Abstract:
An improved lockable container, which is configured to resist being pried open or being otherwise successfully attacked within predetermined time and tool set limits. Also, methods for manufacturing and/or assembling embodiments of the lockable container.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    Not Applicable 
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not Applicable 
       NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT 
       [0003]    Not Applicable 
       REFERENCE TO A SEQUENCE LISTING, A TABLE, OR COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON COMPACT DISC 
       [0004]    Not Applicable 
       BACKGROUND OF THE INVENTION 
       [0005]    1. Field of the Invention 
         [0006]    The field of the invention relates to key control generally, and more particularly to certain new and useful advances in lockable containers and the manufacture thereof, of which the following is a specification, reference being had to the drawings accompanying and forming a part of the same. 
         [0007]    2. Description of Related Art 
         [0008]    Sundry types of lockable containers, such as lockboxes of the pushbutton and electronic type are known, but many lockboxes, particularly those configured for use in the private residential and assisted living markets, cannot successfully resist or thwart physical assaults, with one or more kinds of tools, such as hammers, screwdrivers, pliers and the like, for durations of a minute or longer. 
       BRIEF SUMMARY OF THE INVENTION 
       [0009]    Disclosed and/or claimed herein is an improved lockable container, which is configured to resist being pried open or otherwise being successfully attacked within predetermined time and tool set limits, such as those defined by the Loss Prevention Certification Board&#39;s (LPCB&#39;s) Loss Prevention Standard (LPS) 1175 Level 1, which is promulgated and maintained by BRE Global Limited of Watford, United Kingdom, or other attack-resistance standards. Methods for manufacturing and/or assembling embodiments of the improved lockable container are also disclosed. Other features and advantages of the improved lockable container will become apparent by reference to the following description taken in connection with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0010]    Reference is now made briefly to the accompanying drawings, in which: 
           [0011]      FIG. 1  is a right-side perspective view an embodiment of a lockable container in an open position; 
           [0012]      FIGS. 2 ,  3  and  5  are each a top perspective view of an interior of a second housing of the lockable container of  FIG. 1 ; 
           [0013]      FIG. 4  is a top perspective view of an interior of a first housing of the lockable container of  FIG. 1 ; 
           [0014]      FIG. 6  is a perspective view of the lockable container of  FIG. 1  in a closed position; 
           [0015]      FIG. 7  is a left-side perspective view of the lockable container of  FIG. 1  in the open position; 
           [0016]      FIG. 8  is a bottom perspective view of an exterior of an embodiment of the lockable container of  FIG. 1  illustrating a failed attempt to break into the lockable container; 
           [0017]      FIG. 9  is a top perspective view of an exterior of an embodiment of the lockable container of  FIG. 1  illustrating another failed attempt to break into the lockable container; 
           [0018]      FIGS. 10A and 10B  are a flowchart illustrating an embodiment of a method of manufacturing an embodiment of the lockable container of  FIG. 1 ; and 
           [0019]      FIG. 11  is another flowchart illustrating an embodiment of a method of assembling an embodiment of the lockable container of  FIG. 1 . 
       
    
    
       [0020]    Like reference characters designate identical or corresponding components and units throughout the several views, which are not to scale unless otherwise indicated. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0021]    As used herein, an element or function recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding plural said elements or functions, unless such exclusion is explicitly recited. Furthermore, references to “one embodiment” of the claimed invention should not be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. 
       Improved Lockable Container 
       [0022]      FIG. 1  is a right-side perspective view of an embodiment of a lockable container  100  in an open position.  FIGS. 2 ,  3  and  5  are each a top perspective view of an interior of a second (or front) housing  104  of the lockable container  100 .  FIG. 4  is a top perspective view of an interior of a first (or back) housing  102  of the lockable container  100 .  FIG. 6  is a perspective view of the lockable container  100  in a closed position.  FIG. 7  is a left-side perspective view of the lockable container  100  in the open position. 
         [0023]    Referring to  FIGS. 1 ,  2 ,  3 ,  4 ,  5 ,  6 , and  7 , an embodiment of the lockable container  100  has at least one housing  102 ,  104  comprising a sacrificial material, e.g. a material that breaks away, deforms and/or deflects during physical attempts to pry open or otherwise break into the lockable container  100 . In one embodiment, the sacrificial material comprises cast zinc. The at least one housing  102 ,  104  may comprise a first (back) housing  102 , which is configured to be attached to a support surface  146 , such as an exterior wall of a building, with one or more permanent or removable first fasteners  118 . In one embodiment, the one or more first fasteners  118  are removable threaded hex-bolts, for example of size ¼-20×2½″. In another embodiment, the one or more first fasteners  118  are permanent anchors. In either case, the one or more first fasteners  118  are configured to adhere to masonry, concrete, metal, wood, and the like, and pass through openings in both the liner  108  and the second housing  102  before entering the support surface  146 . The length, diameter and/or number of the one or more fasteners  118  will vary depending on the type of support surface  146 . 
         [0024]    The first housing  100  has a first (top) end  180  and a second (bottom) end  184 , and a base coupled with a first sidewall  132 , which is coupled with a second sidewall  134 . The second sidewall  134  is angled relative to the first sidewall  132  and is further coupled with a first interior wall  136 , which is inset within a perimeter of the first sidewall  132 . A portion of the first interior wall  136  is also angled, but in a direction reversed from an angled portion of a second interior wall  138  of the second housing  104 . 
         [0025]    The first housing  102  has a cast outer body comprising the sacrificial material and is configured to retain the liner  108 , which comprises one of a metal, a metal alloy and/or other type(s) of attack-resistant material(s). As shown in  FIG. 9 , the cast body may be double-walled. In one embodiment, the liner  108  comprises stainless steel. The liner  108  comprises a base  122  coupled with sidewalls  120 , and  124 . One function of the liner  108  is to provide a tough material under the heads of the one or more first fasteners  118  to keep them from tearing through the sacrificial housing material during a pry attack carried out against the lockable container  100  while it is coupled with or attached to the support surface  146 . 
         [0026]    Optionally, the liner  108  may further comprise a first latch sheer plate  154  coupled with the base  122 , as shown in  FIG. 4 . In another embodiment, the first latch sheer plate  154  may be coupled with one or both of the liner sidewalls  120  and  124 . The first latch sheer plate  154  comprises a latch opening  156 , which is positioned to correspond to a latch recess  158  formed in an interior portion of the first housing&#39;s sidewall  132  at the first end  180  of the first housing  102 . A portion of the first latch sheer plate  154  may be positioned to engage a reinforcement member  160  formed as part of first housing  102  at the first end  180  thereof. The reinforcement member  160 , which may comprise cast zinc, is configured to strengthen and stabilize the first latch sheer plate  154  and/or a second latch sheer plate  116  that is coupled with the second housing  104 . 
         [0027]    Referring to  FIGS. 1 and 4 , each of the liner sidewalls  120  and  124  protrudes a predetermined distance  164  above a surface of a first interior wall  136  ( FIG. 1 ) to block a tool inserted between the first housing  102  and the second housing  104  from penetrating into the interior of the lockable container  100  and/or from gaining leverage that could be used to break open the lockable container  100 . The portions of the liner sidewalls  120  and  124  that protrude from the first housing  102  are configured to engage the second housing  104  to strengthen the lockable container  100  against pry and hammer attacks. In other words, one or more portions of the liner  108  overlap a gap  187  that forms between the first housing  102  and the second housing  104  when the lockable container  100  is in the closed position. 
         [0028]    In one embodiment, one or more first hinge portions  128  are formed at the second (bottom) end  184  of the first housing  102 , and one or more second hinge portions  130  are formed at the second (bottom) end  178  of the second housing  104 . A cylindrical hinge fastener  138  joins the first hinge portion(s)  128  and the second hinge portion(s)  130 . Together, the hinge fastener(s)  138 , the first hinge portion(s)  128  and the second hinge portion(s)  130  form a hinge  106 . The hinge fastener(s)  138  comprise a metal, such as, but not limited to, stainless steel. In one embodiment, there are two hinge pins  138  that bottom out in holes formed in the second hinge portion  130  of the second housing  104 , so the hinge pins cannot be driven out. 
         [0029]    A frame  110  having one or more engagement portions  185  is positioned in an interior of and coupled with the second housing  104 . As further explained below, the one or more engagement portions  185  are configured to engage one or more tabbed portions  139  of the first anti-tamper plate  148 . One or more second fasteners  140  may be used to couple the frame  110  with the second housing  104 . As shown in  FIGS. 1 and 2 , the frame  110  may fit within the perimeter of a second interior wall  141  formed on a mating surface of the second housing  104 . As shown in  FIG. 2 , the second interior wall  141  is angled on the side closest to an exterior of the lockable container  100  to deter and/or defeat pry and/or hammer attacks. More particularly, a portion of the second interior wall  141  is reverse-angled relative to an angled portion of the first interior wall  136  of the first housing  102 . When the second housing  104  is in the closed position (as shown in  FIG. 6 ), the second interior wall  141  overlaps the portions of the liner sidewalls  120  and  124  that protrude from the first housing  102 . This overlap not only increases the strength of the lockable container  100 , but also makes it difficult for a pry tool to slip between the mating surfaces of the first housing  102  and the second housing  104  and gain leverage against either of the liner  108 &#39;s sidewalls  120 ,  124 . The second interior wall  141  and the first interior wall  136  may each comprise the sacrificial material that comprises the remainder of the second housing  104  and the first housing  102 , respectively. 
         [0030]    The first end  180  of the first housing  102  comprises a recess  158  configured to receive a latch  114 , which protrudes from a latch housing  112  that is positioned within an interior of and coupled with the second housing  104 . In one embodiment, as shown in  FIG. 3 , the latch  114  is multi-sided, having a base  115  coupled with two sidewalls  113 . This multi-sided configuration increases the sheer strength of the latch  114 . An advantage of the multi-sided latch  114  is that it comprises a thinner and/or lesser expensive piece of material than might normally be required to resist a pry attack, but which is configured as shown and described herein to provide increased bend (e.g., sheer) resistance. 
         [0031]    The latch housing  112  and a second latch sheer plate  116 , having a latch opening  117  therein, are each positioned within an interior portion and coupled with the second housing  104  and/or with the frame  110  via third fasteners  142 . In one embodiment, the second latch sheer plate  116  has first and second members that are substantially orthogonal to each other. The first member of the second sheer plate  116  contains the latch opening  116 . The second member of the second sheer plate  116  is positioned beneath the latch housing  112  and may contain one or more openings through which the one or more third fasteners  142  pass to couple the second sheer plate  116  and the latch housing with the frame  110  and/or the second housing  104 . 
         [0032]    The first latch sheer plate  154  and the second latch sheer plate  116  are configured to overlap when the second housing  104  is in the closed position. When the first latch sheer plate  154  and the second latch sheer plate  116  are overlapped, the latch  114  protrudes through the latch openings  116  and  156  and into the latch recess  158 . Use of the first latch sheer plate  154  and the second latch sheer plate  156  adds strength to the lockable container  100  and reduces play and give in the latch. Each of the first latch sheer plate  154  and the second latch sheer plate  116  comprises a metal such as, but not limited to, stainless steel. 
         [0033]    The latch  114  is coupled with an actuator  176 , which may protrude through the body or sidewall of the second housing  140  and/or the first housing  102 . The actuator  176  is configured to move the latch  114  from the latch recess  158  and the latch opening  156  after the lock  144  is unlocked. As used herein, the phrase “move the latch” means to release and/or retract the latch. 
         [0034]    The lock  144  is coupled with the latch  114  and is configured to configured to retain the latch  114  in a fixed position, protruding through the latch opening  117  formed in the second latch sheer plate  116 , through the latch opening  156  formed in the first latch sheer plate  154  and into the latch recess  158  when the second housing  104  is in the closed position (shown in  FIG. 6 ), until an authorized key and/or access code is provided to unlock the lock  144 . In the exemplary embodiment shown in the figures, the lock  144  is a pushbutton lock. However, lock  144  is not limited to pushbutton locks, and may be any type of mechanical, electrical or electro-mechanical locking apparatus. 
         [0035]    Referring to  FIGS. 2 and 5 , a first anti-tamper plate  148  is positioned within an interior portion of and coupled with the second housing  104  and/or the frame  110 . For example, in one embodiment, a fourth fastener  150  protrudes through an opening in the first anti-tamper plate  148  and into an opening  166  in the frame  110 . As shown in  FIG. 2 , one or more tabbed portions  139  of the first anti-tamper plate  148  are overlapped and secured by corresponding one or more portions of the latch housing  112 . Additionally, or alternatively, the one or more tabbed portions  139  of the first anti-tamper plate  148  may contain openings through which the second fasteners  140  pass. In one embodiment, the first anti-tamper plate  148  is configured to prevent elements of the lock  144  from being punched inward and broken. 
         [0036]    Referring to  FIG. 6 , a second anti-tamper plate  168  is positioned on an exterior portion of and coupled with the second housing  104 . The second anti-tamper plate  168  may be positioned within a recess  174  formed in the exterior body of the second housing  104 . One or more fifth fasteners  172  may pass through one or more corresponding openings in the second anti-tamper plate  172  and into the body of the second housing  104 . In one embodiment, the one or more fifth fasteners  172  are rivets. The second anti-tamper plate  168  may have an opening  171  formed therein to allow a button  170  to protrude therethrough. In one embodiment, the button  170  is movable between a first position that does not clear any code entered on lock  144  and a second position that clears any code entered on lock  144 . 
         [0037]    Turning now to  FIG. 7 , a storage tray  186 , configured to store an object, may be coupled with the liner  108 . The object stored by the tray  186  may be a key, a card key, a smart card, or any other type of useful object. The storage tray  186  is configured to move between a first closed position (shown in  FIG. 6 ), in which it is within an interior of the liner  108 , and second open position (not shown), in which it parallels the second housing  104  and protrudes from the liner  108 . The storage tray  186  may be coupled with the liner  108  by a hinge or fastener  188 . In  FIG. 7 , this hinge or fastener  188  is located at an end of the storage tray  186 . 
         [0038]    Referring back briefly to  FIG. 3 , an embodiment of the lockable container  100  may comprise an alarm sensor  152  configured to output a signal when an unauthorized attempt is made (i) to open the lockable container  100  and/or (ii) to remove the lockable container  100  from the support surface  146 . The alarm sensor  152  may also be configured to output a signal when the lockable container  100  is actually opened and/or when the lockable container  100  is actually removed from the support surface  146 . In one embodiment, the alarm sensor  152  comprises a donut-shaped magnet positioned in a recess formed in the latch housing  112 . In one embodiment, the alarm sensor  152  may be a magnetic sensor such as sensor model R1075 manufactured by the General Electric Company. An active part of the alarm sensor  152  is located in, on, or behind the support surface  146 , in an area thereof proximate the first housing  102  that is within activation range of the magnet and/or the magnet&#39;s magnetic field only when the second housing  104  is closed and the first housing  102  is properly positioned on, and/or coupled with or attached to, the support surface  146 . In one embodiment, a single alarm sensor is used to detect both an opening of the lockable container  100  and removal of the lockable container  100  from the support surface  146 . 
       Prototypes and Test Results 
       [0039]      FIG. 8  is a bottom perspective view of an exterior of an embodiment of the lockable container  100  illustrating a failed attempt to break into the lockable container.  FIG. 9  is a top perspective view of an exterior of an embodiment of the lockable container  100  illustrating another failed attempt to break into the lockable container. 
         [0040]    A prototype of the lockable container  100  described herein was built and tested for attack resistance against tools ranging from a small screwdriver to a sledgehammer and to a crowbar approximately 0.77 m long. Results are shown in  FIGS. 8 and 9 , and it is believed that the prototype passed at least Loss Prevention Certification Board&#39;s (LPCB&#39;s) Loss Prevention Standard (LPS) 1175 Level 1, promulgated and maintained by BRE Global Limited of Watford, United Kingdom. 
         [0041]    As shown in  FIG. 8 , the attacked area  190 , at the junction of the second (bottom) end  178  of the second housing  104  and the second (bottom) end  184  of the first housing  102 , reveals that the cast sacrificial material merely deformed and/or chipped away, thus preventing the lockable container  100  from being pried open. 
         [0042]    As shown in  FIG. 9 , the attacked areas  192  and  194 , at the junction of the first (top) end  182  of the second housing  104  and the first (top) end  180  of the first housing  102 , reveals that the cast sacrificial material again merely deformed in attack area  194  and chipped away in attack area  192 , thus preventing the lockable container  100  from being pried open. In this figure, an inner wall of the first housing  102 , not the liner  108 , can be seen through the attack area  192 . 
         [0043]    The physical properties of the cast sacrificial material and the configuration of the various elements of the lockable container  100  are such that it is very difficult to gain leverage when attempts are made to pry the lockable container  100  open. In fact, use of the 0.77 m crowbar only resulted in pulling the first fasteners  118  out of the support surface  146 . All attempts to breach the liner  108  with various screwdrivers, hammers and other pry tools were unsuccessful. 
       Exemplary Operation 
       [0044]    Referring again to  FIGS. 1 ,  2 ,  3 ,  4 ,  5 ,  6  and  7 , in use, a predetermined access code is provided to the lock  144  while the lockable container  100  is in the closed position shown in  FIG. 6 . The actuator  176  protruding from an exterior of the second housing  104  is then turned. If the access code is valid and was entered correctly, turning the actuator  176  causes the latch  114  to move to an unlocked position, allowing the second housing  104  to hinge open, as shown in  FIGS. 1 and 7 . If the access code was invalid or entered incorrectly, the actuator  176  will not turn or will turn without allowing the second housing  104  to hinge open. A tray  186 , coupled within an interior of the metal liner  108  is configured to store one or more types of predetermined objects, just as keys, card keys, smartcards, etc. In one embodiment, the tray  186  is configured to hinge open as the second housing  104  hinges open and to hinge shut as the second housing  104  hinges shut. Alternatively, the tray  186  is configured to be hinged open and/or closed by hand, independent of the opening or closing of the second housing  104 . 
         [0045]    Under pry attack the cast outer wall of either the second housing  104  or the first housing  102  gives way before enough leverage can cause the locking mechanism to fail. The inner liner  108  provides a last line of defense against physical attack. The cast housing delays the access to the inner liner  108 . Additionally, the reverse angled adjoining (e.g. mating) surfaces of the first interior wall  136  of the first housing  102  and of the second interior wall  141  of the second housing  104  make it difficult to insert a tool such as a screwdriver into the gap  187  because the tool handle hits the support surface  146  first before the longitudinal axis of the tool becomes parallel with the mating surfaces of the first housing  102  and the second housing  104 . In other words, the first housing  102  comprises an angled interior wall  136  and the second housing  104  comprises a reverse-angled interior wall  141 , which are configured to cause an longitudinal axis of an attack tool to intersect a support surface  146  when the first housing  102  and the second housing are in a closed position  104 , shown in  FIG. 6 . Even though second housing  104  is made of a sacrificial material, its thick walls make it resistant to penetration attack, while the thin leading edge of the first housing  104 &#39;s first interior wall  136  make it difficult to pry. 
       Methods 
       [0046]      FIGS. 10A and 10B  are a flowchart illustrating an embodiment of a method  1000  of manufacturing an embodiment of the lockable container  100  of  FIG. 1 . Unless otherwise noted, the elements  1002 ,  1004 ,  1006 ,  1008 ,  1010 ,  1012 ,  1014 ,  1016  and  1018  can be performed concurrently and/or in any suitable order. It is contemplated that a machine, such as a robot, can be configured to perform one or more of these elements. 
         [0047]    Referring to  FIGS. 1 ,  2 ,  3 ,  4 ,  5 ,  6 ,  7 ,  10 A and  10 B, the method  1000  comprises casting  1002  a sacrificial material to form a first housing  102  of a lockable container  100 . Components of the first housing  102  were described above. The method  1000  further comprises casting  1004  the sacrificial material to form a second housing  104  of the lockable container  100 . The second housing  104  and components thereof were described above. The method  1000  further comprises forming  1006  a liner  108  configured to be positioned within an interior of and coupled with the first housing  102 . The method  1000  further comprises forming  1008  a frame  110  configured to be positioned within an interior of and coupled with the second housing  104 . The method  1000  further comprises forming  1010  a latch housing  112  configured to be positioned within the interior of and coupled with the second housing  104 . The method  1000  further comprises forming  1012  a first sheer plate  154  configured to be positioned within the interior of and coupled with the first housing  102 . The method  1000  further comprises forming  1014  a second sheer plate  116  configured to be positioned within the interior of and coupled with the second housing  104 . The method  1000  further comprises forming  1016  a first anti-tamper plate  148  configured to be positioned within the interior of the second housing  104  and coupled with the frame  110 . The method  1000  optionally further comprises forming  1018  a second anti-tamper plate  168  configured to be positioned on an exterior of and coupled with the second housing  104 . 
         [0048]      FIG. 11  is another flowchart illustrating an embodiment of a method  1100  of assembling an embodiment of the lockable container  100  of  FIG. 1 . Unless otherwise noted, the elements  1102 ,  1104 ,  1106 ,  1108 ,  1110 ,  1112 ,  1114 ,  1116  and  1118  can be performed concurrently and/or in any suitable order. It is contemplated that a machine, such as a robot, can be configured to perform one or more of these elements. 
         [0049]    Referring to  FIGS. 1 ,  2 ,  3 ,  4 ,  5 ,  5 ,  7  and  11 , an embodiment of the method  1100  comprises positioning  1102  a liner  108  having a base  122  coupled with at least two sidewalls  120 ,  124  within an interior of a first housing  102  of a lockable container  100 , the first housing  102  cast of a sacrificial material comprising zinc. The method  1100  further comprises coupling  1104  a tray  186  with the liner  108 , the tray  186  configured to store an object, and the tray  186  being movable between a first closed position and a second open position. A fastener  188  may couple the tray  186  with the liner  108 . The method  1100  further comprises coupling  1106  a frame  110  with the second housing  104 , the frame  110  configured to be positioned within an interior of the second housing  104 . The method  1100  further comprises coupling  1108  a second latch sheer plate  116  with the second housing  104 , the second latch sheer plate  116  configured to be positioned within the interior of the second housing  104 . The method  1100  further comprises coupling  1110  a latch housing  112  comprising a latch  114  with the frame  110 . The method  1100  further comprises coupling  1112  a lock  144  with the latch  114  and with the second housing  104 . The method  1100  further comprises coupling  1114  an actuator  176  with the latch  114  so that movement of the actuator  176  causes the latch  114  to engage or disengage at least one of a recess  158  formed in a first end  180  of the first housing and a first latch sheer plate  154 . The method  1100  further comprises coupling  1116  a second anti-tamper plate  168  with the second housing  104 , the second anti-tamper plate  168  configured to be positioned on an exterior of the second housing  104  so as to protect the lock  144 . The method  1100  further comprises coupling  1118  the first housing  102  to the second housing  104 , wherein the second housing  104  is configured to move between a first closed position and a second open position. 
       Areas of Application 
       [0050]    Embodiments of the lockable container  100  described herein have application in various fields, particularly the home-health care market. Other fields include, but are not limited to: real-estate, homeowner use, property management, vacation rentals, lockable containers such as tool boxes, and the like. 
         [0051]    This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. 
         [0052]    Although specific features of the invention are shown in some drawings and not in others, this is for convenience only as each feature may be combined with any or all of the other features in accordance with the invention. The words “including”, “comprising”, “having”, and “with” as used herein are to be interpreted broadly and comprehensively and are not limited to any physical interconnection. Moreover, any embodiments disclosed in the subject application are not to be taken as the only possible embodiments. Other embodiments will occur to those skilled in the art and are within the scope of the following claims.