Tamper-Evident Lockable Container and Method of Assembly

Abstract

A tamper evident lockable container and method of assembly is provided, the container formed from a sheet material such as cardboard, the sheet material movable from a blank condition to an erect cond

Description

The invention to which this application relates is to a container that is lockable and, when locked, is unable to be opened without evidence of tampering, and a method of assembling the same from a sheet material. The sheet material is typically cardboard as commonly used in the online goods delivery industry. There has been a rise in the demand for home deliveries in a number of industries in recent years, typically facilitated through the internet. This online shopping involves a user placing an order for a product on a website, and the seller shipping the product to their address directly, typically via a courier or logistics service. Online retailers often advertise significantly low or even no fees for a user to receive their goods in this manner, increasing demand. Online shopping recently further saw a surge in popularity during the coronavirus pandemic, when it was less convenient to shop for goods in person. The goods to be transported are often stored in single use containers, as this protects the goods from becoming damaged during transportation and conceals the goods before it is received by the customer, reducing the likelihood of opportunistic thieves attempting to steal the goods. The containers are often single use as they are relatively simple and inexpensive to mass produce and there is no requirement for the containers to be collected from the customer following the delivery of the goods. These single use containers often include a tamper-evident sealing means, wherein the goods are located within the container which is then sealed shut. This provides the advantage that a customer receiving the goods is able to identify if the container has been unsealed, which may have compromised the contained goods. The sealing is often by a strong adhesive that quickly cures when applied between two panels of the container, such that if the container is unsealed the cured adhesive layer is unable to be used to reseal the container. Alternatively, the sealing is by a uniquely branded or distinct tape layer connecting two panels of the container that, once cut or removed, is unable to reseal the same. The aforementioned sealing means often contain products that are not biodegradable or otherwise harmful to the environment, such as microplastics or toxic chemicals in the adhesives. The large scale at which the single use containers are produced magnifies the impact of these harmful products, and as such there is a need for a single use tamper-evident container that contains no, or a reduced amount, of the said harmful products. An aim of the present invention is therefore to provide a container that is free from microplastics or would otherwise be formed by a process involving the application of adhesive. A further aim of the invention is to provide a means of forming a tamper evident container in a single manufacturing process from a sheet material, such that no further processes such as sealing or adhering are required. In a first aspect of the invention, there is provided a lockable tamper evident container formed from a sheet material, the sheet material movable from a blank condition to an erect condition to form the container comprising side walls, a base and a lid which define a cavity within the container when the lid is closed and wherein locking means are provided to lock the container in the erect condition, said locking means include a portion of the sheet material which is selectively movable to a locking position through an aperture provided in the blank and biased to retain said container in said locked position. In one embodiment the erected container includes multiple sidewalls, in one embodiment at least four sidewalls, a base, and a lid defining a cavity of the container. In one embodiment the Ed is movable with respect to a sidewall to which it is pivotably attached between an open position and a closed position. In one embodiment, when the container is unlocked, the cavity is accessible when the lid is in the open position and inaccessible when the Ed is in the closed position. In one embodiment the said locking means portion is defined within the outer edges of the blank. In another embodiment the said locking means portion depends from an edge of the blank. In one embodiment the locking means portion is folded back onto itself along a crease line. The material properties of the sheet material and / or the thickness of the same and / or the profile of the crease line such that the folded portion has a resilient bias towards unfolding. In one embodiment the folded sheet material of the locking means is arranged to be insertable through an aperture of the lid, the aperture height being approximately double the thickness of the sheet material and hence substantially the same as the thickness of the locking means portion when folded. Typically, on insertion of the folded portion through the aperture, the said resilient bias is released and the portion at least partially unfolds, such that the locking portion cannot be removed from the aperture from the exterior of the container without damaging the sheet material, and hence rendering the container tamper evident. In one embodiment the container includes a frangible portion, wherein the frangible portion is breakable to allow access to the container. Typically the frangible portion may be broken without affecting the integrity of the locking means. Preferably the frangible portion is located on the lid of the container. In one embodiment the sheet material is movable from the blank condition to the erected and locked condition without the need for a secondary process, such secondary process any of gluing, taping and / or the like. In one embodiment the sheet material blank includes prefabricated fold lines and / or breakable portions. In one embodiment the container is biodegradable and / or does not include any microplastics. In one embodiment the erected container is relatively rigid. In another aspect of the invention, there is provided a locking means for a tamper evident container formed from a sheet material, the locking means comprising at least one aperture and at least one portion provided to be folded on itself, and when folded, said portion is passed through the said aperture which has a length and a width substantially matching the said portion when in the folded condition and wherein said portion is biased to an at least partially unfolded condition to prevent the locked portion from returning through said aperture and so retain said container in said locked position. In yet another aspect of the invention there is provided a sheet material in the form of a blank to be moved to an erect position to form the locked tamper-evident container as herein described. In one embodiment the blank comprises: a base portion, a first sidewall, a second sidewall, a third sidewall, a fourth sidewall and a lid, the first sidewall including a side wall panel, first sidewall wing and second sidewall wing, the lid including a lid panel, a first lid wing and a second lid wing, each lid wing comprised of a first portion and a second portion, the base including a base panel, a first base wing and a second base wing, each wing comprised of a first portion, a second portion and a third portion, a latch panel located with the lid panel and a locking means portion located with the first sidewall panel. In one embodiment the aperture is provided in a latch panel for the reception of a locking means portion formed with the locking panel. In yet another aspect of the invention there is provided a method of forming a locked tamper evident container from a sheet material, said method comprising the steps of providing a blank to be moved to said erect position, said blank comprising a base, a number of side walls, a lid, and a locking means; forming a number of crease lines in the blank; folding the blank along the crease lines so as to form a container; wherein said locking means includes a portion, folding said portion such that the said portion has a resilient bias; and inserting the folded portion through an aperture in the blank when the blank is at least partially erected, to an extent to allow at least partial release of the said portion to allow the same to at least partially unfold to an extent sufficient to prevent the locking means portion being removed back through the aperture without tamper evident damage being caused to the sheet material. In one embodiment, the folding of the blank along the crease lines so as to form a locked tamper ^evident container including the steps of: i) folding a second side wall and a third side wall with respect to a fourth side wall, such that the second side wall and third side wall are parallel and perpendicular to the fourth side wall; ii) folding the fourth side wall with respect to a panel of the base such that the fourth side wall is perpendicular to the panel of the base, a second portion of a first wing of the base portion is located against the base panel, a second portion of a second wing of the base portion is located against the base panel, a third portion of the first wing of the base is folded against the underside of the second portion of the first wing of the base, and a third portion of the second wing of the base is folded against the underside of the second portion of the second wing of the base; iii) folding a panel of the first side wall with respect to the base panel such that the first side wall panel is perpendicular to the base panel, a first portion of the first wing of the base is folded against the underside of the third portion of the first wing of the base, and a first portion of the second wing of the base is folded against the underside of the third portion of the second wing of the base, such that the underside of a first wing of the first sidewall is located against the second side wall and the underside of a second wing of the first sidewall is located against the third sidewall; iv) folding the locking panel located with the first sidewall panel with respect to the first side wall panel such that the locking panel is perpendicular to the first side wall panel; v) folding the lid panel with respect to the fourth side wall such that the first portion of the first wing of the lid is located against the underside of the underside of the locking panel, the first portion of the second wing of the lid is located against the underside of the locking panel, the underside of the second portion of the first wing of the lid is folded against the underside of the first portion of the first wing of the lid, the underside of the second portion of the second wing of the lid is folded against the underside of the first portion of the second wing of the Ed, and the Ed panel is located against the second portion of the first wing of the Ed and the second portion of the second wing of the Ed; vi) folding the latch panel with respect to the Ed panel such that the latch panel may be received within a slot between the first sidewall panel and the locking panel; and vE) locking the locking panel to the latch panel by a locking means. In one embodiment the locking panel is locked to the latch panel by inserting a locking means of the formed with the locking panel through an aperture of the latch panel. In one embodiment the locking means comprises a portion of the sheet material folded back onto itself along a crease line, such that when the folded portion is inserted through the aperture of the Ed, the folded portion is under elastic tension such that the portion unfolds when inserted through the aperture. In an alternative embodiment, the folding of the blank along the crease lines so as to form a locked tamper-evident container including the steps of: i) folding a latch panel with respect to a panel of the base of the container, such that a slot of the latch panel is located against the panel of the base; E) folding a second side waU and a third side wall with respect to a fourth side wall, such that the second side wall and third side wall are parallel and perpendicular to the fourth side wall; Hi) folding the fourth side wall with respect to the panel of the base such that the fourth side waU is perpendicular to the panel of the base, a second portion of a first wing of the base portion is located against the base panel, a second portion of a second wing of the base portion is located against the base panel, a third portion of the first wing of the base is folded against the underside of the second portion of the first wing of the base, and a third portion of the second wing of the base is folded against the underside of the second portion of the second wing of the base; iv) folding a panel of the first side wall with respect to the base panel such that the first side wall panel is perpendicular to the base panel, a first portion of the first wing of the base is folded against the underside of the third portion of the first wing of the base, and a first portion of the second wing of the base is folded against the underside of the third portion of the second wing of the base, such that the underside of a first wing of the first sidewall is located against the second side wall and the underside of a second wing of the first sidewall is located against the third sidewall; v) folding the lid panel with respect to the fourth side wall such that the first portion of the first wing of the lid is located against the underside of the lid panel, the first portion of the second wing of the lid is located against the underside of the lid panel, the underside of the second portion of the first wing of the lid is folded against the underside of the first portion of the first wing of the lid, the underside of the second portion of the second wing of the lid is folded against the underside of the first portion of the second wing of the lid, and the lid panel is located against the second portion of the first wing of the lid and the second portion of the second wing of the lid; vi) folding a cover panel located with the lid panel such that the cover panel is located against the first sidewall, such that a locking means of a locking panel located with the cover panel may be inserted through a slot of the first side wall; and vii) locking the locking panel to the latch panel by a locking means. Specific embodiments of the invention are herein described with reference to the figures, wherein: Figure 1 illustrates a plan view of a blank to be moved to an erect position forming a tamp er-evident container in accordance with an embodiment of the invention; Figure 2 illustrates a perspective view of the first step of the method of forming a container from a single sheet material tn accordance with the invention; Figure 3 illustrates a perspective view of the second step of the method of forming a container from a single sheet material in accordance with the invention; Figure 4 illustrates a perspective view of the third step of the method of forming a container from a single sheet material in accordance with the invention; Figure 5 illustrates a perspective view of the fourth step of the method of forming a container from a single sheet material in accordance with the invention; Figure 6 illustrates a perspective view of the fifth step of the method of forming a container from a single sheet material in accordance with the invention; Figure 7 illustrates a perspective view of the sixth step of the method of forming a container from a single sheet material in accordance with the invention; Figure 8 illustrates a perspective view of the seventh step of the method of forming a container from a single sheet material m accordance with the invention; Figure 9 illustrates a perspective view of the formed container; Figure 10 illustrates a perspective view’ of a formed container in a second embodiment of the invention; Figure 11 illustrates a plan view’ of a blank to be moved to an erect position forming a tamper-evident container in accordance with an alternative embodiment of the invention; Figure 12 illustrates a perspective view of the first step of the method of forming a container from a single sheet material m accordance with the embodiment of Figure 11; Figure 13 illustrates a perspective view of the second step of the method of forming a container from a single sheet material in accordance with the embodiment of Figure 11; Figure 14 illustrates a perspective view of the third step of the method of forming a container from a single sheet material in accordance with the embodiment of Figure 11; Figure 15 illustrates a perspective view of the fourth step of the method of forming a container from a single sheet material in accordance with the embodiment of Figure 11; Figures 16a-16b illustrate a section view of the steps of inserting the locking means of the container in accordance with the embodiment of Figure 11; and Figure 17 illustrates a perspective view of the formed container in accordance with the embodiment of Figure 11. Referring firstly to Figure 1 there is illustrated a sheet material in the form of a blank 2 which is able to be moved to an erect position to form a tampenevident container 1. The blank is formed of a suitably stiff material such as cardboard that is suitable to be both movable between a blank position and an erected position, and maintain structural integrity in its erected position. The blank 2 is comprised of a number of portions separated by fold lines, as indicated by broken lined in the figures. The blank 2 further comprises a number of cuts and apertures, as indicated by solid lines in the figures. The blank 2 includes a base portion 4, a first sidewall 6, a second sidewall 8, a third sidewall 10, a fourth sidewall 12 and a lid 14. The first sidewall includes a panel 16, a first wing 18 and second wing 20. The lid 14 includes a panel 22, a first wing 24 and a second wing 26, each wing comprised of a first portion 28,30 and a second portion 32,34. The base 4 portion includes a panel 36, a first wing 38 and a second wing 40, each wing comprised of a first portion 42,44; a second portion 46,48; and a third portion 50,52. A latch panel 54 is located with the lid panel 22 and a locking panel 56 is located with the first sidewall panel 16. The latch panel 54 includes a slot for the reception of a locking means 57 formed in the locking panel 56. The locking means 57 is formed of a first portion 59, a second portion 61 and a third portion 63. The second portion 61 includes a tab 65. The locking panel 56 includes a slot 66 for the reception of the latch panel 54. The first portions 42, 44 of the wings 38, 40 of the base 4 include tabs 58, 60 to be inserted into respective slots 62, 64 of the second sidewall 8 and the third sidewall 10 respectively durmg the formation of the container. Referring now to Figure 2, there is illustrated the first step of forming the container 1, wherein the second side wall 8 and third side wall 10 are raised to be perpendicular to the fourth sidewall 12, as indicated by arrows 68 and 70. Figure 3 illustrates the second step, wherem the fourth sidewall 12 is folded with respect to the base panel 36 so as to be perpendicular to the same, as indicated by arrow 72. This allows the second portions 46, 48 of the first and second wings 38, 40 of the base 4 to be located against the base panel 36. The underside of the third portion 50 is then located against the underside of the second portion 46, and the underside of the third portion 52 is then located against the underside of the second portion 48. Figure 4 illustrates the third step, wherein the first sidewall panel 16 is then folded with respect to the base panel 36 so as to be perpendicular to the same, as indicated by arrow 74. This brings the underside of the first sidewall first wing 18 into contact with the second sidewall 8, and the underside of the first sidewall second wing 20 into contact with the third sidewall 10. It further bangs the underside of the first base wing first portion 42 into contact with the third portion of the first base wing 50, which locates the first base wing tab 58 m the slot 62. Similarly, the underside of the second base wing first portion 44 is brought into contact with the third portion of the second base wing 52, which locates the second base wing tab 60 in the slot 64. The location of the tabs 58, 60 within the respective slots 62, 64 locks the structure in this position, preventing the progress of the assembly from being undone. The locking in this position further provides structural stability to the finished container. Figure 5 illustrates the fourth step, wherein the locking panel 56 is folded with respect to the first side wall panel 16 such that the locking panel is perpendicular to the first side wall panel 16 as indicated by arrow 76. Figure 6 illustrates the fifth step, wherein the locking means is folded to be perpendicular to the underside of the first sidewall panel 16, as indicated by arrow 77. Following this, the lid panel 22 is folded with respect to the fourth sidewall 22 to be perpendicular to the same, as indicated by arrow 78. This causes the first portion of the first wing of the lid 28 and the first portion of the second wing of the lid 30 to be located against the underside of the locking panel 56. The underside of the second portion of the first wing of the lid 32 is then located against the underside of the first portion of the first wing of the lid 28, and the underside of the second portion of the second wine of the lid 34 is then located against the underside of the first portion of the second wing of the lid 30. The lid panel 22 is then located against the second portions of the wings of the Ed 32, 34. Figure 7 illustrates the sixth step, wherein the latch panel 54 is folded with respect to the Ed panel 22 so as to be perpendicular to the same. The latch panel 54 is then inserted through the slot 66 of the locking panel 56 to form the container. Figure 8 illustrates the seventh step, wherein the locking means 57 is folded such that the first portion 59, the second portion 61, and the third portion 63 form a Z shape. It can be seen that the tab 65 extends outwards from the Z shape. Figure 9 illustrates the formed container forming the final step of the method, that is inserting the second portion 61 and third portion 63 of the locking means through the slot 55 of the latch panel 54, as indicated by arrow 80 of Figure 8. The leading edge 82 of the fold between the second and third locking means portions 61, 63 is passed through the slot 55 which is marginally wider than double the thickness of the sheet material of the blank 2, and as such the fold is under elastic tension. When the third portion 63 has fully passed through the slot 55 and the tab 65 is located against the underside of the latch panel 54, the elastic tension is released and the third portion 63 springs away from the second portion 61 within the container 4. As such, the released third portion 63 cannot be returned to be located against the second portion 61 from the exterior of the container 4, and there is no way of pulling the locking means 57 back through the slot 55 of the latch 54 without affecting the structural integrity of the container. Figure 10 illustrates a means of accessing the container 1 without affecting the structural integrity of the same. A perforated strip 84 runs along the width of the lid panel 22. A user is able to grip a tab 86 of the strip 84, and tear the same from the panel 22, which results in a portion of the lid panel 22 being able to be opened to make the interior of the container 1 accessible, whilst maintaining the structural integrity of the same. Figures 11 illustrates a blank 102 for a further container 100. In this embodiment, the blank 102 includes a base portion 104, a first sidewall 106, a second sidewall 108, a third sidewall 110, a fourth side wall 112 and a lid 114. The first sidewall includes a panel 116 including a slot 117, a first wing 118 and second wing 12O.The lid includes a panel 122, a first wing 124, a second wing 126, each wing comprised of a first portion 128,130 and a second portion 132, 134. The base 104 portion includes a panel 136, a first wing 138 and a second wing 140, each wing comprised of a first portion 142,144; a second portion 146,148; and a third portion 150,152. A latch panel 154 is located with the first sidewall panel 116, and includes two portions 154a, 154b defined by a foldline. The latch panel 154 includes a slot 155 for the reception of a locking means 157 which is located with a cover panel 160. The cover panel 160 is located with the Ed panel 122. Referring now to Figure 12, there is illustrated the first step of forming the container 100, wherein the latch panel 154 is folded in direction 162 so as to he flat with the panels 116 and 136. Figure 13 illustrates the second step, wherein the second side wall 108 and third side wall 110 are raised to be perpendicular to the fourth sidewall 112, as indicated by arrows 168 and 170. Figure 14 illustrates the next step, wherein the second portions 148, 146 have been located against the folded latch panel 154 and the base panel 136; the third portions 150,152 have been located against the respective second portions 146,144; and the first sidewall panel 116 has been raised to be perpendicular to the base panel 136. This arrangement allows locking tabs 161 to be located in respective locking slots to allow the blank 102 to be retained in this position. Figure 15 illustrates the next step, wherein the first portions 128, 130 have been lowered to be parallel with the base panel 136, and the second portions 132, 134 have been located against the respective first portions 128,130. The lid panel 122 is lowered to contact the second portions 132,134 and the container 100 is assembled. Figures 16a-b illustrate a section view of the locking means of this embodiment. The locking means 157 is formed of three portions 157a, 157b, 157c defined by three fold lines. To lock the means, as illustrated in Figure 16b, the locking means 157 is folded so as to bring portions 157b and 157c into contact. These portions are then inserted through slot 117. The resilient bias of the material from which the blank is formed causes the portion 157c upwards towards the slot 155 of the latch panel 154, through which the portion 157c partially protrudes. In this embodiment, the locking means 157 cannot be retracted through the slot 117 without accessing the cavity of the container 100. Figure 17 illustrates the assembled container 100. The container is tamperevident, in that the only way to access the interior of the container is to remove a perforated strip 172 of the cover panel 160. There is therefore provided a means of assembling a tamper evident container from a single sheet material in a single process. There is no requirement for the application of an adhesive layer or material such as glue, tape or the like, which significantly reduces or removes the microplastic content of the packaging. Furthermore, the forming of the container in one folding process, removes the time required and associated costs of additional processes such as the application of adhesive, sealing the container and / or the like. The product may be formed of a biodegradable material, reducing the environmental impact of disposing of the product. The erected container is tamper-evident and is formed preferably of a unitary single blank of cardboard sheet material and, once the locking means is engaged, there is no means of separating the same without affecting the integrity of the container. This destruction of the container to access its contents will be evident to a user or recipient of a container or another user during any transportation or storage process.

Claims

1. A lockable tamper evident container formed from a sheet material, the sheet material movable from a blank condition to an erect condition to form the container comprising side walls, a base and a lid which define a cavity within the container when the lid is closed and wherein locking means are provided to lock the container in the erect condition, said locking means include a portion of the sheet material which is selectively movable to a locking position through an aperture provided in the blank and biased to retain said container in said locked position.

2. A container according to claim 1 wherein when the container is unlocked the lid of the container is movable with respect to at least one of the side walls to which it is pivotably attached between an open position in which access is possible to the cavity and a closed position in which the cavity is inaccessible.

3. A container according to any of the preceding claims wherein the said locking means portion is defined within the outer edges of the blank.

4. A container according to any of claims 1 or 2 wherein the said locking means portion depends from an edge of the blank.

5. A container according to any of the preceding claims wherein the said locking means portion is folded back onto itself along a crease line and the sheet material and crease line produce said resilient bias.

6. Apparatus according to claim 1 wherein the locking means portion is positioned so as to be insertable through an aperture provided in the lid or a side wall of the container.

7. A container according to any of the preceding claims wherein upon insertion of the said locking means portion through the aperture, at least part of said portion is released and biased to least partially unfold to an extent sufficient to prevent the locking means portion being removed back through the aperture without tamper evident damage being caused to the sheet material.

8. A container according to any of the preceding claims wherein the container includes a frangible portion which is selectively breakable to allow access to the container once the locking means portion is in position.

9. A container according to claim 9 wherein the frangible portion is breakable without affecting the integrity of the locking means and provides evidence of tampering of the container when in the erected and locked condition.

10. A container according to any of the preceding claims wherein the frangible portion extends substantially between two opposing side walls of the container when the container is erect.

11. A container according to any of the preceding claims wherein the frangible portions extends between opposing edges of one of the side walls, lid or base so as to form a tear off strip.

12. A container according to any of the preceding claims wherein the sheet material is movable from a blank condition to the erected, locked condition and retained therein without the need for a secondary process to attach any portions of the container together.

13. A container according to any of the preceding claims wherein the sheet material blank includes prefabricated fold lines and / or breakable portions formed therein.

14. A locking means for a tamper evident container formed from a sheet material, the locking means comprising at least one aperture and at least one portion provided to be folded on itself, and when folded, said portion is passed through the said aperture which has a length and a width substantially matching the said portion when in the folded condition and wherein said portion is biased to an at least partially unfolded condition to prevent the locked portion from returning through said aperture and so retain said container in said locked position.

15. A sheet material in the form of a blank to be moved to an erected position to forming a locked tamper evident container of the type described in any of claims 144.

16. A method of forming a locked tamper evident container from a sheet material, said method comprising the steps of providing a blank to be moved to said erect position, said blank comprising a base, a number of side walls, a Ed, and a locking means; forming a number of crease lines in the blank; folding the blank along the crease lines so as to form a container; wherein said locking means includes a portion, folding said portion such that the said portion has a resilient bias; and inserting the folded portion through an aperture in the blank when the blank is at least partially erected, to an extent to allow at least partial release of the said portion to allow the same to at least partially unfold to an extent sufficient to prevent the locking means portion being removed back through the aperture without tamper evident damage being caused to the sheet material.

17. A method according to any of the preceding claims wherein the locking means comprises a portion of the sheet material folded back onto itself along a crease line such that when the folded portion is inserted through the aperture of the lid, the folded portion is under elastic tension such that the portion is released to be biased to at least partially unfolds when inserted through the aperture.

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