GB2570617A

GB2570617A - A collapsible container and method of manufacturing the same

Info

Publication number: GB2570617A
Application number: GB1703374.7A
Authority: GB
Inventors: Joanna Whitehead Katie
Original assignee: Proplas 2008 Ltd
Current assignee: Proplas 2008 Ltd
Priority date: 2017-03-17
Filing date: 2017-03-17
Publication date: 2019-08-07
Also published as: GB201703374D0

Abstract

The present invention provides for a collapsible molded container 1, comprising one or more walls (2, 2’), a base 18 and integral fold lines 14 which connect each wall to the base and any adjacent wall, and wherein the wall(s), base and fold lines are formed from a continuous molded piece of material. Preferably the folded lines are living hinges. A second invention is disclosed wherein the fold lines are required to be living hinges. The following a preferable features for both inventions; that the walls(s) comprise a further fold line or living hinge (8, 8’) ; these may divide the wall(s) into multiple sections, preferably into triangular sections; forming inverse ‘V-sections’ wherein the apex is located in the upper edge of the wall and extends to the corners of the base. The container may thus as a result fold between a substantially flat and expended positions. There may be locking members 12 to keep the container in the expanded condition. The application discloses a further invention for a mold to make the container of the first and/or second invention.

Description

It is known in the art to provide containers comprising side panels and a base which may be folded down into a flat configuration, for storage or transportation. These containers are predominantly manufactured from cardboard, wherein the folding method requires folding a blank and connecting at least one flap or tab to secure the blank in its final, folded configuration. These cardboard containers offer a lightweight container solution and the folding of said containers into a substantially flat configuration allows for relatively efficient storage. However, cardboard containers have a number of drawbacks such as a lack of structural integrity, poor performance in wet conditions and offering a low maximum carrying weight limit. The requirement to adhere or attach one or more flaps or tabs also increases cost and manufacturing complexity.

It is also known in the art for containers comprising side panels and a base to be manufactured from a plastics or polymer material, and these offer relatively superior performance in wet conditions, are relatively robust and allow for a greater maximum carry weight. Containers made from a plastics or polymer material may be manufactured by an injection moulding process. This process has the advantages of a relatively high production rate, low unit cost for high volume manufacturing and low wastage. However, the said plastics or polymer containers are manufactured in a fixed, non-collapsible configuration, and do not allow the user to fold them into a configuration that is more suitable for storage or transport, for example. Embodiments of such containers that are operable to be collapsed or folded into a substantially flat configuration generally comprise a releasable connection or similar means, and are formed from a plastics or polymeric blank and folded into the final, open configuration, at which point the connection is utilised to secure the container in its open configuration.

When determining which type of container to use, consideration must be given to the suitability of the container in varying environmental conditions, the maximum weight that can be transported by the container, ease of manufacture and also storage and transportation suitability.

It would therefore be desirable to provide a container that maintains full functionality in varying environmental conditions, is relatively robust and/or has a greater maximum carrying weight than cardboard containers; but is also collapsible for ease of storage and transportation, without the requirement of a releasable connection means to secure the container in the desired configuration.

It is therefore the aim of an embodiment or embodiments of the present invention and/or methods of manufacture to overcome or at least partially mitigate at least one problem associated with the prior art.

Summary of the Invention

According to a first aspect of the present invention there is provided a collapsible moulded container comprising one or more walls, a base and integral fold lines which connect each wall to the base and any adjacent wall, and wherein the wall(s), base and fold lines are formed from a continuous, moulded piece of material.

The continuous, moulded piece of material has no connections.

Forming the wall(s), base and fold lines from a continuous, moulded piece of material, with no connections, reduces manufacturing time and complexity and increases the structural integrity of the container.

In some embodiments each wall may be connected to the base and/or adj acent walls by living hinges. A living hinge may be defined as a flexible hinge made from the same material as the walls or base connected by said hinge with the hinge and adjacent walls or base being formed as a unitary piece. The living hinges may be of any suitable thickness and width to allow rotation of each wall relative to connected adjacent walls or base. The living hinges may allow for the walls to be operable to fold in towards the centre of the base, or fold out away from the centre of the base, or fold in both directions, for example.

According to a second aspect of the invention there is provided a collapsible moulded container comprising one or more walls and a base, and wherein each wall is connected to any adjacent walls and the base via living hinges.

The following statements apply to both the first and second aspects of the invention.

The moulded container is preferably an injection moulded container.

In some embodiments one or more walls may comprise one or more further fold lines or living hinges to assist in the folding of the container. In some embodiments, two or more living hinges may extend across or through a wall, such that the wall is divided into multiple sections separated by living hinges. In this way, when a wall is folded away from or towards the base by the living hinge connecting the walls and base, the wall may also fold such that one or more sections of the wall stack on top or below one or more other sections.

In some embodiments, two living hinges may be configured into a V-shape on a wall, wherein the arms of the V-shaped hinges are furthest apart at or towards the base and may be closest together at or towards the free, upper edge of the wall. The living hinges may extend from the upper edge of the wall down to the fold line between the wall and the base. Towards the upper edge of the wall the living hinges may not contact each other, or they may contact at the upper edge, for example. In some embodiments the wall or walls which comprise further living hinges, such as V-shaped living hinges, may be operable to fold in a way that the upper comers of each wall move towards each other whilst the said wall substantially folds away from the centre of the base, or the upper corners move towards each other whilst each wall folds towards the centre of the base panel, for example. In some embodiments, the container comprises four walls and a base, each wall being connected to each adjacent wall and the base by a living hinge. In some embodiments, one pair of opposite walls comprise a V-shaped living hinge as described above.

In this way there is provided a means for an (injection) moulded plastics container to fold into a substantially flat configuration without requiring any panel or wall to be connected to adjacent panels or walls using connection means.

Previous containers have required one or more connections such as a connection which enables coupling of two walls.

In some embodiments the container may be manufactured from any suitable plastics or polymer material that can be injection moulded. This includes, but is not limited to, materials such as polystyrene, nylon, polypropylene, acrylonitrilebutadiene-styrene, polycarbonate or any combination thereof. The plastics or polymer material may be reinforced with glass fibres or carbon fibres, for example.

An injection-moulded plastics or polymer material offers a far stronger container than a cardboard alternative; with a much higher carry weight and without the significant reduction of performance when wet.

In some embodiments the container may consist of four walls, arranged in a square or rectangular configuration around the perimeter of a square or rectangular base. The length and width of the base may be independently less than or equal to 100mm, or at least 100mm, 200mm, 300mm, 400mm, 500mm, 750mm, or 1000mm. There may be any suitable number of walls arranged around the perimeter of the base. The walls may be positioned substantially orthogonally to the base. The walls may all be of the same height. The height of the walls may be less than 100mm, or at least 100mm, 200mm, 300mm, 400mm, 500mm, 750mm, or 1000mm. The walls and base may be of any suitable thickness, which may be less than or equal to 1mm, or at least 1mm, 2mm, 3mm, 4mm, 5mm, 6mm, 7mm, 8mm, 9mm, or 10mm for example. The walls and the base may be of equal thickness, or the base may have a different thickness to the walls, for example.

In some embodiments the walls may be solid panels. In other embodiments the walls may comprise one or more apertures, for example. The apertures may be of any suitable size, shape, number and configuration. For example, the walls may contain a number of apertures arranged in one or more rows and/or columns. Apertures may enable reduction of the weight of the walls but without reducing the strength. One or more of the walls may include a handle aperture or apertures to allow for the container to be more easily carried by hand. There may be a single handle aperture on each of two opposite walls, for example. The handle aperture or apertures may be substantially rectangular in shape, and may comprise rounded comers, for example; and may be positioned at any suitable location on the walls.

In some embodiments the base may comprise a substantially flat sheet. In some embodiments the upper and lower surface of the base may be smooth or rough and may comprise grooves, ridges or dimples, for example. In some embodiments the base may comprise one or more apertures of any suitable size and shape.

In some embodiments there may be a cut out portion or aperture at one or more of the vertices or comers where two walls and the base meet, to further assist in the folding of the container. The cut-out portion or aperture may be located at the junction of a living hinge joining two walls, or may be located at a junction of a living hinge joining two walls and the living hinges joining the same two walls with the base. In some embodiments there may be a cut-out portion or an aperture at all of the vertices or corners where two walls and the base meet. In such embodiments each cut-out portion or aperture may comprise a cut-out portion in one or both of the adjoining walls, which may form a continuous cut-out portion extending through the fold-line between the two walls, and the cut-out portion may be formed optionally in the base panel in addition to the wall or walls. The cut-out portion may extend an equal distance into each of the adjoining walls and optionally the base. The cut-out portions may comprise a straight edge or a curved edge, for example, and may extend up to 1mm along each wall, or at least 1mm, 2mm, 3mm, 4mm, 5mm, or 10mm, 20mm or 50mm, for example.

In some embodiments there may be one or more securement devices operable to secure one or more of the fold lines or living hinges in place to prevent movement of the fold-lines(s) and hence prevent the container from collapsing, in use. Each securement device may be permanently attached to the container and moved between a locked and unlocked position, for example by means of a sliding or rotating mechanism, or may comprise an attachable and detachable device. Each securement device may comprise any suitable material, and this may include any suitable metal, alloy, plastics or polymer material, for example.

Each securement device may comprise a clip or clamping member arranged to prevent folding of a fold line or living hinge of the container. In some embodiments each securement device comprises a clip or clamping member arranged to straddle a portion of a fold line or living hinge and prevent rotation thereof. The clip or clamping member may be fully detachable and reattachable to the container. Alternatively the clip or clamping member may be permanently attached to the container and moveable between the locked and unlocked positions. Each securement device may be positioned to straddle a portion of a fold line at or towards the upper edge of a wall of the container. Each clip or clamping device may be resiliently biased to grip the wall. The resilient bias may be effected by the clip or clamping member being formed of a resilient material or by way of a spring or other resilient biasing means.

At least one securement device may comprise a corner clip or clamping member, arranged in use, to prevent folding of a corner fold-line or living hinge between two adjacent walls. In embodiments in which at least one wall comprises a living hinge within or extending through a wall, such as two living hinges forming a V-shaped living hinge, at least one securement device may be arranged, in use, to prevent folding of said living hinge, such as the living hinges at or in the region of the apex of the or each V-shape.

The securement device or devices, in use, maintain the container in the open position, and prevent the container from collapsing. When the securement device comprises one or more comer clips or clamping members, each corner clip or clamping member may be arranged to secure adjacent walls at a desired angle (e.g. a 90° angle for a square or rectangular container).

In other embodiments the securement device may comprise a detachable rim structure that may be placed on top of the container around the entire rim of the wall or walls in order to prevent it from collapsing, in use. This structure may be made of any suitable material, including but not limited to, metal, alloy, plastics or polymer material, or any combination thereof for example. The rim structure may comprise a number of rim members equal to the number of side walls of the container, either integrally formed or attached by connections that maintain the members in substantially fixed positions relative to each other. The rim structure may comprise an elongate channel configuration, connectable over the rim of the wall or walls, in order to prevent the container from collapsing, in use, but so that it may be removed with relative ease when the container is to be collapsed.

According to a third aspect of the invention there is provided a method of manufacturing a container of the first or second aspect of the invention, the method comprising providing a mould of the container and injection-moulding a polymeric material into the mould. The polymeric material may be selected from polystyrene, nylon, polypropylene, polyethylene, acrylonitrite-butadiene-styrene, polycarbonate, or any combination or co-polymer thereof, for example.

In this way, a collapsible container is produced with integral fold-lines, such as living hinges, and formed from a single, continuous moulded piece, with no breaks or connections which must be subsequently joined after moulding.

According to a fourth aspect of the invention there is provided a mould comprising a base, a plurality of walls surrounding the base, the walls and base forming a central cavity, and a core arranged in use to be located within the central cavity, spaced apart from the base and walls; wherein edges between adjacent walls and between the walls and the base comprise protrusions extending into the central cavity and which are arranged to form fold lines in a container moulded in the mould, in use; and wherein at least one wall comprises an inverted V-shaped protrusion with the arms of the V-shaped protrusion extending from the lower corners of the wall and the apex of the V-shaped protrusion is located at the upper edge of the wall.

In some embodiments, a pair of opposing walls comprises the inverted Vshaped protrusions.

In this way, the space between the core and the wall and base enables material to be injected into the space to form the walls and base of a container.

The plurality of walls may be movable from an operable position, in which the walls from a continuous wall around the base, and a release position in which each wall is spaced apart from adjacent walls and base. The release position allows an injection moulded container to be released, once formed. The walls may be mounted on a resilient biasing means, such as a spring, which may be operable to move the walls between the operable and release positions.

The walls may be moved from the release position before, during or after the central core is located within the central cavity. The central core may be lowered into the central cavity via any suitable means such as a pneumatic or robotic arm, for example.

In the operable position the side edges of each adjacent wall abut, and form a liquid-tight join. At least one side edge of a pair of abutting side edges may comprise a protrusion (which may be a linear protrusion) which protrudes into the mould cavity to form a living hinge at the junction of the said abutting side edges. In some embodiments, at least one side edge of each wall comprises a protrusion, and each wall may have a protrusion extending from along both side edges. The protrusions from adjacent side edges of adjacent walls abut when the mould is in the operable position, and enable a living hinge to be formed in a container moulded in the mould, in use.

The mould may comprise the shape of the container, which may comprise a square or rectangular base and four walls surrounding the base.

The mould may be made from any suitable material, for example any suitable metal, alloy, plastics or ceramic material.

The central core may include an integral or connected cover, or lid, arranged to cover the central cavity and form a liquid-tight seal with the outer wall.

The base of the mould may comprise an array of grooves or channels, arranged in a pattern, such as a checkerboard pattern, for example. The grooves or channels may comprise a square, V-shape or rounded profile. The width and depth of the grooves may be of any suitable dimensions. The base of the mould may further comprise one or more apertures for injecting the polymeric material into the mould, and these may be of any suitable dimensions. The one or more apertures may be arranged in any suitable position. In alternative embodiments, the polymeric material may be injected through one or more apertures in the wall or central core.

The central core may be of any suitable dimensions in relation to the mould walls and base that enables the manufacture of a container as described herein. The core dimensions may comprise the desired internal cavity dimensions of a collapsible container.

The walls of the mould may be of any suitable dimensions that allow the manufacture of a collapsible container as described herein.

One or more walls of the mould may comprise a plurality of circular protrusions extending into the central cavity. These protrusions may be of any suitable radius, and of a thickness that allows the mould to close uninhibited but with the furthest extending face of the circular protrusions making contact with the core. These circular protrusions may create circular apertures in the collapsible container during the moulding process. The wall of the mould may comprise any number of circular protrusions, and these may be arranged in any suitable format.

One or more walls of the mould may comprise one or more protrusions arranged to form a handle within a container formed with the mould. In currently preferred embodiments, two opposite walls comprise a handle shaped protrusion; preferably located in the top half of the wall. The or each handle protrusion may be of any suitable perimeter dimensions, and the thickness may be substantially similar to that of the circular protrusions. During the injection phase of the moulding process, an outer face of the handle protrusions may remain in contact with a surface of the core. This may enable the manufacture of an injection moulded container comprising handle apertures, without the need for the apertures to be fabricated after the moulding phase. The handle protrusions may comprise any suitable shape, such as linear, rectangular, oval, stadium or square, for example.

The walls of the mould may comprise protrusions at one or more corners. The protrusions may be located at one or more side edges of the walls and may comprise a circular sector profile, such as a quarter disc or any suitable shape. These protrusions may be arranged in comers of the mould to enable corner apertures to be produced at each vertex of two adjoining walls and the base on the moulded container. In order for corner apertures to be produced in the moulded container during injection moulding, the protrusions are arranged to contact the core in the operable position.

The V-shaped protrusions may extend part-way into the space formed between the wall member and the central core, to form an area of thinner material, in relation to the surrounding material, when the container material is injection moulded. The result is the formation of a V-shaped living hinge. The arms of the V-shaped protrusion may extend from comer protrusions as described hereinabove.

The wall members may comprise a substantially horizontal protrusion at the lower edge of each wall, extending across from one side edge to the other side edge of the wall member. The horizontal protrusions may extend part-way into the space formed between the wall member and the central core, to form an area of thinner material, in relation to the surrounding material, when the container material is injection moulded. The result is the formation of a horizontal living hinge located near to the base of the container. The protrusion may be of any suitable crosssectional shape, such as rectangular, triangular or circular, for example.

According to a fifth aspect of the invention there is provided a method of moulding a collapsible container of the third aspect of the invention, using a mould of the fourth aspect of the invention.

Detailed Description of the Invention

In order that the invention may be more clearly understood embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings, of which:

Figure lisa perspective view of an embodiment of the collapsible container in the open (or unfolded) position;

Figure 2 is a perspective view of the embodiment of the container of Figure 1 wherein the collapsible container is illustrated in a configuration between the open and closed positions;

Figure 3 is a perspective view of the collapsible container of Figure 1 in the closed position.

Figure 4 is a perspective partial view of a mould used in the method of manufacture of a collapsible container of the invention, the mould wall being in the release position;

Figure 5 is a close-up perspective view of a corner portion of the mould of Figure 4;

Figure 6 is a side cross-sectional view through the mould of Figure 4, with the central core located within the central cavity; and

Figure 7 is a side cross-sectional view perpendicular to that of Figure 6.

Figures 1 and 2 illustrate an embodiment of a collapsible container 1. The container 1 includes a base 18 that is square in shape and substantially planar. Walls 2, 2’, 4 and 4’ are connected orthogonally to the base 18 when the container 1 is in the unfolded configuration as shown in Figure 1. The walls 2, 2’, 4 and 4’ are rectangular and substantially planar, and are adjoined to the base 18 by means of fold-lines in the form of living hinges 16, 16” and 16”’ respectively. The walls 2, 2’ and 4, 4’ are opposing pairs. The living hinges 16, 16’, 16” and 16’” allow each side wall to rotate freely about a single axis, and enable the walls 2, 2’, 4 and 4’ to fold in to the centre of the base 18.

Adjoining walls are connected by means of further living hinges 14, 14’, 14”, 14’”. These living hinges enable each of the walls 2, 2’, 4, 4’ to rotate about an axis relative to each adjoining wall. The living hinges 14, 14’, 14”, 14’” extend from each vertex at each corner of the base 18 up to the upper edge of each respective wall 2, 2’, 4 and 4’, when the container is in the configuration as shown in Figure 1. The living hinges 14, 14’, 14”, 14”’ maintain the connection between adjacent walls as the container is moved between the folded and unfolded configurations.

Apertures 20, 20’, 20”, 20’” are located at the vertex situated at each corner of the base 18. These comprise a circle sector cut out from each of the three adjoining panels (walls and base) at each vertex. For example, aperture 20’ comprises cut out sections from the corresponding corner of the base 18 and also the walls 2 and 4’ and extend through the living hinges 14, 14’, 14” and 14’”. The apertures 20, 20’, 20”, 20’” enable the container to be configured between the unfolded and folded configurations.

Handle apertures 6 and 6’ are situated close to the upper edge of opposing walls 4 and 4’ as shown in Figures 1 and 2. The handle apertures 6 and 6’ are substantially rectangular in shape with rounded comers. When the container is in the unfolded configuration as shown in Figure 1, and the base 18 is in a horizontal orientation, the mid-points of handle apertures 6 and 6’ are close to or in line with the central vertical axis of side walls 4 and 4’ respectively. The longitudinal axis of the handle apertures 6 and 6’ are parallel to the upper edges of the walls 4 and 4’ respectively.

The container 1 also includes living hinges 8, 8’, 10 and 10’ formed within opposing walls 2 and 2’ respectively. Living hinges 8 and 8’ form an inverse or upside-down “V” shape within wall 2, with the arms of the V extending to the cutout portions 20, 20’, and living hinges 10 and 10’ form an inverse “V” shape within wall 2’ with the arms of the “V” extending to the cut-out portions 20” and 20’”. As shown in Figure 1, the living hinges 8, 8’, 10 and 10’ are orientated to create triangular configurations on the walls 2 and 2’. These living hinges create three triangular sections on each of the walls 2 and 2’ comprising a centre section formed between the pairs of living hinges 8, 8’ and 10, 10’, and outer sections formed either side of the living hinges 8, 8’ and 10, 10’, and allow the two outer sections to fold on top of the central section when the walls 2 and 2’ fold in towards the centre of the base 18. This folding configuration allows walls 4 and 4’ to fold on top of walls 2 and 2’, and this folding process and fully folded configuration is shown in Figure 2 and Figure 3 respectively.

Securement devices 12 and 12’ are located on the upper edges of walls 2 and 2’ respectively, as shown in Figure 1. The securement devices 12 and 12’ are operable to slide between two positions along the wall they are situated on, in order to either cover or uncover portions of living hinges 8 and 8’ or 10 and 10’. In a first, locked position, as shown in Figure 1 the securement devices 12, 12’ are located over the apex formed by the converging living hinges 8, 8’ and 10, 10’ respectively. In a second unlocked position, as shown in Figure 2, the securement devices 12, 12’ are located away from the living hinges 8, 8’ and 10, 10’. The securement devices 12, 12’ comprise clamping members with an elongate channel configuration, which straddle the rim of the walls 2, 2’ respectively. When the securement devices 12 and 12’ are positioned to cover the living hinges 8, 8’, 10 and 10’, as shown in Figure 1, the walls are prevented from folding. This maintains the container in the unfolded configuration as the living hinges 8, 8’, 10 and 10’ are prevented from allowing folding of walls 2 and 2’.

In use, the container 1 is folded and unfolded as follows. The securement devices 12, 12’ are moved from the first, locked position to the second, unlocked position. The walls 2, 2’ can then be pushed by hand towards the base 18 and this will cause the walls 2, 2’ to fold along the living hinges 8, 8’ and 10, 10’ respectively. The folding motion along the living hinges 8, 8’ and 10, 10’ will cause the outer triangular sections of the walls 2, 2’ to fold up and in towards the centre section of each respective wall, as shown in Figure 2. The folding of the walls 2, 2’ will cause the walls 4, 4’ to begin to fold towards the base 18. Pushing the walls 4, 4’ towards the base 18 will cause the walls 2, 2’ to fold further towards the base 18. The walls 2, 2’ will continue to fold along living hinges 8, 8’ and 10, 10’ respectively, whilst living hinges 14, 14’, 14”, 14’” will allow walls 4, 4’ to fold on top. The walls 4, 4’ can be pushed towards the base 18 until the container 1 is in a flat configuration, as shown in Figure 3, with the walls 2, 2’ folded beneath the walls 4, 4’.

From the flat, folded configuration, as shown in Figure 3, the container 1 can be unfolded back into the open configuration as follows. The handle apertures 6, 6’ can be used to pull the walls 4, 4’ up and away from the centre of the base 18. As the walls 4, 4’ rotate towards an orthogonal configuration in relation to the base 18, living hinges 14, 14’, 14”, 14”’ pull the outer triangular sections of walls 2, 2’ up and away from the respective centre triangular section of each wall. These outer triangular sections of the walls 2, 2’ unfold along living hinges 8, 8’ and 10, 10’. As the walls 4, 4’ cause walls 2, 2’ to unfold further, the centre triangular sections of walls 2, 2’ rotate about living hinges 16, 16”, which leads to the walls 2, 2’ moving into more planar configurations, as shown in Figure 2. The handle apertures 6, 6’ can be pulled by hand until the walls 2, 2’ and 4, 4’ are all in an orthogonal configuration in relation to the base 18, as shown in Figure 1. At this point, the securement devices 12, 12’ can be moved from the unlocked, second position into the locked, first position. By moving the securement devices 12, 12’ over the apex formed on each of the side walls 2, 2’ by living hinges 8, 8’ and 10, 10’ respectively, the living hinges are prevented from allowing the walls 2, 2’ to fold, and so the container 1 remains in the configuration shown in Figure 1.

Figure 4 illustrates an embodiment of a mould 100 for use in a method manufacturing a collapsible container. The mould 100 comprises a base 102 that is square in shape and substantially planar. The base 102 is surrounded by four wall members 104, 104’, 106, 106’, which extend along the four sides of the square base

102. The base 102 and wall members 104, 104’, 106, 106’ form a central cavity therebetween. The base 102 comprises a number of apertures (not shown) for the injection moulding material to enter the mould 100, in use. Wall members 104, 104’, 106 and 106’ extend vertically from the base 102. The wall members 104, 104’ and wall members 106, 106’ are opposing pairs. A separate core 118 which is substantially cuboidal in shape is operable to be lowered into the central cavity formed by the base 102 and the wall members 104, 104’, 106, 106’.

As shown in Figure 5, the base 102 comprises a checkerboard array of evenly spaced grooves or channels. The wall members 104, 104’, 106, 106’ are shown in Figures 4 and 5 not to be in direct contact with one another, this illustrates the mould 100 in an open, or release, position. In this release position, the wall members 104, 104’, 106, 106’ are spaced apart from adjacent wall members and are set back from the base 102. The wall members 104, 104’, 106,106’ are movable between the release positon to an operable position. In the operable position adjacent wall members 104, 104’, 106, 106’ contact each other and form a liquidtight seal therebetween. In addition, in the operable position each wall member 104, 104’, 106, 106’ contacts the base 102 and forms a liquid-tight seal with the base 102. In the operable position the wall members of each opposite pair 104. 104’ and 106, 106’ are closer together than in the open position.

The interior face of wall member 104 comprises a stadium shaped handle protrusion 108 located towards the upper edge of wall member 104, as shown in Figures 5 and 7. Another stadium shaped handle protrusion is located on the opposite wall member 104’ in an identical location. Figure 5 further illustrates a plurality of circular protrusions 112 located on the wall members 104, 106. These circular protrusions are located on each of wall members 104, 104’, 106, 106’. When the central core 118 is positioned inside the cavity and the mould 100 is in the operable position, the stadium shaped protrusions 108 and circular protrusions 112 are in contact with the outer surface of the core 118. This causes the formation of stadium shaped and handle apertures in a collapsible container formed during injection moulding.

Wall members 106 and 106’ include a V-shaped protrusion 110, as shown in Figure 5. Protrusion 110 comprises two linear sections having a rectangular cross sectional shape, arranged into a V-shape that protrudes from the wall members 106, 106’ into the cavity of the mould 100. The two linear sections are angled to form arms extending from opposite lower corners of the side edges of the wall members 106, 106’ and extend upwardly with the apex substantially centrally at the top of wall 106, 106’. When the mould 100 is in the operable configuration, the protrusion 110 is not in contact with the central core 118. This creates a thinner section of material in the shape of protrusion 110 in relation to the surrounding material where the injection moulding material is injected between the wall members 104, 104’, 106, 106’, base 102 and core 118. It is this protrusion 110 on wall members 106, 106’ that creates living hinges 8, 8’ and 10, 10’ on the collapsible container 1 as shown in Figure 2.

The side edges of the walls 104, 104’, 106, 106’ include protrusions which, in use, protrude towards the central core 118, when the core 118 is located in the central cavity of the mould 100. Each of the wall members 104, 104’, 106, 106’ includes a protrusion at both side edges thereof. Each protrusion extends vertically along the side edges of the wall members 104, 104’, 106, 106’. Two of these protrusions 114, 114’ are illustrated in Figure 5 on side edges of adjacent wall members 104, 106. When the wall members are in the operable position each of protrusions 114, 114’ meet the adjacent protrusion to form a protrusion with an approximately square cross section when the mould 100 is in the operable positon. Protrusions 114,114’ are not in contact with the core 118 when the mould 100 is in the operable position, and so create regions of thinner material in relation to the surrounding material. These regions of thinner material form the living hinges 14, 14’, 14”, 14’” on the collapsible container 1 as shown in Figure 1.

As illustrated in Figures 4, 5, 6 and 7 the lower corners of the side edges of the wall members 104. 104’, 106, 106’ include protrusions 116 having a quarter disc shape (with quarter circle cross-section). The protrusions 116 extend along the wall members 104, 104’, 106, 106’ with the arc of the protrusion flush against the wall members. The protrusions 116 are configured to extend into the central cavity of the mould 100 and abut the central core 118, when the wall members are in the operable positon. In this way during the moulding process, the protrusions 116 will be in contact with the core 118 when the mould 100 is in the operable position, creating the formation of apertures 20, 20’, 20”, 20”’ on the collapsible container 1 as shown in Figure 1.

As shown in Figures 4, 6 and 7 the bottom edges of the wall members 104, 104’, 106, 106’ comprise linear protrusions 120 which, in use, protrude into the central cavity of the mould 100. Each of the wall members 104, 104’, 106, 106’ comprise a linear protrusion 120 extending fully between both of the side edges. Protrusions 120 are not in contact with the core 118 when the mould 100 is in the operable position, and so create regions of thinner material in relation to the surrounding material. These regions of thinner material are living hinges 16, 16’, 16”, 16’” on the collapsible container 1 as shown in Figures 2 and 3.

In use, the mould 100 is operated as follows. Starting from the release (open) position, the core 118 is lowered down towards the base 102, and the wall members 104, 104’, 106, 106’ are moved towards the core 118 into the operable (closed) position. In the operable position, adjacent wall members 104, 104’, 106, 106’ are in direct contact with one another and with the base 102, and handle protrusions 108 and circle protrusions 112 will be in contact with the core 118. The linear protrusions 120 along the bottom edges of the wall members, and the linear protrusions 114 extending along the side edges of the wall members extend into the gap between the wall members and the core, but do not contact the core, thereby allowing formation of fold lines in the form of living hinges made from the moulding material. The wall members 104, 104’, 106, 106’ and base 102 form a liquid-tight cavity. The central core 118 is orientated to be spaced apart from the wall members 104, 104’, 106, 106’ and base 102, to form a relatively thin gap therebetween in the shape of the walls 2, 2’, 4, 4’ and base 18 of a container 1 of Figure 1. A cover seal (not shown) is clamped onto the top face of the wall members 104, 104’, 106, 106’ (or will be attached to or integrated with the central core 118 and lowered onto the wall members 104, 104’, 106, 106’ with the core 118) and the core 118, and the wall members 104, 104’, 106, 106’ locked into position.

The injection moulding process may then take place, comprising the following phases: injection of a polymeric material into the space between the core 118, wall members 104, 104’, 106, 106’ and base 102, to form a container; dwelling; and cooling. Once cooled, the clamping mechanisms are released, the wall members 104, 104’, 106, 106’ and core 118 are moved to the open (release) position and an ejection system will release the formed collapsible container 1 from the mould 100.

The above embodiments are described by way of example only. Many 5 variations are possible without departing from the scope of the invention as defined in the appended claims.

Claims

1. A collapsible moulded container; comprising one or more walls, a base and integral fold lines which connect each wall to the base and any adjacent wall, and wherein the wall(s), base and fold lines are formed from a continuous moulded piece of material.

2. A container as claimed in claim 1 wherein the fold lines comprise living hinges.

3. A collapsible moulded container comprising one or more walls and a base, and wherein each wall is connected to any adjacent walls and to the base via living hinges.

4. A container as claimed in any preceding claim wherein one or more walls comprise one or more further fold lines, extending therethrough.

5. A container as claimed in any preceding claim wherein the further one or more fold lines extending through one or more walls comprise living hinges.

6. A container as claimed in claim 5 wherein the living hinges within each wall separate each wall into multiple sections.

7. A container as claimed in claim 5 or 6 wherein the further fold-lines form a triangular configuration within each wall.

8. A container as claimed in claim 7 wherein the further fold-lines form an inverse V shape in which the apex of the V is located at the upper edge of the wall, and the arms of the V extend to the vertices formed between the wall at the base.

9. A container as claimed in any preceding claim comprising at least a cutout portion at each vertex formed between adjacent walls at the base.

10. A container as claimed in claim 9 where each cut-out portion is formed in adjacent walls and extends through the living hinge separating the adjacent walls.

11. A container as claimed in any preceding claim wherein the container is operable to fold into a substantially flat configuration.

12. A container as claimed in any preceding claim further comprising at least one securement device wherein one or more of the fold-lines or living hinges is operable to be secured with the securement device.

13. A container as claimed in any preceding claim wherein the securement device is operable to move between two separate positions, a locking position, in which at least one fold-line or living hinge is locked in an unfolded position, and an unlocking position in which at least one fold-line or living hinge is freely movable.

14. A method of manufacturing a collapsible container of any one of claim 1 to 13, comprising providing a mould corresponding to the wall(s), base and fold-lines of the container, and injection moulding a material into the mould to form the container as a continuous moulded piece.

15. A mould for manufacturing a container, the mould comprising a base, a plurality of walls surrounding the base, the walls and base forming a central cavity, and a core arranged in use to be located within the central cavity, spaced apart from the base and walls; wherein edges between adjacent walls and between the walls and the base comprise protrusions extending into the central cavity; and wherein at least one wall comprises an inverted V-shaped protrusion with the arms of the V-shaped protrusion extending from the lower corners of the wall and the apex of the V-shaped protrusion is located at the upper edge of the wall.

16. A mould as claimed in claim 15, comprising a quadrilateral base surrounded by four walls, wherein a pair of opposite walls both comprise said V-shaped protrusion.

17. A method as claimed in claim 14 using a mould as claimed in claim 15 or 16.

Intellectual Property Office

Application No: GB1703374.7

Claims searched: 1-2 & 4-14

Examiner: Mr James Tagg

Date of search: 12 July 2017

Patents Act 1977: Search Report under Section 17

Documents considered to be relevant:

Category Relevant to claims Identity of document and passage or figure of particular relevance X 1-2 & 4- 14 US5524789 A (JACKMAN) See Figs 1-4 and WPI Abstract Accession No. 1996286061 X 1-2 & 4- 14 DEI 174253 B (FLORJANCIC et al.) See Figs. 1-3 , paragraph [0044] and claim 1 X 1,4& 14 US4136816A (CONTAINER CORP) See Fig 1-3 and WPI Abstract Accession No. 1979-B2887B X 1,4, 11 & 14 WO 98/19921 Al (BLACK) See Figs 1-6 and both EPODOC & WPI Abstract Accession No. 1998-286773 X 1-2, 4-14 EP2840033 Al (SCHACK) See Figs. 1-5 and WPI Abstract Accession No. 201514350V

Categories:

X Document indicating lack of novelty or inventive step A Document indicating technological background and/or state of the art. Y Document indicating lack of inventive step if P Document published on or after the declared priority date but combined with one or more other documents of before the filing date of this invention. same category. & Member of the same patent family E Patent document published on or after, but with priority date earlier than, the filing date of this application.

Field of Search:

Search of GB, EP, WO & US patent documents classified in the following areas of the UKCX :

Intellectual Property Office is an operating name of the Patent Office www.gov.uk/ipo

Intellectual Property Office

International Classification:

Subclass Subgroup Valid From B65D 0001/22 01/01/2006 B65D 0021/08 01/01/2006

Intellectual Property Office

Application No: GB1703374.7

Examiner:

Mr James Tagg