge244. The distance d is from 0 inches to approximately 1 inch, with a preferred range from greater than zero inches to about7/8 inch, and a more preferred range from about1/8 inch to about5/8 inch, and a more preferred range from about1/4 inch to about1/2 inch. Additionally, a plane S2 extending through the rearlateral edge234 and the frontlateral edge244 is at an angle α relative to the plane S1. The angle α is from 0 degrees to approximately 25 degrees, with a preferred range from greater than 0 degrees to about 20 degrees, and a more preferred range from about 2 degrees to about 15 degrees, and a more preferred range from about 5 degrees to about 10 degrees. The distance d and the angle α are selected to provide a tortuous path entry passage having a desired waste clearance and a desired user inaccessibility.
• The perimeter edge of the access opening220 is therefore defined by the rearlateral edge219, the frontlateral edge221 and the upper edge portions of the opposed side edges223 and225. Thus, a substantially rectangular access opening220 (in the embodiment illustrated inFIGS. 15-17) is oriented along a plane that is substantially horizontal but that may be sloped such as toward the rear of thecover210. A substantially rectangular lower opening is defined by thelateral edge244 of thefront slide surface242 and the lower edges portions of the opposed side edges223 and225. This lower opening is oriented in a plane that is substantially vertical or at an angle to a vertical plane, as will be described later in greater detail.
• Medical waste introduced into the tortuous path through the inlet area of thecover210 follows a circuitous path into the interior of thereceptacle2. More specifically, medical waste is deposited within the interior of thereceptacle2 after it passes into the inlet area; travels through the access opening220 defined by the rearlateral edge219, the frontlateral edge221 and upper edge portions of the opposed side edges223 and225; and passes through the lower opening defined by thelateral edge244 of thefront slide surface242 and the lower edges portions of the opposed side edges223 and225.
• To close the access opening220 once the receptacle is filled to a desired level, thecover210 includes alid portion250 configured to cover and close theaccess opening220. In the present embodiment, thelid portion250 is integrally hinged to thebody portion212 along the outer perimeter P of thebody portion212 viastraps253. Thelid portion250 includes alid surface252 configured to complement the shape of theaccess opening220. Eachstrap253 extends between thelid surface252 and a respectiveintegral hinge254 extending along the perimeter P of thebody portion212.
• Due to the deeper nature of the body portion212 (as compared tobody portions12 and112 of other cover embodiments), thestraps253 have an extended length with aintermediate locking tab255 and asecondary hinge257. To move thelid surface252 to an operable position, thestraps253 are pivoted about thehinges254 and theintermediate locking tabs255 are inserted into intermediate locking bores235 in thecovering surface214. Thestraps253 have a length L that is approximately equal to the depth D of thebody portion212 such that when the lockingtabs255 are locked in the locking bores235, thehinges257 are adjacent the top of thebody portion212. As such, to lock thelid portion250 in the closed position, thelid surface252 is pivoted about thehinges257 until eachlocking tab256 engages in a respective locking bore236.
• Thecover210 is configured such that it can be manufactured utilizing the method described above with respect to cover10. The mold surfaces will be arranged to provide cavity portions corresponding to the various components ofcover210.FIG. 15 illustratesbores218 that may be provided to mold internal components, for example, internal locking tabs (not shown). Again, the components are configured such that the mold portions may be linearly separated to remove the integrally formedcover210.
• Although the invention is illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the invention.

Claims (49)

1. A cover for a medical waste disposal receptacle, said receptacle defining a receptacle open end and a receptacle body extending from the open end, the receptacle body having an axis extending in a given direction, said cover comprising:

a body portion configured to substantially close said receptacle open end, said body portion defining a tortuous path access opening having opposed, axially spaced, first and second lateral edges, the body portion including at least a first integral sloped slide surface that defines the first lateral edge; and

wherein said first and second lateral edges are configured such that a plane extending through said first and second lateral edges is at an angle of from 0 degrees to about 25 degrees relative to a plane parallel to the given direction and extending through said second lateral edge.

2. The cover according toclaim 1 wherein the angle is from greater than 0 degrees to about 20 degrees.

3. The cover according toclaim 1 wherein the angle is from about 2 degrees to about 15 degrees.

4. The cover according toclaim 1 wherein the angle is from about 5 degrees to about 10 degrees.

5. The cover according toclaim 1 wherein the given direction extends in a vertical plane.

6. The cover according toclaim 1 wherein the body portion includes a second integral sloped slide surface that defines the second lateral edge.

7. The cover according toclaim 1 wherein the body portion has a given perimeter and a lid portion configured to selectively close said access opening is hinged to the body portion by an integrally formed hinge extending along a portion of said given perimeter.

8. A method of forming a cover for a medical waste disposal receptacle having an open end, said method comprising the steps of:

disposing of moldable material within a mold assembly that is linearly separable in a given direction, the mold assembly having a cavity portion configured to form a cover body portion defining an access opening having opposed, axially spaced first and second lateral edges, the body portion including at least a first integral sloped slide surface that defines the first lateral edge, the cavity portion configured such that a plane extending through said first and second lateral edges is at an angle from 0 degrees to about 25 degrees relative to a plane parallel to the given direction and extending through said second lateral edge;

separating said mold assembly in the given direction; and

removing from the mold assembly a formed cover with an integrally formed tortuous path access opening.

9. The method according toclaim 8 wherein the angle is from greater than 0 degrees to about 20 degrees.

10. The method according toclaim 8 wherein the angle is from about 2 degrees to about 15 degrees.

11. The method according toclaim 8 wherein the angle is from about 5 degrees to about 10 degrees.

12. The method according toclaim 8 wherein the cavity portion is further configured such that the body portion includes a second integral sloped slide surface that defines the second lateral edge.

13. A cover for a medical waste disposal receptacle, said receptacle defining a receptacle open end, said cover comprising:

a body portion including a covering surface configured to substantially close said receptacle open end except for an access opening therethrough, said body portion further including integrally formed, fixed first and second sloped slide surfaces depending from the covering surface adjacent the access opening,

wherein the first and second slide surfaces are axially spaced in non-overlapping relation to define a tortuous path extending from the access opening.

14. The cover according toclaim 13 wherein the first sloped slide surface terminates at a first lateral edge and the second sloped slide surface terminates at a second lateral edge axially spaced from the first lateral edge by a distance d.

15. The cover according toclaim 14 wherein the first lateral edge is spaced a greater distance from the covering surface than the second lateral edge.

16. The cover according toclaim 14 wherein the second lateral edge is spaced a greater distance from the covering surface than the first lateral edge.

17. The cover according toclaim 14 wherein the distance d is from 0 inches to approximately 1 inch.

18. The cover according toclaim 14 wherein the distance d is between greater than 0 inches and about7/8 inch.

19. The cover according toclaim 14 wherein the distance d is between about1/8 inch and about5/8 inch.

20. The cover according toclaim 14 wherein the distance d is between about1/4 inch and about1/2 inch.

21. The cover according toclaim 13 wherein the body portion has a front edge and a rear edge and the first sloped slide surface is closer to the body portion rear edge and the second sloped slide surface is closer to the body portion front edge.

22. The cover according toclaim 21 wherein the access opening defines a planar opening that is sloped toward the body portion rear edge.

23. The cover according toclaim 13 wherein the first sloped slide surface has opposed first and second slide surface side edges and wherein a first support wall extends between the covering surface and the first slide surface side edge and a second support wall extends between the covering surface and the second slide surface side edge.

24. The cover according toclaim 23 wherein the first sloped slide surface terminates at a first lateral edge and the second sloped slide surface terminates at a second lateral edge axially spaced from the first lateral edge, and wherein the first and second lateral edges and first and second support walls define a substantially rectangular lower opening spaced from and at an angle relative to the access opening.

25. The cover according toclaim 13 wherein the access opening is defined by a front opening edge, a rear opening edge and opposed side edges extending between the front and rear opening edges.

26. The cover according toclaim 25 wherein a wall portion extends upward from the covering surface proximal the front opening edge and both side opening edges.

27. The cover according toclaim 26 wherein a lid portion is hingedly connected to the body portion proximate the rear opening edge and wherein the wall portion and the lid portion define a funnel toward the access opening when the lid portion is in an operable position.

28. The cover according toclaim 26 wherein the covering surface has an outer perimeter and at least a portion of the covering surface is downwardly sloped from the wall portion to the outer perimeter.

29. A method of forming a lid assembly for a medical waste disposal receptacle having an open end, said method comprising the steps of:

disposing of moldable material within a linearly separable mold assembly having a first cavity portion configured to form a covering surface configured to substantially close said receptacle open end, a second cavity portion in fluid communication with the first cavity portion and configured to form a first sloped slide surface extending from the covering surface, and a third cavity portion in fluid communication with the first cavity portion and configured to form a second sloped slide surface extending from the covering surface, the second and third cavity portions configured such that the first and second slide surfaces are axially spaced in non-overlapping relation to one another;

separating the mold assembly in a linear direction; and

removing from the mold assembly a formed cover with the first and second slide surfaces defining a tortuous path access opening.

30. The method ofclaim 29 wherein the step of disposing of moldable material includes injecting a moldable material into the cavity portions.

31. The method ofclaim 30 wherein the moldable material is a plastic.

32. A cover for a medical waste disposal receptacle, said receptacle defining a receptacle open end, said cover comprising:

a body portion including a covering surface configured to substantially close said receptacle open end, said body portion having a given perimeter and having an access opening through the covering surface, the body portion further including at least a first fixed sloped surface integrally depending from the covering surface adjacent the access opening;

a lid portion configured to selectively close said access opening; and

an integrally formed hinge extending along a portion of said given perimeter and hingedly interconnecting said lid portion to said body portion.

33. The cover according toclaim 32 wherein a flange depends from at least a portion of the cover surface.

34. The cover according toclaim 33 wherein the flange is configured to engage the receptacle and thereby secure the cover to the receptacle.

35. The cover according toclaim 34 wherein the flange includes at least two inwardly extending tabs configured to engage the receptacle.

36. The cover according toclaim 33 wherein the perimeter is defined by an outer extent of the covering surface, by a portion of the flange or by a combination of the outer extent of the covering surface and a portion of the flange.

37. The cover according toclaim 32 wherein the lid portion includes a lid surface having a lateral edge having a given length and the hinge extends along substantially the length of the lid surface lateral edge.

38. The cover according toclaim 32 wherein at least one strap extends between the lid portion and the hinge.

39. The cover according toclaim 38 wherein the first fixed sloped surface depends from the covering surface a distance Y and the first body portion has a depth D wherein the depth D is greater than the distance Y.

40. The cover according toclaim 39 wherein the lid portion includes a lid surface and a second hinge extends between the strap and the lid surface and wherein the second hinge is spaced from the first hinge by a distance approximately equal to the depth D.

41. The cover according toclaim 40 wherein the strap includes a locking tab positioned between the first and second hinges and the locking tab is configured to lock with respect to the body portion to maintain the lid surface in an operable position.

42. The cover according toclaim 32 wherein the lid portion includes at least one locking tab configured to engage the body portion and lock the lid portion relative to the body portion when the lid portion is positioned to close the access opening.

43. The cover according toclaim 32 wherein the covering surface has a front edge and a rear edge.

44. The cover according toclaim 43 wherein the rear edge has a substantially planar configuration.

45. The cover according toclaim 43 wherein the front edge has a chevron shape.

46. The cover according toclaim 43 wherein the access opening is positioned closer to the rear edge than to the front edge.

47. A method of forming a cover for a medical waste disposal receptacle having an open end, said method comprising the steps of:

disposing of moldable material within a linearly separable mold assembly having a first cavity portion configured to form a body portion having a covering surface configured to substantially close the receptacle open end except for an access opening therethrough, a second cavity portion in fluid communication with the first cavity portion adjacent the access opening and configured to form a sloped slide surface, a third cavity portion configured to form a lid portion of the cover, and a fourth cavity portion extending between and in fluid communication with the first and third cavity portions and configured to form a hinge; and

removing a formed cover from the mold assembly with the lid portion integrally hinged to the body portion and a fixed sloped slide surface depending from the covering surface.

48. The method according toclaim 47 wherein the first cavity portion is further configured to form a flange depending from a portion of the covering surface and wherein at least a portion of the flange is angled inward toward the access opening and away from the hinge.

49. The method according toclaim 47 wherein the fourth cavity portion is further configured to define a strap extending between the hinge and the lid portion.

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