Container for Biologically Contaminated Items

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority from United Kingdom Patent Application No. 06 24 809.0, filed 13 December 2006, United Kingdom Patent Application No 06 25 006.2, filed 15 December 2006, United Kingdom Patent

Application No 07 05 898.5 filed 28 March 2007 and United Kingdom Patent Application No 07 17 752.0 filed 12 September 2007 the entire disclosures of which are incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

[0002] The present invention, relates to containers for containing biologically contaminated items, with specific embodiments being directed towards relatively small containers, tall containers, large transportable containers and foldable containers.

2. Description of the Related Art

[0003] A receptacle for storing biologically contaminated items is disclosed in United Kingdom patent No 2421495 B. This container is constructed substantially from card and has a base portion with four side portions extending therefrom, along with first, third, second and fourth foldable top portions extending from the side portions. The known container may be arranged in a first configuration in which it is open thereby allowing material to be inserted therein. In addition, it is possible for the container to be placed in a second configuration in which the top of the container is fastened. This fastening may take place temporarily, such that the container may be re-

opened and additional items added. However, eventually, a permanent fastening is applied to facilitate transportation and disposal.

[0004] A first problem exists with known containers in that known temporary seals become worn and unreliable. A further problem exists in that known containers do not present an appropriate shape for long contaminated items. Additionally, the size of containers may be limited due to problems associated with transportation; known containers requiring additional carrying devices in order to facilitate transportation. Furthermore, a problem also exists in that known containers are relatively bulky making transportation relatively cumbersome.

BRIEF SUMMARY OF THE INVENTION

[0005] A first aspect of the present invention provides a container constructed substantially from card or card-like material for storing biologically contaminated items. The card defines an opening for allowing contaminated items to be placed into the container. The opening includes foldable edges for closing the opening when the edges are placed in a folded condition. The container also includes a temporary seal that may be reopened to allow additional items to be placed therein. The container includes a permanent seal for sealing the container prior to decontamination. The temporary seal is a metal plate located over one of the foldable edges such that the plate is folded with the foldable edge to thereby retain the foldable edge in its folded configuration.

[0006] In a preferred embodiment, the container has a substantially square base and the side walls of the container taper outwards such that the opening is wider than the base to facilitate the storage and transportation of containers prior to use.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0007] Figure 1 shows a fully constructed container receiving a contaminated item;

[0008] Figure 2 shows a folding operation to effect closure of the container;

[0009] Figure 3 shows closure flaps being pressed together;

[0010] Figure 4 shows temporary sealing;

[0011] Figure 5 shows a temporarily sealed container;

[0012] Figure 6 shows how the container is permanently sealed; [0013] Figure 7 shows an unfolded carton blank;

[0014] Figure 8 shows a folded container derived from the blank of Figure

7;

[0015] Figure 9 shows the container of Figure 8 being unfolded;

[0016] Figure 10 shows the container of Figure 9 being fully unfolded into its open configuration;

[0017] Figure 11 shows the stacking of open containers;

[0018] Figure 12 shows the container of Figure 10 in a permanently sealed configuration;

[0019] Figure 13 shows a container substantially similar to the container of Figure 1 ;

[0020] Figure 14 shows the container of Figure 13 positioned in a stand;

[0021] Figure 15 shows a fabrication stage of the stand identified in

Figure 14;

[0022] Figure 16 shows the stand of Figure 15 after fabrication; [0023] Figure 17 shows a container of the type shown in Figure 13 being applied into a stand of the type shown in Figure 16;

[0024] Figure 18 shows an example of a reinforcement member;

[0025] Figure 19 shows a partially assembled container derived from the blank shown in Figure 7;

[0026] Figure 20 shows additional reinforcement;

[0027] Figure 21 shows an assembled container;

[0028] Figure 22 shows the container of Figure 21 with temporary seals;

[0029] Figure 23 shows the container of Figure 21 permanently sealed; [0030] Figure 24 shows sealed container being carried.

DESCRIPTION OF THE BEST MODES FOR CARRYING OUT THE

INVENTION Figure 1

[0031] A first embodiment is shown in Figure 1 in which a container has been fully constructed. In this embodiment, the container rests substantially upon its corners so as to enhance stability and stability is further enhanced by providing a substantially square cross-section.

[0032] Side walls 101 and 102 present a substantially tapered profile such that it is relatively easy to store one container within another, so that many containers of this type may be stored together in a relatively small space.

[0033] In the embodiment of Figure 1 , the container is arranged to store biologically contaminated items, such as contaminated laboratory implements including plastic loops and similar non-sharp items which although not presenting a mechanical hazard, could present a significant biological threat.

[0034] The container of the embodiment presents a storage portion, shown generally at 103 and a closure portion shown generally at 104, each fabricated from plastic coated card or similar material. The closure portion 104 may be placed in an open condition, as shown in Figure 1 , for receiving contaminated items. Furthermore the closure portion 104 may be placed in a closed configuration in which the container becomes liquid-tight so as to ensure that any biologically contaminated liquid contained therein cannot

escape during transportation.

[0035] A first sealing device is provided by acrylic foam double-sided tape

105 which allows the closure portion to be sealed permanently so as to facilitate transportation. However, having inserted contaminated items within the container, an operator may wish to leave the container for a short period of time and then reuse the container upon their return. To facilitate this mode of operation, the container is provided with a secondary temporary sealing device taking the form of a metal plate located over one of the foldable edges such that the plate is folded with the foldable edge to thereby retain the foldable edge in its folded configuration.

Figure 2

[0036] Temporary folding is illustrated in Figure 2, in which outer edges 201 and 202 are brought together such that a closure flap 203 is brought into contact with a co-operating flap 204.

Figure 3

[0037] As illustrated in Figure 3, closure flap 203 has been brought into contact with the co-operating flap 204. The closure flap 203 includes adhesive strip 301 and securing tabs 203. These provide the permanent means for securing the apparatus but do not assist with the temporary closure of the apparatus. The adhesive strips are protected by a tape and this tape is removed when the adhesive strip is to be used to provide a permanent sealing mechanism.

Figure 4

[0038] As shown in Figure 4, temporary sealing is achieved by the presence of a metal plate 4501 located over folding edge 402 of the closure flap 203. In a preferred embodiment, the plate is stuck to the container by strong glue or thin double-sided adhesive tape. In a preferred embodiment, the

metal plate 401 is constructed from a soft aluminium alloy. Typically, the alloy plate may have a thickness of between 0.3mm and 0.7mm. The hardness of the plate in combination with its thickness are selected such that it is possible for a plastic hinge to be created as the closure flap 203 is folded by the application of finger pressure. However, a material is selected such that having been folded in the manner shown in Figure 4, the metal plate 401 retains this folded shape until manual pressure is applied to release the temporary seal. It may be possible for the metal plate 401 to be pre-folded at the position of the fold present on the closure flap 204 so as to facilitate the folding and the temporary closure of the apparatus.

Figure 5

[0039] As shown in Figure 5, when manual pressure is removed from the plate 401, the plate retains its folded configuration thereby ensuring that the closure flap 203 remains in contact with the co-operating flap 204. The metal plate 401 will undergo metal fatigue and failure if used too many times.

However for its intended application, it is likely that the metal plate would not be used too many times before the container becomes full and thereby requires the permanent seal to be applied.

Figure 6 [0040] As shown in Figure 6, the permanent seal is applied by the removal of a protective strip from adhesive tape 301. Thereafter the closure flap 203 is folded downwards and the securing flaps 302 are secures to the sides of the container.

Figure 7 [0041] In a preferred embodiment, the container is fabricated from a blank that is substantially similar to the blank described in British patent No 2 421 495, the full contents of which are incorporated herein by reference. In addition, GB 2 421 495 also describes procedures for folding the blank and

sealing the blank so as to define a container in an open configuration.

[0042] In a preferred embodiment, the blank has been modified such that selected portions are provided with additional folds to provide a substantially folded configuration prior to the container being placed in its open configuration. Thus, the container in this preferred embodiment may be considered has having a total of four configurations, namely: a folded configuration for transportation; an open configuration to facilitate the reception of contaminated articles; a temporarily sealed configuration and a permanently sealed configuration.

[0043] In the example of Figure 7, internal lines shown within the blank represent score lines or folds, most of which are present in the known blank. The additional folds shown as bold lines represent modifications introduced to the preferred embodiment such that selected side portions are provided with additional folds to provide the substantially folded configuration prior to the container being placed in its open configuration. The folded configuration primarily facilitates the bulk transportation of new containers.

[0044] In this embodiment, four side portions are identified as 701 , 702, 703 and 704 that when folded extend from a base. The base itself is defined by portions 705, 706, 707 and 708. A first foldable top portion 711 and a third foldable top portion 712 fold over to define a top. A second foldable top portion and a fourth foldable top portion fold inwards under the first and third top portions. Closure portions 715 extend from the foldable top portions 711 to 714. In its open configuration, the foldable top portions are maintained in their unfolded state and thereby essentially extend from the side portions.

[0045] Side portion 701 is provided with an additional longitudinal fold

721 that also extends to foldable top portion 113. A similar longitudinal fold

722 is provided in side portion 703 with its associated top portion 714. Side

portion 701 also includes a first diagonal fold 723, a second diagonal fold 724 and a transverse fold 725. Similarly, a first diagonal fold 726 is provided in side portion 703 along with a second diagonal fold 727. A horizontal fold 729 is provided in side portion 702.

[0046] The preferred embodiment is assembled substantially as described in GB 2421495. In addition, by applying pressure in order to effect folding along the score lines, it is possible to transform the container from its open configuration into a folded configuration ready for transportation.

[0047] In a preferred embodiment, during the formation of the blank, an additional circular portion 730 is defined which is subsequently used to define a handle to assist in the transportation of a sealed container.

Figure 8

[0048] The blank of Figure 7 is shown in Figure 8 having been assembled into its open configuration and then folded into its folded configuration. Thus, in this folded configuration it is possible to include substantially more containers within a transportable unit and as such transportation costs may be substantially reduced. Thus, the flat-packed folded configuration of Figure 8 represents an example of how a container would look when initially removed from a transportation unit.

Figure 9

[0049] Having removed a container from a transportation unit, manual pressure is applied as shown in Figure 9, so as to unfold the additional folds and thereby return the container to its open configuration.

Figure 10 [0050] Having partially eased the container from its folded configuration, as illustrated in Figure 9, further pressure is applied and a hand may be

inserted within the container so as to expand the container into its full open configuration as illustrated in Figure 10.

Figure 11

[0051] The preferred embodiment of Figure 1 presents a trapezoidal design when in its open configuration. Thus it is possible to effect stacking of the containers as illustrated in Figure 11. Thus it is envisaged that a substantially large quantity of containers would be transported in a transportation unit in the folded configuration and at after an opening exercise, it is likely that a plurality of containers would be unfolded so as to present them in their open configuration whereafter, temporarily, the containers would be stacked one within another as illustrated in Figure 11.

Figure 12

[0052] The closing of the container after contaminated items have been introduced therein is performed in a fashion substantially as that described with reference to Figures 2 to 6. However, in addition, in a preferred embodiment, transportation may be facilitated, once permanently sealed, by manual application of the extending circular portion 730.

Figure 13

[0053] A container is shown in Figure 13 substantially similar to the container shown in Figure 1. However, the container of Figure 13 is designed for storing contaminated items such as a pipette 1301 that is longer that 250mm. Like the container of Figure 1 , the container of Figure 13 is constructed substantially from card or card-like material. In addition is also provided with a stand for supporting the container. In a preferred embodiment, the container has a base with a width of between 80mm and 150mm that is substantially square in shape and from which side walls extend having a height of between 400mm and 550mm to allow the long contaminated items such as pipettes to be stored. Furthermore, the stand supports the container in an

upright configuration so as to allow long items to be stored in a substantially upright orientation so as to reduce the container footprint while maintaining stability. Thus, the container has side walls 1302 that are substantially longer than side walls 101 of the container shown in figure 1.

Figure 14

[0054] As can be seen in Figure 14, a container 1401 is provided with a relatively small substantially square shaped base 1402 and relatively high side walls 1403 which allows the long contaminated items, such as pipettes, to be stored in a substantially upright position. It is provided with a stand 1404 for supporting the container. The stand supports the container in an upright configuration which allows the long items to be stored upright thereby reducing the container footprint while maintaining stability.

Figure 15

[0055] As shown in Figure 15, the stand may be machined from a sheet of stainless steel and a blank 1501 may be cut from a sheet of stainless steel by a process of laser cutting. This allows the edges to be cut cleanly with rounded corners 1502 and without creating any burrs.

[0056] A first portion 1503 defines the base of the stand and a second portion 1504 defines an upper support member for supporting side walls of the container at a distance displaced from the base. In addition, a third central region 1505 is folded into an inclined orientation thereby defining an overall Z- shape for the stand. Consequently, the upper support portion 1504 has a substantially square shaped hole 1506 cut therein so as to support the square cross-section of the container. Inclined portion 1505 has a quadrilateral (trapezoidal) hole 1507 cut therein which is narrower at a lower end 1508 compared to being wider at an upper end 1509. In this way, hole 1507 supports the tapering side walls of the container throughout the length of its inclined portion.

Figure 16

[0057] As shown in Figure 16, the stand is bent at hinge 1601 and again at hinge 1602. The stainless steel material is sufficiently strong and thick so as to retain its shape after the plastic hinges have been created. In addition, 5 rubber or similar material feet may be secured to the base plate 1603 so as to minimise the risk of the stand slipping when in use and also to. minimise the risk of damage being inflicted upon a supporting surface.

Figure 17

[0058] As shown in Figure 17, in use, a stand 1701 is located on a flat 0 surface such as the surface of a bench. A container 1702 is removed from storage and manually lowered in the direction of arrow 1703 into the stand 1701 to provide the configuration as illustrated in Figure 2. As previously described, tapering trapezoidal hole 1507 ensures that the container 1702 is firmly supported along its side walls and is not allowed to move within the 5 confines of the stand 1701.

Figure 18

[0059] In a preferred embodiment, a reinforcement member may be attached to a foldable edge of the container blank, such that the reinforcement member is configured to facilitate manual carrying of the container and to 0 facilitate secure closing of the container. Preferably, the reinforcement member is constructed from coated card to define a handle opening and the handle opening is reinforced with board.

[0060] An example of a reinforcement member 1801 is shown in Figure 18. The reinforcement member includes an attachment section 1802 that is !5 attached to a foldable edge (shown in Figure 19). The reinforcement member also includes a handle portion 1803 that facilitates the manual carrying of the container. However, and not required for this purpose, the carrying handle 1803 is folded along fold 1804 so as to lie flat against the upper surface of the

container. In addition, the reinforcement member 1802 also facilitates the secure closing of the container by the provision of a first flap reinforcement 1805 and a second flap reinforcement 1806.

[0061] When used for securing the container, flap reinforcement 1805 is folded along fold line 1807. Similarly, flap reinforcement 1806 is folded along fold line 1808. It is therefore appreciated that stresses are applied to these folds. Similarly, when being carried, stress folding occurs along fold line 1804. However, after attachment of the reinforcement member 1801, the carrying functionality and the securing functionality are not actually related. As such, a cut 1809 exist between flap reinforcement 1807 and the carrying portion 1803, with a similar cut 1810 existing between the second flap reinforcement 1806 and the carrying portion 1803. A minimal attachment 18011 and 1812 is provided so as to provide a single unified reinforcement member which in turn facilitates assembly. However, once assembled, the carrying handle portion 1803 and the flap reinforcements 1805 and 1806 provide independent functionality.

Figure 19

[0062] A partially assembled container 1901 is shown in Figure 19, derived from a blank of the type shown in Figure 7. Reinforcement member 1801 is also shown in Figure 19. Adhesive is applied to attachment section

1802 and to flap reinforcements 1805 and 1806. The attachment section is thereafter attached to a foldable edge 1902, with flap reinforcement 1805 being secured to a foldable flap 1903 and flap reinforcement 1806 being secured to a flap 1904. In addition, the handle portion 1803 has been reinforced.

Figure 20

[0063] Reinforcement of the reinforcement member 1802 is illustrated in

Figure 4. The reinforcement member 1801 includes an attachment section

1802, a handle portion 1803 and flap reinforcements 1805, 1806. The handle portion 1803 is reinforced by a solid board 2001 typically having a thickness of 2mm. In addition, board 2001 is sandwiched by an additional coated card portion 2002.

Figure 21

[0064] An assembled container is illustrated in Figure 21 , in which the reinforced reinforcement member has been attached to the folded container. The inside of foldable edge 1902 and the inside of securing flaps 1903 and 1904 have peel off adhesive attached thereto, such that after a cover has been peeled off; these areas may be securely attached. In this way, the container provides a secure closure such that biologically contaminated liquids may be retained without leakage.

[0065] In addition to the permanent closure, temporary fastenings are also provided configured to be unfastened so as to allow the introduction of additional contaminated items prior to the permanent secure closure being applied to the container. In an alternative embodiment, temporary fastenings are provided by the provision of mushroom fasteners so as to facilitate the unfastening of the components and also to reduce the risk of biological contamination. Thus, in this way, when folded, mushroom component 2101 is secured against component 2102 and mushroom component 2103 is secured against component 2104.

Figure 22

[0066] The container of Figure 21 is shown in Figure 22 after having the temporary seals applied. In this configuration, using the temporary sealing elements 2101 to 2105 it can be seen that a top surface 2201 of the container has been restrained such that it is no longer open but at the same time it is not permanently secured. Furthermore, peel off strips have not been removed therefore the securing flaps 1903 and 1904 extend outwards and have not

been placed in a secured configuration.

Figure 23

[0067] A secured configuration for the container of Figure 21 is illustrated in Figure 23. In this configuration, the peel off strips have been removed from the foldable edge 1902 and from securing flaps 1903 and 1904. The adhesive provided on foldable edge 1902 is located in place, whereafter downward pressure is applied to upper surface 2201 so as to force said upper surface into a substantially horizontal configuration. Thereafter, with the upper surface held in this orientation by a first hand, the second hand of an operative is used to permanently secure securing flaps 1903 and 1904 onto side walls of 2301 of the container. Thus, as shown in figure 23, when in its permanently secured configuration, foldable flap 1904 is secured against side wall 2301.

Figure 24

[0068] The sealed container of Figure 23 is shown being carried in Figure 24. The foldable edge allows the handle portion 1803 to extend substantially vertically from the horizontal top surface 2201. In this way, manual carrying is easily facilitated by the provision of the handle 1803 thereby ensuring that the container may be transported in a manner such that it is held away from the nose and face of the operative. However, prior to disposal, it is possible for a plurality of boxes to be stored and where appropriate boxes may be stacked.

To facilitate the stacking of boxes, handle portion 1803 folds substantially horizontally by means of fold 1804 such that it is possible for boxes to be stacked one upon the other.