CONTAINER
The present invention relates to containers and particularly, although not exclusively, relates to containers assembled from a folded sheet of thin material, for example, cardboard, laminate or the like, and may be used for packaging or storing products, such as biological and/or chemical waste.
Research carried out in biological and chemical research laboratories results in the production of large amounts of waste. This waste includes a wide variety of disposable materials used to carry out the research, for example, pipette tips, Eppendorf tubes, PCR tubes, culture vessels, plates, and also liquids used for the research, such as restriction endonucleases, loading dyes, and cultures of micro-organisms such as bacteria and yeast. All of this waste requires safe and efficient disposal prior to removal from the laboratory.
Currently available containers used for storing and transporting biological and chemical waste, include plastic or metal boxes and bottles. However, problems associated with such containers include the fact that, because they are made of plastic or metal, they tend to be expensive and also difficult to dispose of themselves irrespective of the type of waste they contain. In addition, current containers manufactured out of tough materials have rigid sides, which are designed to prevent waste from escaping once it has been placed therein. However, the rigidity of the container means that may not be conveniently stackable either before or after use. Hence, when empty, and the container is transported to the
laboratory, it actually contains a large amount of air. This wasted space dramatically increases the cost of transporting a large number of containers to laboratories.
Another problem associated with currently available containers is that they have a tendency to leak due to being poorly sealed following use in the laboratory. Leakage of biological and chemical waste from the container has significant health and safety issues.
Waste which also contains "sharps", for example, needles and blades, is particularly difficult to dispose of in a safe and efficient manner. Containers which are used to dispose of plastic parts, for example pipettes, are generally not suitable to also contain sharps. This is because there is a tendency for the sharps to pierce the container walls . This can cause the biological and chemical waste to leak from the container. Further, there is a risk that a person handling the container may be scratched or cut.
Known containers for sharps are generally made from tough plastic. However, sharps, in particular needles, may still puncture the walls of the plastic containers. Also, there is a tendency for these containers to be rigid and therefore, they are not conveniently stackable either before or after use. This makes the containers difficult to transport in a cost-effective manner.
It is an aim of embodiments of the present invention to address the above problems and to provide a container which is easy to assemble from a small number of parts,
which is simple to use, which has improved sealing characteristics and which is easily transported.
It is a further object of the present invention to provide an improved container for handling sharps waste.
According to a first aspect of the present invention there is provided a container comprising a base, a plurality of side walls each having an upper wall attached thereto, and sealing means attached to a first peripheral margin of a first upper wall, which sealing means is adapted to be folded over a second peripheral margin of a second upper wall, thereby sealing the second peripheral margin substantially between the sealing means and the first peripheral margin.
Preferably, the sealing means sealingly engages with the second peripheral margin of the second upper wall. Preferably, the sealing means and preferably, the first peripheral margin form an outside of the seal, preferably sandwiching the second peripheral margin substantially therebetween. Preferably, a top of the container is substantially flat when the sealing means sealingly engages with the second peripheral margin of the second upper wall. Advantageously, the upper walls do not buckle when the seal is made which reduces the risk of leakage from the container.
Preferably, the container has at least three side walls and, in a preferred embodiment, the container comprises at least four side walls, although more side walls may be envisaged. Preferably, an upper wall is attached to each side wall of the container. Preferably, the container has
first and second pairs of mutually opposing side walls, and first and second pairs of mutually opposing upper walls .
Suitably, the sealing means is adapted to sealingly engage with at least two, preferably, at least three, more preferably, at least four, even more preferably, at least five, and most preferably, at least six, peripheral margins of the container.
Preferably, the sealing means is adapted to sealingly engage with at least one peripheral margin to which the sealing means is not attached. The peripheral margin with which the sealing means engages may be on an upper wall adjacent the peripheral margin to which the sealing means is attached. Preferably, the sealing means is adapted to sealingly engage with a peripheral margin on either side, and more preferably, both margins, of the peripheral margin to which the sealing means is attached.
Preferably, the sealing means is adapted to sealingly engage with a peripheral margin, which is mutually opposite to the peripheral margin to which the sealing means is attached. Preferably, the sealing means is adapted to sealingly engage with the peripheral margin to which the sealing means itself is attached. Preferably, the sealing means is adapted to sealingly engage with any combination or all of the peripheral margins on the container.
Advantageously, the container has improved sealing characteristics over current containers due to the sealing
engagement of the sealing means with the at least one peripheral edge.
Preferably, each side wall is attached to the base adjacent a fold line, which is preferably, substantially horizontal. Preferably, each side wall is adapted to fold along the fold line. Preferably, each upper wall is attached to its respective side wall adjacent a fold line, which is preferably, substantially horizontal. Preferably, each upper wall is adapted to fold along its respective fold line.
Preferably, each peripheral margin is attached to its respective upper wall adjacent a fold line, which is preferably, substantially horizontal. Preferably, each extended peripheral margin is adapted to fold along its respective fold line. Preferably, each peripheral margin extends along a side of the upper wall, which is opposite to its respective fold line. Preferably, each peripheral margin is an extension of the upper wall on an opposite side of the fold line. The peripheral margin may include a peripheral band, which extends along a plane of the upper wall, or a section thereof.
Preferably, each side wall is attached to a neighbouring side wall adjacent a fold line, which is preferably, substantially vertical. Preferably, the side wall is adapted to fold along its respective fold line.
Preferably, the side walls of the container diverge as they extend away from the base. Preferably, the angle formed by a side wall and the base is approximately between 90.1°-130°, more preferably between 90.5°-105°,
and even more preferably, between 91.0°-100°. Most preferably, the angle formed between the side wall and base is between approximately 92°-95°.
Preferably, the area of the base of the container is less than the area of the opposite end of the container. Advantageously, and preferably, the container is adapted to be stacked in a nested configuration with a first container fitting substantially inside a second container. Preferably, the base of a first container may fit inside an opening of a second container. This greatly improves the transportation of many containers when they are empty, for example, from a supplier to a laboratory.
Preferably, at least one upper wall is adapted to incline towards a centre region or centre line of the container. Preferably, the at least one upper wall is adapted to incline towards a mutually opposing upper wall. Preferably, a pair of upper walls, which preferably oppose each other, are adapted to converge together, preferably such that their respective peripheral margins converge together. Preferably, the peripheral margins are adapted to converge such that they abut each other.
Preferably, the peripheral margin of an upper wall is adapted to be sealed between the sealing means and the peripheral margin to which the sealing means is attached. Preferably, the peripheral margin is sandwiched in between the sealing means and its respective peripheral margin. Preferably, the peripheral margin of an upper wall is adapted to be folded inwardly between the sealing means and the peripheral margin to which the sealing means is attached. Preferably, the peripheral margin of the upper
wall comprises a fold line, which may extend substantially transverse to a longitudinal axis of the margin. Preferably, the fold line is approximately midway along the said peripheral margin. Preferably, the peripheral margin is adapted to fold inwardly along the said fold line .
Preferably, the peripheral margins of a pair of upper walls are adapted to be folded inwardly between the sealing means and the peripheral margin to which the sealing means is attached. Preferably, the pair of upper walls mutually oppose each other. Preferably, the upper walls are adjacent the peripheral margin to which the sealing means is attached.
Preferably, the sealing means is flexibly attached to its respective peripheral margin, more preferably, adjacent a fold line, which is preferably, substantially horizontal. Preferably, the sealing means is adapted to fold along its respective fold line. Preferably, the sealing means is adapted to fold in either direction about the said fold line adjacent its respective peripheral margin. Advantageously, this allows the container to be folded back on itself when being sealed.
Preferably, the sealing means comprises a foldable flap which, preferably extends substantially along the length of the peripheral margin. Preferably, at least one end of the sealing means is adapted to be folded about a fold line, which fold line, preferably extends transverse to the fold line between the sealing means and its respective peripheral margin. Preferably, the at least one end of the sealing means is adapted to sealingly engage with an upper
wall of the container. Preferably, both ends of the sealing means may be folded to engage and seal with an upper wall. Preferably, the length of the sealing means is greater than the length or width of the container such that each end of the sealing means may be foldable thereover .
Preferably, the sealing means comprises sticking means adapted to stick the sealing means to a surface, for example, a peripheral margin and/or an upper wall of the container. Preferably, the sticking means comprises a compressible material. Advantageously, the compressibility of the sticking means allows it to achieve an improved contact with the surface it engages, including the peripheral margins. Preferably, the sticking means comprises compressible sticky tape. Preferably, the sticking means comprises double-sided foam tape. Preferably, the sticking means comprises adhesive. Preferably, the sealing means comprises removable cover means on the sticking means. Advantageously, the cover means prevents unwanted sticking of the sticking means to a surface. Advantageously, and preferably, the cover means may be removed, for example, by peeling off to thereby expose the sticking means prior to sealing the container.
Preferably, the container is of the gable top type. The container may be used to contain biological and/or laboratory and/or medical waste material.
According to a second aspect of the present invention, there is provided a method of containing an article, the method comprising inserting an article in the container defined in the first aspect.
According to a third aspect of the present invention, there is provided a method of containing an article, the method comprising the steps of:- (i) inserting an article in a container, which container comprises a base, a plurality of side walls each having an upper wall attached thereto, and sealing means attached to a first peripheral margin of a first upper wall; and (ii) folding the sealing means over a second peripheral margin of a second upper wall, thereby sealing the second peripheral margin substantially between the sealing means and the first peripheral margin.
Preferably, the sealing means is folded in a first direction. Preferably, the method comprises the step of folding the sealing means and the peripheral margin to which it is attached in a second direction, wherein the sealing means and its respective peripheral margin lie substantially flat against a side of the container, preferably a top of the container. Preferably, the method comprises the step of folding at least one end of the sealing means in a third direction wherein it sealingly engages with an upper wall of the container. Preferably, the method comprises folding both ends of the sealing means in the third direction such that each end sealingly engages with an upper wall of the container. Preferably, the two upper walls oppose each other.
According to a fourth aspect of the invention, there is provided a blank used for the manufacture of the container defined in the first aspect.
Preferably, the blank comprises paper, cardboard, laminate or the like which is, preferably, adapted to be folded.
According to a fifth aspect of the invention there is provided a laminate material comprising at least one layer of steel and at least one layer of fibre based material for use in manufacturing the container as defined in any one of the previous aspects of the invention. The laminate material preferably has a unique resistance to puncture by sharp waste, particularly needles.
Preferably, the laminate material comprises multiple layers. More preferably, the laminate material comprises 12 layers, preferably comprising at least one steel layer and at least one fibre based material layer together with a number of polymer and/or adhesive layers.
In a preferred embodiment, the steel is configured as the layer in primary contact with the sharps. In this arrangement, the laminate material is particularly resistant to puncturing by, for example, a needle.
Preferably, the fibre based material comprises paper or a cellulose acetate material. A preferred arrangement incorporates Clarifoil™ which is derived from wood pulp or cotton. Any suitable wood fibre material may be used, for example, that known generally as 'liquid packaging board' . Advantageously, liquid packaging board maintains a rigid structure. Preferably, bleached sulphate pulp is used .
Preferably, the fibre based material is between 150 to 600 grams per square meter in weight. More preferably, the fibre based material is 150 to 600 grams and is preferably coated with a thin layer of polymer, preferably polyethylene or polypropylene film. The coating may be on one or more sides of the fibre based material and, preferably on two sides of the fibre based material.
Preferably, the steel layer is between 20 microns to 240 microns in thickness. More preferably, the steel layer is between 80 microns to 120 microns. Preferably, the steel layer is coated on at least one side with a polymer. Suitable polymers include polyethylene, polypropylene or polyethylene terephthalate . Most preferably, the steel layer is film coated on both sides with any one of the aforesaid polymers.
The laminate material may alternatively comprise a metal as a substitute for the fibre based material. Alternatively, the laminate material may further comprise a glass or preferably, a ceramic material as a substitute for the fibre based material.
Preferably, the steel is electrolytic chromium. This is otherwise known as chromium oxide coated steel which is a low carbon steel coated equally on both sides with a complex layer of chromium and hydrated chromium oxide applied by electro deposition.
Alternatively, electrolytic tinplate (ET) , which is a low carbon steel coated with tin by electro deposition, may be used.
The invention extends to a container made from the laminate material described in the fifth aspect.
All of the features described herein may be combined with any of the above aspects, in any combination.
For a better understanding of the invention, and to show how embodiments of the same may be carried into effect, reference will now be made, by way of example, to the accompanying diagrammatic drawings, in which:-
Figure 1 is a perspective view of a container in a partially closed configuration;
Figure 2 is a schematic side view of the container in an open configuration;
Figures 3 to 6 are perspective views of the container shown during different stages of being sealed; and
Figure 7 is a plan view of a blank of the container.
Figure 8a is a partial cross sectional view of the container of Figure 1.
Figure 8b is an exploded view of a part of the container of Figure 1.
Referring to Figure 1, there is shown a sealable container 2 in which biological and/or laboratory and/or medical waste (not shown) may be stored. The container 2 can be used in a laboratory in which biological, medical or chemical research is carried out. The sealable container 2
has two mutually opposing rectangular vertical side walls 4 which extend upwardly away from a base 5, and two mutually opposing, but shorter, vertical end walls 6 which extend upwardly away from the base 5. Because Figure 1 is a perspective view, only the forward facing side wall 4 and the forward facing end wall 6 can be seen, but it will appreciated that the rear facing side wall 4 and rear facing end wall 6 are on the other side.
Referring to Figures 1 and 2, a sloping side wall upper portion 8 extends from an upper edge of each side wall 4, and a sloping end wall upper portion 10 extends from an upper edge of each end wall 6. Along the upper free margin of each side wall upper portion 8, there is provided a marginal portion 16,17. The marginal portions 16,17 are divided from their respective side wall upper portion 8 by a fold line 36, the side wall upper portions 8 and respective side wall 4 are divided by a fold line 32, and the end wall upper portions 10 and respective end wall are divided by a fold line 34.
The two side walls upper potions 8 and hence, marginal portion 16,17 extend inwardly towards a centre line over the opening of the container 2 which extends along a longitudinal axis thereof where they converge and are attached together forming a marginal portion sealing strip 12. Ends 14 of the marginal sealing strip 12 are foldable and secured in place against the end walls 6 by adhesive as will be described hereinafter. The two end wall upper portions 10 extend inwardly towards the centre line of the container 2 but do not converge and are not secured to each other.
Referring to Figure 2, there is shown a side view of the container 2, which illustrates that the end walls 6 are not squarely attached to the base 5. Instead, the end walls 6 diverge by approximately 3° as they extend upwardly away from the base 5. Similarly, the side walls 4 also diverge by approximately 3° outwardly as they extend upwardly away the base 5. The purpose of the container having diverging side walls 4 and end walls 6 is so that, during transportation, one empty container 2 may be placed inside another empty container 2. Hence, a number of empty containers 2 may be nested together, one inside another, to thereby improve the transportation thereof.
Referring to Figure 2, there is shown further detail of the sealing area of the container 2. At the upper free margin, connected along fold line 38, the marginal portion
17 is connected to the marginal sealing strip 12. The inner surface of the sealing strip 12 is covered with adhesive 19 along the length thereof, which adhesive 19 is covered with a removable cover 18, to prevent the adhesive from sticking to unwanted surfaces prior to sealing the container 2. The removable cover 18 may be peeled away from the adhesive 19 when sealing the container 2. Along the upper free margin of each end wall upper portion 10, there is provided marginal portions 20,22. The marginal portions 20,22 are divided from their respective end wall upper portion 10 by the fold line 36.
The marginal portion 16 is on the outer surface of one side of the container 2, and presents one of several surfaces on to which the inner surface of the sealing strip 12 may be secured thereby forming a seal. As can be seen in Figure 2, the design of the container 2 is such
that when sealing the container 2, the end wall marginal portions 20,22 are presented to which the adhesive layer 19 on the sealing strip 12 may adhere in addition to the elongate marginal portion 16.
Referring to Figures 3 to 6, there are shown views of the container 2 at different stages of being sealed, with the λa' view being an enlarged view of the λb' view in the box of each figure.
Referring to Figure 3, there is shown the container 2 in an open, unsealed configuration. In order to seal the container 2, the two end wall upper portions 10 are gently pushed at pressure points 42 shown in Figure 3b, so that they collapse inwardly towards each other. In doing so, the marginal portions 16,17 of the two side wall upper portions 8 are urged together such that they abut each other thereby trapping the marginal portions 20,22 of the end wall upper sections 10, in a gap formed therebetween. As can be seen in Figure 3a, the cover 18 is then peeled away to reveal the adhesive 19 on the inside of the sealing strip 12.
Once the adhesive 19 on the sealing strip 12 has been fully exposed, the sealing strip 12 is then pushed in a direction as illustrated by arrow λA' in Figure 3b towards the marginal portion 16, so that is adopts the position as shown in Figure 4. As shown in Figure 4, the top of the container 2 formed by the two side wall upper portions 8 is substantially flat extending in a plane which is parallel with the base 5.
The sealing strip 12 is then folded over about fold line 38 as illustrated by arrow λB' shown in Figure 4b, such that the adhesive layer 19 comes in to contact with all of the marginal portions 16,17,20,22, of the container 2 as shown in Figure 2. Hence, it will be appreciated that the design of the container 2 allows the adhesive layer 19 on the sealing strip 12 to form a bonding seal with all marginal portions 16, 20 (x2) , 22 (x2) , 17.
The completed sealing strip 12 is then folded back over fold line 36 as illustrated by arrow ΛC in Figure 5b, so that it adopts the position shown in Figure 6. The sealing strip 12 is flat on the top of the container 2. Finally, while maintaining pressure along the length of the sealing strip 12 so that the top of the container 2 maintains the flat top, both ends 14 of the sealing strip 12 are then folded over along fold lines 40 in the direction as illustrated by arrows ΛD' and λE' in Figure 6b, so that they can be stuck against the top of each end wall 6. The container 2 is then fully sealed and can be transported away from the laboratory and be suitably disposed of, for example, by incineration. When a number of containers 2 are being used in the laboratory, and all of these containers 2 require transportation away from the laboratory, the flat top of each container 2 allows them to be conveniently stored on top of each other.
Referring to Figure 7, there is shown a blank sheet 44, which is folded and stuck together to form the container 2. The blank sheet 44 consists of the two side wall panels 4, two end wall panels 6, and four panels 24,26 which go together to form the base 5. The blank sheet 44 also consists of side wall upper portion panels 8 and end wall
upper portion panels 10, the latter of which have pressure points 42 marked thereon to assist in sealing the container 2. As shown in Figure 7, the blank sheet 44 has panels for the marginal portions 20,22 on each end wall upper portion 10, and the marginal portions 16,17 on each side wall upper portion 8. Attached to the panel forming the marginal portion 17, there is provided a panel which forms the sealing strip 12.
The blank sheet 44 has a side flap 28 which is used to maintain the container 2 in shape once it has been folded together by adhesive. The side walls 4 and end walls 6 are formed into a box shape with the base 5 underneath, and adhesive is added to the side flap 28 which is tucked inside the join to keep the 3D shape of the container 2.
Advantages of the container 2 are manifold. Firstly, the arrangement of marginal portions 20,22,16,17 on to which the sealing strip 12 can adhere provides a far better seal than if, for example, the strip 12 could only adhere to marginal portion 16. The design of the blank sheet 44 illustrates the angle of cut of the marginal portions 20,22 on each end 10 of the container 2. Further, when the two marginal portions 16,17 are pushed together when sealing the container 2, they do not align precisely together to cover each other. Instead, the marginal portion 16 aligns with the portion 17 slightly lower and off-set such that the portions 20 (x2) , 22 (x2) , 17 are presented to the sealing strip 12.
Secondly, the diverging side and end walls 4,6 enable a plurality of containers 2 to be stacked together in a nested formation thereby improving transportation thereof
when empty. This is a great improvement over current containers for biological waste which are rigid and result in empty space being transported inside the container.
Figure 8a shows a partial cross sectional view of the container 2. The container 2 is manufactured from a laminate material 60. The material 60 comprises a number of adjacent layers. Figure 8b is an exploded view of a preferred arrangement of the layered configuration viewed from the inside of the container 2 towards the outside of the container, the layers are arranged as polymer 62, steel 64, polymer 66 and fibre based material 68.
The polymer 62 acts as a protective coating for the steel to prevent surface corrosion of the steel through contamination by the waste material inside of the container 2. The polymer 66 also acts as an adhesive to adhere the steel 64 to the fibre based material 68.
The laminate material is produced by heating the steel polymer 62,66 coating to temperatures sufficient to partially melt the polymer 62,66. In this way, the polymer 62,66 acts as an adhesive. When polyethylene is used, the temperature is in the region of 60°C. For polypropylethene or polyethylene terephthalate, the temperature is in the region of 120°C. When the polymer is sufficiently melted, the layers of steel 64 and fibre based material 68 are brought together under pressure so that they are firmly sealed together. Alternatively, if the steel 64 is not provided with a polymer 62.66 coating, an adhesive is used to bond the steel 64 and fibre based material 68 together. Alternatively, a polymer adhesive may be sprayed onto the steel 64.
In this arrangement, the laminate material has a unique resistance to punctures, unlike steel alone which will become dented by 'sharps' . We understand this to be because for an object, no matter how fine, to completely penetrate the steel layer, must displace whatever material is already there. A thin layer of steel offers least resistance in the direction of travel of the object ie the object will push material in front of it forming a dent. The material is not forced to the side (ie in a direction perpendicular to the direction of travel of the object) as the mass of material lies in this direction. A thin film of steel offers substantial resistance. The dent that is formed creates a weak-point as the steel is now free to deform in a direction perpendicular to the direction of travel of the object. As the object continues to force material in front of it, and to the side, it forms a hole.
If the steel is laminated or coated with a material, particularly fibre based material, that prevents the early formation of a dent, there is no opportunity for steel to force material in front of it. The thin layer of steel is thus able to withstand penetration.
In order for the material to be sharps resistant from both sides, an inner fibre based material with further steel layers is provided. The layers are brought together using adhesive means described above.
It will be understood by the reader that a number of alternative configurations of steel to fibre based material are possible.
The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.
All of the features disclosed in this specification (including any accompanying claims, abstract and drawings) , and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.
Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) , may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.
The invention is not restricted to the details of the foregoing embodiment (s) . The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.