WO2024115899A1

WO2024115899A1 - Sharps bin and associated methods

Info

Publication number: WO2024115899A1
Application number: PCT/GB2023/053089
Authority: WO
Inventors: Paul Brown; Christopher Stanton
Original assignee: NeedleDock Limited
Priority date: 2022-11-29
Filing date: 2023-11-29
Publication date: 2024-06-06
Also published as: GB2624895A; GB202217943D0

Abstract

A sharps bin that is foldable from a flat-pack format, with a 'pop-up' type action, into a three dimensional medical sharps container that is made with two or more layers of solid-board (1, 2) which together create a combined thickness and strength that will withstand the penetration of a hypodermic needle.

Description

SHARPS BIN AND ASSOCIATED METHODS

This application claims beneficial priority to UK Patent Application GB2217943.6, the contents of which are incorporated herein by reference.

Field of the invention

The present invention relates to a sharps waste container, otherwise referred to as a sharps bin, for the safe disposal of sharp items of mainly medical, clinical and laboratory waste and, in particular but not exclusively, the ease and speed of assembly of the sharps bin and also the material that the sharps bin is predominantly made with and the eco-friendly benefits that the material and its manufacturing process enables in improving environmental issues and reducing carbon emissions.

Summary

The present invention relates to a sharps bin, such as a medical sharps bin. The sharps bin may comprise a multilayer carton. The solidboard may be hard sized. The solidboard may comprise a hard sized solidboard. In at least some examples, the sharps bin comprises a multilayered solidboard construction, with at least one of the layers of solidboard comprising hard sized solidboard. The hard sized board may be water-resistant. The hard sized board may be resistant to fluid absorption. The hard sized board may comprise a food-grade. The hard sized board may comprise strong sized board. The solidboard may be or have been treated with size to glaze or stiffen. The size may be applied to, or incorporated into, the solidboard, to act as a protective filler or glaze.

The size may be added as agent to increase the bin’s, or at least a component thereof, resistance to water absorption. The size may allow the bin or at least a component thereof, to be water-resistant. The size may comprise internal size. For example, the size may be acid- or alkaline-based rosin and/or alum added to a wet paper pulp for forming the solidboard. Additionally, or alternatively, the size may be applied externally. The size may comprise PVA.

The sharps bin may be a sharps bin in a fold out carton format. The sharps bin of the present invention may relate to the safe disposal of sharp medical instruments such as hypodermic needles, scalpels, lancets, sutures, razors, scissors and glass vials, bottles, containers and ampoules but may also contain small amounts of other non-sharp medical waste items such as card and plastic packaging, medical gloves, masks, tissues and possibly some small amount of liquids emitted from the above named items. Sharps bins, by regulation, are required to meet several rigorous test parameters to withstand safe and robust containment of the above mentioned sharp objects, including requiring to be puncture proof to hypodermic needles, waterproof to small amounts of liquid, tamper proof once sealed closed and strong enough to withstand defined drop tests, all of which tests and more are outlined in test requirements ISO 23907- 1 :2019 and UN3291 , although it is preferable for the present invention to also meet similar international standards of other countries who have their own test requirements for sharps bins.

Accordingly, in at least some examples, there is provided a sharps bin that is foldable from a flat-pack format, with a ‘pop-up’ type action, into a three dimensional medical sharps container that is made with two or more layers of solid-board cardboard which together create a combined thickness and strength that will withstand the penetration of a hypodermic needle according to the test outlined in ISO 23907-1 :2019 and whereby the solidboard material is made predominantly from natural, plant based, sustainable sources and having a high proportion of recycled material content.

Many different types of medical waste container exist and are predominantly manufactured from rigid, injection moulded plastics. They are typically manufactured from an assembly of three plastic parts, a container element, a cover, which requires the end user to click firmly onto the container to close it up before use, and a closure mechanism such as a slider or door. Once the sharp bin becomes full it is closed by the final closure mechanism and locked to provide protection from the sharp items inside and the pathogens and infectious agents contained within those clinical waste items. Commonly, and in the vast majority of cases worldwide and to provide protection to patients, health workers, waste operatives and the general public, both the waste contents and the entire sharps bin are incinerated (burnt) by a high temperature incineration process at professional incineration facilities licensed for processing of medical waste.

The present inventors have noticed other types of medical, general waste bins are used alongside sharps bins to dispose of the ‘non-sharp’ items and include plastic bags and corrugated cardboard or corrugated plastic (fluted) board waste bins, but these are not suitable for sharps waste and are not advertised as sharps bins as they can be easily punctured by sharp items; this is predominantly due to the corrugations or flutes within the thin outer layers of material having long, small tunnels of air running alongside them which reduces the puncture strength of the overall material composition to the extent that would result in sharp items sticking outwards through the bag or box which could harm staff using or carrying the waste bin. In these general use waste bins the thin walls of the plastic bag, cardboard box, or corrugated cardboard/plastic box do not prevent sharps penetration and the closure methods are not suitable to meet the ISO 23907-1 :2019 and UN3291 requirements that would be required if they were sharps bins.

The present inventor has identified a problem with the most commonly used, rigid, injection moulded plastic sharps waste containers is the fact that they are made from virgin (first time use) plastic, normally polypropylene. This means it they are made from a crude oil, petrochemical based material and in extremely high volumes globally which equates to a large amount of virgin plastic having to be manufactured for a product which, by law, is required to be destroyed by incineration. Most traditional sharps bins are classed as ‘single use items’ and therefore legally cannot be re-used or recycled. Therefore they must be destroyed by incineration and so the plastic used to make them can never reenter the plastic recycling scheme and is therefore called a ‘single-use-plastic’. This means that any sharps bins made from 100% virgin, single-use plastics are contributing to the depletion of the world’s limited fossil fuels and, due to the large amount of energy and extensive processing required to make the virgin plastic, the plastic sharps bins are not environmentally friendly.

Furthermore, as sharps bins are incinerated along with the sharps waste inside them, the plastic that the sharps bins are made from breaks down and, due to the burning process, gases, chemicals, toxins and particles are released which can enter the atmosphere. This petrochemical based plastic pollution poses a health threat to humans, animals, vegetation and the food chain, possibly entering the body through respiratory means and into waterways and the food-chain by soil pollution, potentially damaging the wider health of the world’s eco-system. In March 2019, the United Nations Environment Assembly passed a resolution to encourage governments to eliminate the use of single use plastics and instead “promote the more resource-efficient design, production, use and sound management of plastics across their life cycle”. There is a general trend globally to reduce the amount of plastics used in products, particularly to eliminate single use plastics and to encourage the recycling of plastics, neither of which initiatives virgin plastic sharps bins align to. Some sharps bins are being changed to adding a small proportion of recycled plastics but there is normally a larger proportion of virgin plastic in the plastic mix for safety and moulding quality reliability reasons, and those plastic sharps bins are still incinerated, so the partly recycled plastic mix still ends its life being burnt which is bad for the environment and then more fossil fuel based plastic is needed if those products continue to be purchased.

In parallel there is a general and fast growing trend to use natural, sustainably (re-growable) sourced and eco-friendly materials to try to help reduce mankind’s reliance on fossil-fuel, oil based materials, to help reduce pollution, reduce CO2 emissions into the atmosphere, to reduce the greenhouse effect and overall help save the world’s environment.

The UK National Health Service (NHS) uses 8.4 million single-use sharps containers every year. Excluding the waste contents, this results in over 2500 tonnes of single-use plastic sharps bins being incinerated annually in the UK alone. This is likely to increase significantly from 2021 due to the vast additional waste created for the ongoing Covid-19 vaccination programs. It would therefore be good for the future health of the environment to find an alternative solution to plastic moulded sharps bins.

A further problem identified by the present inventors with plastics sharps waste containers is that they are often difficult to assemble. This is primarily because the plastic parts are manufactured as low cost as possible and therefore often have poor tolerances, therefore resulting in poor fitting parts. So adding a plastic lid to a plastic container part can often be very difficult or even almost impossible for many medical staff, particularly those who do not have the strength in their hands and arms to click the two large mouldings together, particularly as there are normally several latches required to be snapped shut in different areas around the rims of the two parts. If the end user does not apply enough pressure by hand to click the lid onto the container then the lid can fall off later on if it becomes loose, which is particularly dangerous if the sharps bin is full of sharp and infected needles. This has been known to happen most commonly when the sharps bins are being moved, picked up or carried away ready for disposal or if they fall over. Rather than fitting the lid by hand it is known that some medical staff have sometimes been required to stand on the plastic sharps bin and apply pressure by foot using their body weight to force the lid on. So an easier to assemble sharps bin design would be a welcome and safer solution. A further problem identified by the present inventors with plastic sharps bins is that they take up a lot of volumetric space due to the fact they are normally a tall, tapered, cylindrical bucket shape, which by its nature contains fresh air. Even though about ten items are normally stacked inside eachother for space efficiency the top cylinder of the stack is still holding a large volume of wasted air. This means it is expensive to store and transport this type of sharps bin and creates problems for hospitals and doctors surgeries who do not enough space to store these bulky items efficiently or conveniently.

It may be an object of one or more aspects, examples, embodiments, or claims of the present disclosure to at least mitigate or ameliorate one or more problems associated with the prior art, such as those described herein or elsewhere.

An object of this invention may be to create a sharps bin which is predominantly made using natural, non-petrochemical, sustainably sourced, recycled and eco- friendly materials to be a more environmentally responsible product and yet still meet the strict safety and performance criteria required of a sharps bin, namely to be puncture proof to hypodermic needles, waterproof to small amounts of liquid, tamper proof once sealed closed and strong enough to withstand defined drop tests as outlined in test requirements ISO 23907-1 :2019; also is an extremely compact design for maximum space and cost efficiencies during storage and transport and yet transforms into a full capacity sharps bin by a transformation process which makes it quick and easy to assemble for the end user, in order to save medical and laboratory professionals time and effort during assembly and to improve their safety by having an assembly process which all medical staff can easily cope with.

Accordingly, this invention may provide a sharps bin which is predominantly made from two or more layers of strong, rigid, waterproof and high density solidboard which preferably is made from naturally sourced, sustainable, eco- friendly, wood based materials, of which a large proportion would be from a recycled source, and that is supplied with all the parts of the sharps bin already integrated for ease of assembly and furthermore, despite being made from a rigid material, is easily and quickly foldable for most end users by means of a user friendly, pop-up action which transforms it from a two dimensional, flat-pack item which is highly compact and therefore very efficient and convenient to store and transport, into a three dimensional, full capacity, ready to use, medical sharps container whereby its construction of two or more layers of the solidboard material work together to create a combined strength that will withstand the penetration of a hypodermic needle according to the safety test outlined in ISO 23907-1 :2019.

The sharps bin may be made with at least one part being a construction of a flat sheet. The flat sheet may be of die cut solidboard. The flat sheet of die cut solidboard may be glued or fixed together along a side edge. The flat sheet may be glued or fixed together along the side edge to create a loop type format. The flat sheet may be glued or fixed together along the side edge to create a loop type format which, when flattened, is a two dimensional, flat-pack carton construction. The flattened, two dimensional, flat-pack carton construction may be for compact storage. The flattened, two dimensional, flat-pack carton construction may have crash-lock type flaps on the base. When the two dimensional flat-pack form is pushed together with side force on the edges, the two dimensional flat-pack form automatically transforms in a pop-up style into a three dimensional carton form for easy and speedy partial assembly. Accordingly, the sharps bin may be made with at least one part being a construction of a flat sheet of die cut solidboard, which is glued or fixed together along a side edge to create a loop type format which, when flattened, is a two dimensional, flat-pack carton construction for compact storage but which has crash-lock type flaps on the base which, when the two dimensional flat-pack form is pushed together with side force on the edges, automatically transforms in a pop-up style into a three dimensional carton form for easy and speedy partial assembly. The sharps bin may be made with two or more pieces of solidboard. Said two or more pieces may be supplied as flat-packed, carton type constructions. Said two or more pieces may be supplied either as separate entities or supplied prepacked inside each other. When pressure is applied to the side edges of the two or more pieces, the two or more pieces may be transformed from flat-pack forms into three dimensional, carton type forms in a pop-up style. The two or more pieces may be designed so that, when transformed into three dimensional, carton type forms, one (or more) piece fits snugly inside the other piece when assembled. The forms may have an array of well-fitting flaps on the top and bottom which, when folded into their designated positions, create a resultant, closed, carton type assembly. All the walls of the closed, carton type assembly may be touching or very close together with at least double wall thickness on all the walls. The at least double wall thickness may offer the required combined wall thickness strength to withstand the penetration of a hypodermic needle. The at least double wall thickness may offer the required combined wall thickness strength to withstand the penetration of a hypodermic needle according to the test outlined in ISO 23907-1 :2019. Accordingly, the sharps bin may be made with two or more pieces of solidboard whereby the said pieces are supplied as flat- packed, carton type constructions, either as separate entities or supplied prepacked inside eachother, but which, when pressure is applied to the side edges of the two or more pieces, transform them from flat-pack forms into three dimensional, carton type forms in a pop-up style and are designed so that one or more piece fits snugly inside the other piece when assembled and furthermore has an array of well-fitting flaps on the top and bottom which, when folded into their designated positions, create a resultant, closed, carton type assembly whereby all the walls are touching or very close together with at least double wall thickness on all the walls offering the required combined wall thickness strength to withstand the penetration of a hypodermic needle according to the test outlined in ISO 23907-1 :2019.

The sharps bin may have a construction technique which includes a set of flaps. The set of flaps, preferably on the top, may include a pair of rectangular shaped side flaps. The pair of rectangular shaped side flaps may have triangular creases applied into them, which, when pushed with a side force, fold inwards to transform into a triangular form and which, when the back and front flaps are folded over the aforementioned side flaps, creates a three dimensional pyramidal form covered with a partly folded over ridge form. The three dimensional pyramidal form covered with the partly folded over ridge form may have the benefit of being naturally sealed and waterproof due to the long folds of the creased material that creates the pyramidal and ridge type forms being continuous pieces of waterproof material. Accordingly, the sharps bin may have a construction technique which includes a set of flaps, preferably on the top, which includes a pair of rectangular shaped side flaps with triangular creases applied into them which, when pushed with a side force, fold inwards to transform into a triangular form and which, when the back and front flaps are folded over the aforementioned side flaps, creates a three dimensional pyramidal form covered with a partly folded over ridge form which has the benefit of being naturally sealed and waterproof due to the long folds of the creased material that creates the pyramidal and ridge type forms being continuous pieces of waterproof material.

The sharps bin may have a form which is a generally tall cuboid form with a pitched ridge top shaped form on top which furthermore has a pyramidal form within the top ridged area.

The sharps bin may be made with two or more pieces of solidboard. The two or more pieces of solid-board may work together to create two or more layers of the said material when put together over all sides of the sharps bin. Additional materials or items may be added at certain areas between the said layers, such as a plastic bag, to add to or enhance the performance of the layered materials, such as adding to or enhancing the waterproofing performance. , with the benefit that the inner layer will protect the middle layer from puncturing due to the strong nature of the material of the inner layer. Accordingly, the sharps bin may be made with two or more pieces of solidboard whereby the two or more pieces of solid-board working together create two or more layers of the said material when put together over all sides of the sharps bin, and furthermore whereby additional materials or items may be added at certain areas between the said layers, such as a plastic bag, to add to or enhance the performance of the layered materials, such as adding to or enhancing the waterproofing performance, with the benefit that the inner layer will protect the middle layer from puncturing due to the strong nature of the material of the inner layer.

It will be appreciated that at least one of the layers may comprise hard-sized solidboard. For example, the inner layer may comprise hard-sized solidboard such that the inner layer has an increased resistance to water absorption (e.g. compared to un-sized solid board and/or compared to the outer layer).

The sharps bin may be made with two or more layers of solidboard cardboard which together create a combined strength that will withstand the penetration of a hypodermic needle. The sharps bin may be made with two or more layers of solidboard cardboard which together create a combined strength that will withstand the penetration of a hypodermic needle according to the test outlined in ISO 23907-1 :2019.

The sharps bin may include a temporary closure door. The temporary closure door may comprise of a long, foldable tab which includes a dedicated integrated tab detail, such as a finger type tab made with two slots. The foldable tab with the dedicated integrated tab detail may allow the door to be partially tucked in another slot or aperture to temporarily close the door and hold it in its place until required to be opened again. Accordingly, the sharps bin may include a temporary closure door comprising of a long, foldable tab which includes a dedicated integrated tab detail, such as a finger type tab made with two slots, which allows the door to be partially tucked in another slot or aperture to temporarily close the door and hold it in its place until required to be opened again. The sharps bin may include a construction technique which includes a tuck tab integrated into a main top flap which when tucked into a slot on the main body holds the main top flap closed. Within the aforementioned tuck tab there may be provided a one-way lock detail. The one-way lock detail, when pushed into the slot region of the main body (akin to a button or small lever), may latch into and/or behind the top edge of the aforementioned slot detail and/or pushes another tab behind it to also latch underneath and/or behind the top edge of the slot which prevents the one-way lock detail, the long tab and the top flap from being removed from the slot, or being opened or tampered with. Accordingly, the sharps bin may include a construction technique which includes a tuck tab integrated into a main top flap which when tucked into a slot on the main body holds the main top flap closed and which includes within the aforementioned tuck tab a one-way lock detail which, when pushed into the slot region of the main body (akin to a button or small lever), latches into and/or behind the top edge of the aforementioned slot detail and/or pushes another tab behind it to also latch underneath and/or behind the top edge of the slot which prevents the one-way lock detail, the long tab and the top flap from being removed from the slot, or being opened or tampered with. The addition of a label with a permanent adhesive applied over the said lock detail may further add to the security of the lock and latch feature.

The sharps bin may be made with two or more layers of solidboard which is made with cardboard.

The sharps bin may be made with two or more layers of solidboard which is made from or partly containing materials including one or more of: cardboard, fiberboard, bio-plastics, PLA, com starch, bamboo, coconut, flax, hemp, wool, straw or fully or partly recycled oil-based plastics.

The sharps bin may have base flaps or top flaps or both. The base flaps or top flaps or both may be sealed together during the factory manufacturing process to make them waterproof by means of glue or compression or heat or sonic joining or a combination of the aforementioned processes. The base flaps or top flaps or both may be foldable into a flat-pack format but which can be folded out into a three dimensional carton form. Accordingly, the sharps bin may have base flaps or top flaps or both which are sealed together during the factory manufacturing process to make them waterproof by means of glue or compression or heat or sonic joining or a combination of the aforementioned processes and are foldable into a flat-pack format but which can be folded out into a three dimensional carton form

The sharps bin may include a set of labels stuck to the outer carton which can be applied later by the end user during assembly and for final closure.

The sharps bin may be coated in a waterproof film on part of or across the entire surface.

The sharps bin may have the outer surface printed.

The sharps bin may have at least one waterproof lamination or coating added.

The sharps bin may have an accompanying wall bracket to enable it to be fixed it to a wall.

The sharps bin may comprise a mechanical part which is fixed in a waterproof manner to the solidboard. The mechanical part may comprise one or more of: such as an injection moulded screw cap, flip-top opening, slider opening or a sharps removal device.

An embodiment of the invention is thus. The sharps bin may be constructed with two main parts, an outer carton and an inner carton. They may be die-cut from flat sheets of suitable grade solidboard material and optionally punched and creased as required to create the workable parts. The solidboard is preferably made form high grade cardboard which is made with two or more layers of paper/card sheets and a suitable mix of pulp cardboard content laminated together, but could also be a solidboard made from or partly containing other suitable materials such as bio-plastics like PLA, or other plant or animal based materials such as com starch, bamboo, coconut, flax, hemp, wool and straw or fully or partly recycled oil- based plastics. At least the outer carton can be printed or graphics applied by another process such as wrapping or labels and both parts can have other properties added or integral to their materials such as waterproofing on at least one side. Both parts have tabs down one side to which glue may be applied and the sheets folded during the fully automated manufacturing process to turn the flat profiles into flattened, carton loop formats. The glue process could be replaced with a suitable alternative fixing method, such as stitching, interlocking or riveting, but gluing offers the best waterproofing characteristics and is therefore the most suitable method for the purpose.

The inner carton may be slightly smaller than the outer carton and is inserted inside the outer carton with a plastic bag added between the two parts so that the bag is sandwiched between the two layers of solidboard. This acts as a waterproof layer and is protected from being pierced by sharps by the strong inner layer of solidboard. A set of labels are stuck to the back of the outer carton which will be applied by the end user later during assembly and for final closure. An optional inner pad, made of solidboard or another material suitable as a liquid absorbing pad or for adding additional needle protection, can be inserted into the inner carton, again ready for assembly by the end user. These aforementioned parts are created using a fully automated manufacturing process, are all created in a flattened format and then assembled into a flattened subassembly, commonly called a flat-pack, and ready for compact storage, transport and/or assembly.

The bag may be positioned relative to at least the inner carton such that a bottom portion of the bag extends below a bottom edge or crease of the inner carton, when in a flat-pack configuration. The bottom edge or crease of the inner carton may be a bottom edge or crease of the inner carton when transformed into the three-dimensional carton. The bag may extend below the inner carton by a predetermined amount, such as a predetermined distance. For example, the bag may extend below the inner carton by at least 50mm. The bag may extend below by 80mm; 100mm; or more. The extension of the bag when the inner carton is in two dimension form may provide for an extension space for the transformation of the inner carton to its three-dimensional form. When transformed, the bag extension may be reduced. In at least some examples, the bag extension may be reduced to a negligible or zero extension when the inner carton is transformed to three-dimensional form. The position of the bag may be fixed relative to at least one of the cartons. The position of the bag may be fixed relative to at least one of the cartons in two-dimensional, flat-packed form. The position of the bag may be fixed to the carton by adhesion. The bag may be adhered to the carton prior to packaging in flat-pack format for transport or storage, such as transport or storage prior to (first) use as a sharps bin. The bag may be adhered to the carton to define the extension of the bag therebelow when flat-packed. The bag may be configured to provide a pocket/s, such as for retaining liquid when transformed into the three-dimensional sharps bin. The bag may comprise a flat bag with a linear bottom, such as a linear bottom seam. The linear bottom may define two bottom comers of the bag. When assembled in three-dimensional form, the bag comers may define pockets for retaining liquid therein.

The sharps bin may be configured to withstand toppling. The sharps bin may be configured to withstand toppling without spilling a content/s. The sharps bin may be configured to retain sharps therein, when toppled. The sharps bin may be configured to withstand toppling from a bench or desktop height, such as 80cm; or higher, such as 1 m; or even 1.5m. The sharps bin may be configured to retain I iquid/s therein; when upright and/or tilted or toppled.

When assembled, the sharps bin may provide a waterproof or watertight container. The sharps bin may be waterproof, containing liquid therein under gravity. The sharps bin may be waterproof when upright in its three-dimensional form. The sharps bin may be configured to contain liquid. The sharps bin may be configured to contain liquid whilst moving, such as being transported (e.g. manually carried and/or in or on a vehicle). In at least some embodiments, when the sharps bin is closed, particularly with a label/s positioned over an aperture/s, such as a door, the sharps bin may additionally be waterproof when tilted or even inverted. The three-dimensional sharps bin may be configured to be substantially watertight when turned or stored upside down.

At least one label may be applied over or across a crease. The at least one label may function as a hinge, such as a living hinge. The at least one label applied over or across the crease may reinforce the crease for use as a flexible hinge. Additionally, or alternatively, at least one label may be applied to connect two portions of solidboard to form a hinge. The label may comprise a resilient, flexible material configured for repeated flexure, such as for repeated use as a hinge. The label may comprise a water resistant material.

To assemble into a sharps bin the flat-pack is simply pushed by light hand force on each side edge and the parts naturally pop open into a tall, square section, cuboid shaped, open topped carton. The inner carton and bag are then lightly pushed down inside the outer carton. A small door on the front is pushed open, in readiness for use, and then the sides of the top of the carton are pushed together to create a pyramid shape which closes up the carton. To fully close the sharps bin the main flap is folded over, concealing the pyramid part and creating a ridge roof shape, and the long tab is then inserted into the front slot to hold the main flap in place. To secure the main flap a locking tab on the front is pushed which activates a latch within the tab making the sharps bin locked. A security label is then stuck over the lock and latch area to make the sharps bin fully secure, tamper-proof and ready for use. To use, the temporary closure tab is opened and the sharp items, such as hypodermic needles, syringes and scalpels, can be inserted through the aperture within the angled, ridge top as required. A fill line is printed on the outer carton to indicate how high to safely fill up the sharps bin. To close the sharps bin temporarily the temporary closure tab is folded into its closed position and it has a middle protruding tab which is inserted into the top edge of the aperture to hold it in place until it is required to be opened again for use. For final closure, i.e. when the sharps bin is full and/or ready for disposal, the two doors are closed and a second label is stuck over the top to seal the sharps bin closed, ready for incineration.

The sharps bin may comprise an insert. The insert may be provided, for insertion as an inner or innermost component at the bottom of the popped-out three- dimensional sharps bin. The insert may comprise a bottom insert for covering or at least partially covering the interior or inner bottom of the sharps bin. The insert may comprise an absorbent insert, such as a sheet of fibrous or non-fibrous absorbent. The insert may comprise a planar insert, for packaging flat-packed with the flat-packed, two-dimensional cartons. The insert may be inserted into the sharps bin after the sharps bin has been transformed into three-dimensional form. The insert may comprise a tray. The insert may comprise a flat bottom with side walls that can be folded upwards. The insert may comprise a “+” shape, when flattened in a two-dimensional form, for transport or storage. The insert may comprise a flat net with a central square or rectangle, corresponding to an inner or innermost shape or are of the interior of the three-dimensional, assembled sharps bin. The central square or rectangle may be formed with rectangles attached at each edge of the square or rectangle. The insert may be creased along the edges of the central square or rectangle. The insert may comprise a flat The side walls may be absorbent. The side walls may be configured to absorb moisture by wicking or capillary action. The provision of the side walls may provide for an increased volume and/or absorption capacity of the insert. The provision of the side walls may provide for an increased volume and/or absorption capacity of the insert without increasing a thickness of the insert when packaged, such as flat-packed for transport or storage. In at least some examples, a plurality of inserts are provided. Providing a plurality of inserts can provide for an increased absorption volume or capacity without increasing a total thickness of the flat-packed assembly. The insert may be for insertion within the bag. Accordingly, the insert may be configured to absorb liquid or moisture within the bag, such as deposited with sharps placed in the sharps bin.

It will be appreciated that in at least some examples, a third carton may be provided. Accordingly, the three-dimensional sharps bin may comprise a triple wall thickness. The third carton may comprise an intermediate carton. The intermediate carton may be positioned between the inner carton 2 and the outer carton 1. The intermediate carton may be positioned between the inner carton 2 and the bag 3. Alternatively, the intermediate carton may be positioned between the outer carton 1 and the bag 3. It will also be appreciated that the intermediate carton may be supplied pre-packed, in a flat-pack assembly generally similar to that shown in Figure 3. That is, the sharps bin may be supplied in a pre-use format as a flat-packed, pre-packed assembly with at least three cartons supplied in a two-dimensional flat-pack form, each of the respective intermediate and inner cartons being pre-packed within the outer carton.

The present invention includes several unique details which enable it to fold and seal so easily. Firstly the sharps bin is made with two separate layers of solidboard which are assembled in close proximity to eachother; this creates a double wall thickness which gives the combined walls a thickness and strength enough to pass the hypodermic needle penetration test and yet also allow the walls to have creases put into them to enable them to fold readily for easy assemble with low bending stresses.

Also the inner carton has four generally triangular tabs on top (including a truncated triangular tab and triangular tabs with extra areas added) which, when the carton is folded into a cuboid shape, automatically transform the triangular tabs into a pyramidal shape (with the truncated tab area remaining open to allow sharps through the aperture). These four triangular tabs automatically create a double wall thickness, where required, for the top area of the sharps bin to enable it pass the hypodermic needle penetration test. Also, to transform the aforementioned tabs into the pyramid shape, the top areas of the side walls of the outer carton have triangular shaped creases added which, when pushed inwards, transform the rectangular shaped side walls into triangular shaped walls which, as they fold inwards with a gentle push by the end user, push the four triangular tabs on the inner carton inwards to create the pyramid form and furthermore create a ridge shape on the top of the outer carton, closing up the entire top of the sharps bin.

Also both the inner carton and the outer carton have crash-flap base designs which enable the cartons to transform automatically from a flat-pack format into a three dimensional, cuboid carton format with minimal effort from the user; a single push on each side of the flat-pack will enable the mechanically, automatic transformation of the bottom flaps to go from vertical to horizontal, lay them down into their designated flat positions and also lock them into place to hold the carton in its final solid 3D shape. Crash-flaps are a well known rapid action, strong and reliable box folding method which works by two pairs of flaps being glued together with one flap within each pair having a folding crease. The flaps are then typically creased and folded upwards and stored inside the flattened box until ready to be deployed by simply opening up the box form by pushing on each side of the flat-pack where they automatically fold downwards into place with an over-centre action; the flaps are normally then required to be finally pushed down in place by hand to ensure they bed into their designated positions in the bottom of the box or carton. In this present invention one crash flap will be full length and cover the entire base of the carton and be a tight fit for strength, sharps protection, security and to hold the carton shape well. The crash-flaps offer a high level of ease of assembly. Uniquely, in the present invention, both the inner carton and the outer carton crash-flaps work in tandem when the two parts are inserted inside eachother (as supplied in the subassembly) and opened at the same time, offering extreme ease of assembly by having the two cartons working together and creating a final, double wall thickness (in the side and upper walls) and quadruple wall thickness (in the base) achievement. Having a carton inside another carton, both with crash-flaps, means the flaps cannot be pushed inwards from the bottom by external pressure (e.g. by tampering, and so naturally create a strong product. The overall construction of four layers of solidboard in the base and the two layers of solidboard in the middle and upper parts and the slight, natural flexibility of the solidboard material makes the finished sharps bin product very strong and forgiving if accidentally dropped. Alternatively the base flaps could be a different design whereby the flaps are fully sealed together during the factory manufacturing process to make them waterproof by means of glue or compression or heat or sonic joining or a combination of the aforementioned processes and are foldable into a flat-pack format but which can be folded out into a three dimensional carton form, akin to a typical drinks carton construction often used for storing fruit juice. Likewise the top flaps could be sealed and made waterproof in the same manner. The aperture could be replaced with a mechanical part such as an injection moulded screw cap, flip-top opening, slider opening or a sharps removal device which is fixed in a waterproof manner to the solidboard.

Also the folded pyramid shape on the top area of the outer carton offers excellent water retention due to the fact it is created by folds only, with no cuts or apertures, so any small amounts of liquids inside the sharps bin will not leak out if the sharps bin is knocked over onto its side. The top edge of the bag is positioned partly up into the pyramid and ridge area further ensuring liquids stay firmly in the main, lower, cuboid shaped container area.

Also the use of sticky labels to seal the sharps bin is much easier and requires considerably less strength to apply compared to trying to snap an injection moulded lid onto an injection moulded container so is more user friendly and will ensure the sharps bin is always sealed properly for increased safety. Also the design of the push button tab to lock the tuck flap and main top flap closed is unique, using the different layers and properties of the solidboard to create a strong and effective one-way lock which prevents the sharps bin being opened, either accidentally or on purpose by tampering, offering added safety and eliminating any chance of spillage of the sharps inside. The addition of a label over the lock further enhances the safety and security and would be a requirement of the finished product.

Also the ability to print all over the outer carton gives the benefit of having a large amount of surface area to apply clear instructions for the assembly, usage and closure and disposal, as well as other details such as warnings and contact details. Alternatively the carton parts could be coated in a waterproof film which could be stretchy or a shrink-wrap on part of or across the entire surface.

Also the fact the present invention is a tall, square section cuboid form means it is more stable on the table compared to tapered sharps bins by having a more bottom-heavy load inside. Also it has a larger footprint area compared to a circular sharps bin so is naturally more stable if accidentally knocked and, likewise, when hung on a wall the flat back shape will be more secure and stable against the wall compared to a cylindrical sharps bin. The ridge top shape reduces the top weight, also helping to make it more stable and the angled face of the ridge offers a better user experience by naturally facing the aperture towards the user for obvious and clear insertion of the sharp items. The areas underneath the ridge top and each side of the pyramid shape create two hollows which act as handles both sides for ease of picking up and carrying the assembled sharps bin with either the left or the right hand or both.

The solidboard material used in the construction is intended to be made partly from sustainable, responsibly managed, renewable natural sources (e.g. using cardboard pulp and papers from wood that is certified by The Forest Stewardship Council (FSC) the world’s most respected and widespread forest certification system) and combined with a larger amount of recycled card materials to reduce the amount of virgin wood fibre. A suitable ratio of this mix is required to give a good balance of strength, thickness, stiffness, durability, weight, ease of processing and cost. The typical card/paper wall thickness suitable for the present invention that will enable material thick enough and dense enough for a hypodermic needle not to puncture through it is approximately 2.5mm to 4.0mm, although typically the denser the material the thinner the wall can effectively be, so approximately 1 ,5mm to 2.5mm would be workable if the card/paper is extremely high quality, such as 100% Kraft paper, to create a strong, final, high density material. The solidboard weight could be 350-550 grams per metre squared, 551-900 grams per metre squared, or 901 -1350 grams per metre squared. Multiple substrates may be combined in a plurality of layers to meet the defined needle penetration requirement. The weight of the solidboard will additionally be selected based on its ability to be converted from sheet into a preformed, two dimensional template. Cuts and creases will be added to the two dimensional form to aid its conversion to a three dimensional structure.

Adhesives, glues, chemical agents or mechanical fixings or mechanical interlocking features may be added to the substrate as it is converted to a three dimensional structure. The three dimensional structure may then be folded flat to aid transportation and minimize storage volume. The sharps bin will be created from one or more of these folded flat three dimensional structures.

As cardboard based solidboard is not from a petrochemical source it leaves little environmental footprint on the planet. For comparison, plastics manufacturing processes create on average a total of 6Kg of CO2 for every 1 Kg of virgin plastic made, whereas cardboard equals on average just 0.5Kg of CO2 for every 1 Kg of virgin cardboard made. Using recycled cardboard reduces this impact even further.

Furthermore, when incinerated, as is legally required for all common sharps bins, the plant based cardboard will release no man-made petrochemical gases, fumes or plastic particles; instead breaking down to mainly natural, wood based ash and collected at the base of the incinerators for safer disposal and therefore overall being safer for the environment. The burning of cardboard based items in industrial incinerators is also much preferred by the incinerator operators as it is an easily combustible material and requires little additional energy to bum it, whereas plastic based sharps bins are problematic to bum as they can block up incinerators, often require additional mixing of more combustible materials and additional energy is sometimes needed to help them bum and break down.

As previously mentioned, very strict, specific and technically demanding requirements and international standards determine the suitability of medical sharps containers for their purpose, including the need to be puncture proof to hypodermic needles up to 18 Newtons force, waterproof to small amounts of liquid, tamper proof once sealed closed and strong enough to withstand defined drop tests as outlined in international test requirements ISO 23907-1 :2019. It is not obvious to a skilled person that paper or card based solidboard could achieve these testing requirements and be comparable to, or have superior performance to, rigid plastics, or that creating a structure of paper/card and thin film layers joined together could resist a hypodermic needle being pushed through the wall section. It is also not obvious that a sharps bin could be created using a natural, plant based and recycled material such as cardboard that offers environmental benefits to the world’s eco-system. Furthermore nor that all the above mentioned features and benefits could be formulated into a 2D to 3D, flat-pack to full capacity sharps bin which gives additional benefits to many stakeholders in the way it enables 100% optimal space saving for ultimate value storage in a warehouse, whilst being transported and at a goods-in depot at a hospital or doctors surgery, and yet is still be easy to pop into shape by the end user for excellent ease of assembly by all medical staff, no matter what their strength, and to ensure safe and reliable assembly and handling throughout the whole lifespan of the product from assembly to disposal. The sharps container may contain features for floor mounting, wall mounting, surface mounting or incorporation into or onto a trolley or movable unit. A bracket for fixing the product to the wall and a stabilizing base would be accessory options. A liquid absorbing material, liquid container or sharps protection enhancing pad or tray may be present inside of the sharps bin. The invention includes an integrated carrying handle and on larger sizes this may be externally attached, fixed to the product or a combination.

The present invention can be used as a sharps bin and for a variety of other purposes including a standard medical waste bin, a standard household or office waste bin, outdoor waste bins, specific item storage containers, foodstuffs, drinks, liquids, powders, pastes, flowing solids or food containers. The size and proportions of the product and/or the aperture can be adjusted to suit the desired purpose.

Clauses

Examples of the present disclosure are hereby described in the following numbered clauses, noting that these clauses are distinct from the claims appended to this application, with the scope of protection being defined by the claims as appropriate in respective jurisdictions.

1 . A sharps bin made with at least one part being a construction of a flat sheet of die cut solidboard which is glued or fixed together along a side edge to create a loop type format which, when flattened, is a two dimensional, flat-pack carton construction for compact storage but which has crash-lock type flaps on the base which, when the two dimensional flat-pack form is pushed together with side force on the edges, automatically transforms in a pop-up style into a three dimensional carton form for easy and speedy partial assembly.

2. A sharps bin made with two or more pieces of solidboard whereby the said pieces are supplied as flat-packed, carton type constructions, either as separate entities or supplied pre-packed inside eachother, but which, when pressure is applied to the side edges of the two or more pieces, transform them from flat-pack forms into three dimensional, carton type forms in a pop-up style and are designed so that one or more piece fits snugly inside the other piece when assembled and furthermore has an array of well fitting flaps on the top and bottom which, when folded into their designated positions, create a resultant, closed, carton type assembly whereby all the walls are touching or very close together with at least double wall thickness on all the walls offering the required combined wall thickness strength to withstand the penetration of a hypodermic needle according to the test outlined in ISO 23907-1 :2019. A sharps bin according to any preceding clauses which has a construction technique which includes a set of flaps, preferably on the top, which includes a pair of rectangular shaped side flaps with triangular creases applied into them which, when pushed with a side force, fold inwards to transform into a triangular form and which, when the back and front flaps are folded over the aforementioned side flaps, creates a three dimensional pyramidal form covered with a partly folded over ridge form which has the benefit of being naturally sealed and waterproof due to the long folds of the creased material that creates the pyramidal and ridge type forms being continuous pieces of waterproof material. A sharps bin made with one or more parts with at least one of the outer profiles akin to those illustrated in FIGURE 1 of the present invention. A sharps bin made with one or more parts with at least one of the outer profiles and crease lines akin to those illustrated in FIGURE 1 of the present invention. A sharps bin made with one or more parts with at least one of the outer profiles, the crease lines and the punched shapes akin to those illustrated in FIGURE 1 of the present invention. A sharps bin according to any preceding clauses which has a form which is a generally tall cuboid form with a pitched ridge top shaped form on top which furthermore has a pyramidal form within the top ridged area. A sharps bin according to any preceding clauses made with two or more pieces of solidboard whereby the two or more pieces of solid-board working together create two or more layers of the said material when put together over all sides of the sharps bin, and furthermore whereby additional materials or items may be added at certain areas between the said layers, such as a plastic bag, to add to or enhance the performance of the layered materials, such as adding to or enhancing the waterproofing performance, with the benefit that the inner layer will protect the middle layer from puncturing due to the strong nature of the material of the inner layer. A sharps bin according to any preceding clauses made with two or more layers of solidboard cardboard which together create a combined strength that will withstand the penetration of a hypodermic needle according to the test outlined in ISO 23907-1 :2019. A sharps bin according to any preceding clauses which includes a temporary closure door comprising of a long, foldable tab which includes a dedicated integrated tab detail, such as a finger type tab made with two slots, which allows the door to be partially tucked in another slot or aperture to temporarily close the door and hold it in its place until required to be opened again. A sharps bin according to any preceding clauses which includes a construction technique which includes a tuck tab integrated into a main top flap which when tucked into a slot on the main body holds the main top flap closed and which includes within the aforementioned tuck tab a oneway lock detail which, when pushed into the slot region of the main body (akin to a button or small lever), latches into and/or behind the top edge of the aforementioned slot detail and/or pushes another tab behind it to also latch underneath and/or behind the top edge of the slot which prevents the one-way lock detail, the long tab and the top flap from being removed from the slot, or being opened or tampered with. The addition of a label with a permanent adhesive applied over the said lock detail further adds to the security of the lock and latch feature. A sharps bin or other type of container according to any preceding clauses made with two or more layers of solidboard which is made with cardboard. A sharps bin or other type of container according to any preceding clauses made with two or more layers of solidboard which is made from or partly containing materials including cardboard, fiberboard, bio-plastics, PLA, com starch, bamboo, coconut, flax, hemp, wool, straw or fully or partly recycled oil-based plastics. A sharps bin according to any preceding clauses which has base flaps or top flaps or both which are sealed together during the factory manufacturing process to make them waterproof by means of glue or compression or heat or sonic joining or a combination of the aforementioned processes and are foldable into a flat-pack format but which can be folded out into a three dimensional carton form. A sharps bin according to any preceding clauses which includes a set of labels stuck to the outer carton which can be applied later by the end user during assembly and for final closure. A sharps bin according to any preceding clauses which is coated in a waterproof film on part of or across the entire surface. A sharps bin according to any preceding clauses which has the outer surface printed. 18. A sharps bin according to any preceding clauses which has at least one waterproof lamination or coating added.

19. A sharps bin according to any preceding clauses which has an accompanying wall bracket to enable it to be fixed it to a wall.

20. A sharps bin according to any preceding clauses with a mechanical part such as an injection moulded screw cap, flip-top opening, slider opening or a sharps removal device which is fixed in a waterproof manner to the solidboard.

According to an aspect, there is provided a method of using the apparatus, such as the sharps bin or portion/s thereof, according to an aspect, claim, embodiment or example of this disclosure.

According to an aspect, there is provided a method of manufacturing and/or assembling the apparatus, such as the sharps bin or portion/s thereof, according to an aspect, claim, embodiment or example of this disclosure.

The steps of the methods described herein may be in any order.

According to an aspect of, there is provided an apparatus configured to perform a method according to an aspect, claim, embodiment or example of this disclosure.

Within the scope of this disclosure it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

Preferred embodiments of the invention will now be described with reference to the accompanying drawings whereby the described parts are numbered thus:

1 Outer carton

2 Inner carton

3 Bag

4 Main flap of the outer carton

5 Aperture door

6 Temporary closure door

7 Aperture

8 Tuck flap

9 Locking button/lever

10 Latch

11 Slot

12 Security label

13 Final closure label

14 Temporary closure door tongue

15 Crash lock flaps

16 Inner pad

17 Rectangle to triangle folding walls

18 Triangular walls (some with more or less material)

19 Pyramidal form

20 Ridge top form

21 Permanent fixing/glue tabs and in which the drawings demonstrate the following elements and features whereby: FIGURE 1 shows the outer carton 1 and the inner carton 2 as flat sheets of solidboard material after profile cutting, punching and creasing.

FIGURE 2 shows the outer carton 1 and the inner carton 2 after folding and gluing into loop formats and flattened, the bag 3, and the optional inner pad 16, as separate parts ready for subassembly.

FIGURE 3 shows a front view of the subassembly of the main parts (the outer carton 1 , the inner carton 2 and the bag 3) and the optional inner pad 16 in flatpack mode.

FIGURE 4 shows the product in 3D carton mode whereby the base flaps 15 will have flattened automatically to close the base and the top flaps, 4, 17 and 18, and the upper folding walls are still in the open positions.

FIGURE 5 shows the first action of closing up the top triangular flaps 18, and the upper folding walls 17, whereby the aperture door 5 is firstly opened to the front ready for use and the rectangle to triangle folding wall sides 17 of the rim of part 1 are pushed inwards to start to transform the top section into a pyramidal form 19.

FIGURE 6 shows the pyramidal form 19 completed and the main flap 4 of the outer carton folded over the top to create a ridge 20, the tuck flap 8 tucked into the slot 11 on the front and the lock button/tab 9 pushed inwards to activate the latch 10 which locks the sharps bin top flap 4 and tuck flap 8 and thus prevents the top from being opened or tampered with.

FIGURE 7 shows a label stuck over the lock button/lever 9 to further enhance the security and prevent the main flap 4 from being opened. FIGURE 8 shows the present invention ready for use with the aperture door 5 folded down, the aperture 7 open and the temporary closure door 6 also open.

FIGURE 9 shows the temporary closure door 6 closed and held in place by the temporary closure door tongue or tab 14 which is tucked inside the top edge of the aperture 7.

FIGURE 10 shows the temporary closure door 6 open and the aperture door 5 closed.

FIGURE 11 shows the temporary closure door 6 closed.

FIGURE 12 shows the final closure label 13 covering the temporary closure door 6.

FIGURE 13 shows a general simplified section through the product.

FIGURE 14 shows front, side, plan and underside views of the partly assembled sharps bin with the security label 12 missing revealing various details as described.

FIGURE 15 shows front, side, plan, back and underside views of the fully assembled sharps bin with the security label 12 in place and a part section B-B.

FIGURE 16 shows a pack of ten of the subassembly flat-packs.

The following descriptions describe the associated illustrations in more detail:

FIGURE 1 shows the outer carton 1 and the inner carton 2 as flat sheets of solidboard material after profile cutting, punching and creasing (whereby punching and creasing are referred to forthwith as treating). They may also be printed and have other properties added such as waterproof layers. The outer carton 1 has four upper walls or panels; one wall is untreated with the main flap 4 attached to it, two walls have triangular creases 17 pressed into them and one has an aperture door 5 cut into it. The middle area has four walls or panels; three walls are untreated and one has the slot 11 and the locking button tab 9 cut into it.

The inner carton 2 has four generally triangular tabs 18 (one truncated tab and three tabs with small extra areas added to improve the folding, functioning and build strength of the product) at the top which, when the carton is folded into a cuboid shape, transform the generally triangular tabs into a pyramid shape 19 (with the truncated tab area remaining open) (see FIGURE 5).

On both parts, the outer carton 1 and the inner carton 2, the primary vertical fold lines 22 are used to flat-pack the parts and the sub-assembled product and the secondary vertical fold lines 23 are used in addition to lines 22, and also using all the other fold lines shown within the profile line, to transform the pieces from flatpack into a 3D carton form.

Both parts have tabs 21 down one side which are used to apply glue to convert each flat profile into separate entity loop formats (see FIGURE 2) using a carton or box forming machine.

Both the outer carton 1 and the inner carton 2 have crash-flap bases 15 which, when the flaps 15 are glued together in a particular way and folded up inside the flat-packed cartons, enable each carton to transform automatically from a flatpack format into a three dimensional cuboid carton format with minimal effort from the user; a single, lightweight compression on each side of the flat-pack will enable the mechanically automatic transformation of the flaps 15 to maneuver from a vertically flattened mode into a horizontally flat mode, which also locks the crash-flaps 15 into place in the base of the carton for a high level of ease of assembly. Furthermore, the crash-flap bases 15 of both the outer carton 1 and the inner carton 2 work in tandem when the parts are inserted inside eachother (see FIGURE 3) for extreme ease of assembly, with a final, double wall thickness subassembly being achieved by way of the two parts are inserted inside eachother.

FIGURE 2 shows the outer carton 1 and the inner carton 2 after folding the primary vertical fold lines 22 and gluing into loop formats and flattened whereby the crash-flaps 15 are now folded up inside the cartons out of view, the bag 3, and the optional inner pad 16, as separate parts ready for subassembly and in the series order ready for insertion into eachother to create the ready pack, or they can be left as separate items and assembled by the end customer. The main flap 4 can be folded away down the back of the outer carton 1 for space saving if required. All these parts will have been manufactured by a fully automated process so that the end customer has minimal assembly actions for a quick and easy assembly process.

FIGURE 3 shows a front view of the subassembly of the main parts (the outer carton 1 , the inner carton 2 and the bag 3) and the optional inner pad 16 (not visible due to being stored inside the inner carton 2) in flat-pack mode, ready for compact storage, transport and for quick and easy assembly by the end customer. The security label 12 and the final closure label 13 may be stuck to the rear of the outer carton (not visible) 1 in readiness to be used to seal the sharps bin as required. The large grey arrows indicate the areas to apply hand pressure on the creased vertical edges 22 to transform the flat-pack subassembly into a usable, 3D, carton form sharps bin. This fully integrated subassembly means the end customer has minimal further actions to complete the build of sharps bin, offering an attractive, quick and easy assembly process.

FIGURE 4 shows a perspective view of the product transformed from the two dimensional flat-pack into in a three dimensional, cuboid shaped, open carton mode which is achieved using a quick and easy ‘pop-up’ type action by pushing on the side edges, (as shown in FIGURE 3), to open up the form and then pushing both the inner carton 2 and the bag 3 down inside the outer carton 1 , whereby the crash-lock base flaps 15 (not visible in this view) of both the inner carton 2 and the outer carton 1 automatically flatten to close up the base and the top flaps 18, 17 (and adjacent top flaps) remain in the open positions. A uniqueness of the present invention is that the open topped, cuboid carton form is created simply by applying hand pressure on the two, creased corner edges 22, making the product quick and easy assemble with the double wall thickness and the waterproof bag already in place.

FIGURE 5 shows the next step in the assembly process whereby the aperture door 5 is opened to the front, preparing it ready for use, and the Tectangle-to- triangle folding walls’ 17 each side of the top of the outer carton 1 are pushed inwards to transform the top section into a part pyramidal form and part ridge top form. The triangular flaps 18 of the inner carton 2 also automatically fold into the pyramid shape on the inside, automatically creating a double wall thickness throughout the product.

FIGURE 6 shows the pyramidal form 19 completed and the main flap 4 of the outer carton 1 folded over the top of the pyramid to create a ridge shape 20. The tuck flap 8 is then tucked into the slot 11 on the front and the lock button tab 9 pushed inwards to activate the latch 10 which locks the sharps bin top flap 4 and prevents it from being opened or tampered with.

FIGURE 7 shows the security label 12 stuck over the lock button tab 9 to further enhance the security and prevent the main flap 4 from being opened. In at least some examples (not shown), the security label 12 extends upwardly to cover the crease for the temporary closure door 6. Accordingly, the hinge for opening the temporary closure door 6 can be reinforced by the security label 12. It will be appreciated that a width of the security label 12 can be adapted to be equal to or less than a width of the hinge (e.g. equal to or less than a width of the temporary closure door 6). The width of the label 12 may be equal to or less than the width of the hinge at least at the portion of the label corresponding to the hinge. In at least some examples the width of the entire label may be equal to or less than the hinge. For example, the security label 12 may be applied in a portrait orientation rather than the landscape orientation shown in Figure 7, with the label functioning both as a security label 12 over the lock button tab 9 and a hinge for the temporary closure door 6.

FIGURE 8 (READY FOR USE) shows the aperture door 5 folded down with the aperture 7 open (ready to accept sharp medical items), and the temporary closure door 6 also open making the sharps bin ready for use.

FIGURE 9 (TEMPORARY CLOSURE MODE) shows the temporary closure door 6 closed and held in place by the temporary closure door tongue/tab 14 which is tucked inside the top edge of the aperture 7; the resistance against the pair of side tabs each side of the tongue/tab 14 holds the temporary closure door 6 place until it is desired to be opened for use again.

FIGURE 10 shows the temporary closure door 6 open and the aperture door 5 closed in preparation for final closure at the end of life of the product, e.g. when the sharps bin is full or passed its expiry date.

FIGURE 11 shows the temporary closure door 6 closed, and the aperture door 5 closed underneath, it as described in FIGURE 10, ready for final sealing and disposal of the product.

FIGURE 12 shows the final closure label 13 covering the temporary closure door 6 which permanently seals the product making it ready for disposal and incineration. FIGURE 13 shows a simplified section through the product to illustrate the way two or more wall thicknesses are achieved throughout the product by all the parts, 1 , 2 and 3, working together on all walls of the pyramidal area and the cuboid area to create a strong wall thickness design as required to resist the penetration of a hypodermic needle according to test ISO 23907-1 :2019.

FIGURE 14 shows front, side, plan and underside views of the partly assembled sharps bin with the security label 12 missing revealing the locking tab 9, the top part of the tuck flap 8 and the slot 11 , the aperture door 5 and the temporary closure door 6 in horizontal positions (although these two doors are preferably bent further downwards for more clearance for ease of use) and the glued but automatically foldable crash-lock flaps 15 on the base.

FIGURE 15 shows front, side, plan, back and underside views of the fully assembled sharps bin with the security label 12 added (also shown on the back with the final closure label 13 as an example of positioning of the labels on the product before use during storage and transport) and the temporary closure door 6 closed. Also shown is a part section B-B showing the innovative double wall thickness feature of the pyramid area 19 which sits underneath the ridge area 20 whereby the pyramid area 19 is automatically created by the folding inwards of the ‘rectangle to triangle’ side walls 17 and the subsequent folding inwards of the triangular flaps 18.

FIGURE 16 shows a pack of ten of the subassembly flat-packs of the present invention sharps bins demonstrating the relative lack of air or gaps and the very compact nature of the bulk pack which offers optimal convenience and commercial efficiencies for storage, handling and transport costs which can be passed on to benefit the health authorities and medical professionals purchasing the sharps bins. It will be appreciated that at least one of the cartons 1 , 2 may comprise hardsized solidboard. For example, the inner carton 2 may comprise hard-sized solidboard such that the inner carton 2 has an increased resistance to water absorption (e.g. compared to un-sized solid board and/or compared to the outer carton 1).

When assembled, the sharps bin may provide a waterproof or watertight container. The sharps bin may be waterproof, containing liquid therein under gravity. The sharps bin may be waterproof when upright in its three-dimensional form. The sharps bin may be configured to contain luiquid. The sharps bin may be configured to contain liquid whilst moving, such as being transported (e.g. manually carried and/or in or on a vehicle). In at least some embodiments, when the sharps bin is closed, particularly with a label/s positioned over an aperture/s, such as a door, the sharps bin may additionally be waterproof when tilted or even inverted. The three-dimensional sharps bin may be configured to be substantially watertight when turned or stored upside down.

Although not visible, it will also be appreciated that an insert may be provided, for insertion as an inner or innermost component at the bottom of the popped-out three-dimensional sharps bin. The insert may comprise a bottom insert for covering or at least partially covering the interior or inner bottom of the sharps bin. The insert may comprise an absorbent insert, such as a sheet of fibrous or non-fibrous absorbent. The insert may comprise a planar insert, for packaging flat-packed with the flat-packed, two-dimensional cartons. The insert may be inserted into the sharps bin after the sharps bin has been transformed into three- dimensional form. The insert may comprise a tray. The insert may comprise a flat bottom with side walls that can be folded upwards. The insert may comprise a “+” shape, when flattened in a two-dimensional form, for transport or storage. The insert may comprise a flat net with a central square or rectangle, corresponding to an inner or innermost shape or are of the interior of the three-dimensional, assembled sharps bin. The central square or rectangle may be formed with rectangles attached at each edge of the square or rectangle. The insert may be creased along the edges of the central square or rectangle. The insert may comprise a flat The side walls may be absorbent. The side walls may be configured to absorb moisture by wicking or capillary action. The provision of the side walls may provide for an increased volume and/or absorption capacity of the insert. The provision of the side walls may provide for an increased volume and/or absorption capacity of the insert without increasing a thickness of the insert when packaged, such as flat-packed for transport or storage. In at least some examples, a plurality of inserts are provided. Providing a plurality of inserts can provide for an increased absorption volume or capacity without increasing a total thickness of the flat-packed assembly. The insert may be for insertion within the bag 3. Accordingly, the insert may be configured to absorb liquid or moisture within the bag, such as deposited with sharps placed in the sharps bin.

It will be appreciated that the relative proportions of the sharps bins shown are shown to scale with the relative proportions of the cartons, flaps, etc. in all directions (e.g. x, y and z). 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 any foregoing embodiments. 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. The claims should not be construed to cover merely the foregoing embodiments, but also any embodiments which fall within the scope of the claims, including with equivalence.

Claims

1 . A sharps bin made with two or more pieces of solidboard whereby the said pieces are supplied as flat-packed, carton type constructions, which, when pressure is applied to the side edges of the two or more pieces, transform them from flat-pack forms into three dimensional, carton type forms in a pop-up style; and are designed so that at least one piece fits snugly inside another piece when assembled and furthermore has an array of well-fitting flaps on the top and bottom which, when folded into their designated positions, create a resultant, closed, carton type assembly whereby all the walls are touching or very close together with at least double wall thickness on all the walls offering the required combined wall thickness strength to withstand the penetration of a hypodermic needle.

2. The sharps bin of claim 1 , wherein the two or more pieces of solidboard are supplied as flat-packed, carton type constructions, pre-packed inside each other.

3. The sharps bin of claim 1 or 2, with at least one part of the two or more pieces of solidboard being a construction of a flat sheet of die cut solidboard which is glued or fixed together along a side edge to create a loop type format which, when flattened, is the two dimensional, flat-packed carton type construction for compact storage but which has crash-lock type flaps on the base which, when the two dimensional flat-pack form is pushed together with side force on the edges, automatically transforms in a pop-up style into a three dimensional carton form.

4. The sharps bin according to any preceding claim, which has a construction technique which includes a set of flaps, preferably on the top, which includes a pair of rectangular shaped side flaps with triangular creases applied into them which, when pushed with a side force, fold inwards to transform into a triangular form and which, when the back and front flaps are folded over the aforementioned side flaps, creates a three dimensional pyramidal form covered with a partly folded over ridge form which has the benefit of being naturally sealed and waterproof due to the long folds of the creased material that creates the pyramidal and ridge type forms being continuous pieces of waterproof material. The sharps bin according to any preceding claim, which has a form which is a generally tall cuboid form with a pitched ridge top shaped form on top which furthermore has a pyramidal form within the top ridged area. The sharps bin according to any preceding claim, whereby the two or more pieces of solidboard working together create two or more layers of the said material when put together over all sides of the sharps bin. The sharps bin according to claim 6, whereby additional materials or items are provided between the said layers, to add to or enhance the performance of the layered materials. The sharps bin according to claim 7, wherein the two or more pieces of solidboard define a respective inner layer and an outer layer; and the additional materials or items comprise a plastic bag as a middle layer between the inner layer and the outer layer, adding to or enhancing the waterproofing performance, with the inner layer protecting the middle layer from puncturing. The sharps bin according to claim 8, wherein the inner layer is an inner carton and the outer layer is an outer carton; and the inner carton is slightly smaller than the outer carton and is positioned as an insert inside the outer carton, with the plastic bag between the two cartons so that the bag is sandwiched between the two layers of solidboard, acting as a waterproof layer that is protected from being pierced by sharps by the inner layer of solidboard. The sharps bin according to claim 9, wherein the inner and outer cartons are supplied flat-packed, pre-packed inside each other, with the bag sandwiched therebetween. The sharps bin of any preceding claim, wherein the at least double wall thickness on all the walls provides the required combined wall thickness strength to withstand the penetration of a hypodermic needle according to the test outlined in ISO 23907-1 :2019. The sharps bin of claim 11 , wherein two or more pieces of solidboard comprise two separate layers of solidboard which are assembled in close proximity to each other to create the double wall thickness which gives the combined walls the thickness and strength to pass the hypodermic needle penetration test and yet also allow the walls to have creases put into them to enable them to fold readily for easy assemble with low bending stresses. The sharps bin of claim 12, wherein the two separate layers each comprise a lower bending stress than a single layer of an equivalent thickness as the combined thickness of the two separate layers. The sharps bin of any preceding claim, wherein each piece of the at least two pieces of solidboard comprises a wall thickness of between 1 ,5mm and 4.0 mm. The sharps bin of any preceding claim, wherein each piece of the at least two pieces of solidboard comprises a weight of between 350-1350 grams per metre squared. The sharps bin according to any preceding claim, wherein the sharps bin includes a temporary closure door comprising of a long, foldable tab which includes a dedicated integrated tab detail, such as a finger type tab made with two slots, which allows the door to be partially tucked in another slot or aperture to temporarily close the door and hold it in its place until required to be opened again. The sharps bin according to any preceding claim, wherein the sharps bin includes a construction technique which includes a tuck tab integrated into a main top flap which when tucked into a slot on the main body holds the main top flap closed and which includes within the aforementioned tuck tab a one-way lock detail which, when pushed into the slot region of the main body, latches into and/or behind the top edge of the aforementioned slot detail and/or pushes another tab behind it to also latch underneath and/or behind the top edge of the slot which prevents the one-way lock detail, the long tab and the top flap from being removed from the slot, or being opened or tampered with. The sharps bin according to claim 17, wherein a label with a permanent adhesive is applied over the said lock detail, further adding to the security of the lock and latch feature. The sharps bin according to any preceding claims made with two or more layers of solidboard which is made with at least one of the layers of solidboard comprising a hard-sized solidboard. The sharps bin according to any preceding claims made with two or more layers of solidboard which is made from or partly containing materials including cardboard, fiberboard, bio-plastics, PLA, com starch, bamboo, coconut, flax, hemp, wool, straw or fully or partly recycled oil-based plastics. The sharps bin according to any preceding claim, wherein the sharps bin has base flaps or top flaps or both which are sealed together during the factory manufacturing process to make them waterproof by means of glue or compression or heat or sonic joining or a combination of the aforementioned processes and are foldable into a flat-pack format but which can be folded out into a three dimensional carton form. The sharps bin according to any preceding claim, wherein the sharps bin includes a set of labels stuck to the solidboard piece defining the outer carton which can be applied later by the end user during assembly and for final closure. The sharps bin according to any preceding claim, wherein the sharps bin is coated in a waterproof film on part of or across the entire surface. The sharps bin according to any preceding claim, wherein the sharps bin has at least one waterproof lamination or coating added. The sharps bin according to any preceding claim, wherein the sharps bin has a wall bracket to enable it to be fixed it to a wall. A method of assembling a sharps bin, the method comprising: supplying two or more pieces of solidboard as flat-packed, carton type constructions; applying pressure to the side edges of the two or more pieces, thereby transforming them from flat-pack forms into three dimensional, carton type forms in a pop-up style; wherein one or more piece fits snugly inside the other piece when assembled; and folding an array of well-fitting flaps on the top and bottom into designated positions, thereby creating a resultant, closed, carton type assembly whereby all the walls are touching or very close together with at least double wall thickness on all the walls offering the required combined wall thickness strength to withstand the penetration of a hypodermic needle. The method of claim 27, wherein the two or more pieces of solidboard are supplied as flat-packed, carton type constructions, pre-packed inside each other. The method of claim 26 or 27, wherein the method comprises: die-cutting with at least one of the pieces of solidboard being a construction of a flat sheet of die cut solidboard; gluing or fixing together along a side edge of the flat sheet of die cut solidboard to create a loop type format; flattening the loop type format into a two dimensional, flat-pack carton construction for compact storage; and automatically transforming the two dimensional, flat-pack carton construction in a pop-up style into the three dimensional carton form, using crash-lock type flaps on its base, by pushing the two dimensional flat-pack form together with the side force on the edges. The method of any of claims 26 to 28, wherein the method comprises: sealing base flaps or top flaps or both together during the factory manufacturing process to make them waterproof by means of glue or compression or heat or sonic joining or a combination of the aforementioned processes; folding the flaps into a flat-pack format; and folding the flaps out from the flat-pack format the into the three dimensional carton form.