GB2571787A

GB2571787A - Integrally-formed foldable container and method

Info

Publication number: GB2571787A
Application number: GB1803838.0A
Authority: GB
Inventors: Thorn Daniel; Conway James
Original assignee: Individual
Current assignee: Individual
Priority date: 2018-03-09
Filing date: 2018-03-09
Publication date: 2019-09-11
Also published as: WO2019170902A1; WO2019170902A4; GB201803838D0; CN209080422U

Abstract

The present invention relates to a method of manufacturing an integrally-formed foldable container (100, figure 1) by injection moulding the container in a partially assembled configuration. The container has panels 110, 120, 130, 140, 150, 160, 170 joined by living hinges, and some adjacent panels 110, 120, 130, 140, 150 are joined by tabs 180, 185, 190, 195. The container is collapsible to a substantially flat collapsed configuration (figure 7) by collectively rearranging the panels. The tabs 180, 185, 190, 195 may be joined to the side panels 120, 130 by a living hinge 189, 199 or may be attachable to form the assembled configuration (figure 12). Living hinges 182, 187, 192, 197 may extend along the entire end panel 140, 150 edge or only part of it. The container may comprise a top panel 160 with a closure means comprising a flap 170 provided with push-fit features configured to engage and disengage with a panel 120 (or 320, figure 10). The container may be formed of polypropylene plastic.

Description

INTEGRALLY-FORMED FOLDABLE CONTAINER AND METHOD

FIELD [01] The present disclosure relates in general to a foldable container and particularly to an integrally-formed foldable container and method of manufacturing an integrally-formed foldable container.

BACKGROUND [02] Containers of numerous sizes and shapes are known to be utilised for storage of objects. For example, a protective case may be used to store spectacles and to prevent accidental damage to the spectacles. In practice a relatively large volume of space is required for storage and transportation of such a container, especially when considering that the container may not see any use until the end user. Conveniently, a foldable container is convertible from an assembled configuration to a collapsed configuration in which the foldable container has a reduced volume.

[03] Various types of foldable containers are known. Some foldable containers, sometimes referred to using the keyword “origami”, are quickly assembled manually and capable of maintaining their assembled configuration. However, such containers have component parts which are typically manufactured individually. Production therefore requires additional manufacturing steps, which may particularly affect mass production adversely as the manufacturing process is complicated and cost increased.

[04] Although injection moulding may be considered suitable for mass production, it has been found that a foldable container so fabricated may not be capable of being brought into a collapsed configuration which is fully collapsed or an assembled configuration which is fully assembled. This problem may arise because the flexible hinges joining individual panels of the container, the so-called living hinges, may not allow for sufficient movement between joined panels as a result of the thickness of the panels. In principle, reducing the panel thickness would address this problem, but the required reduction of the panel thickness may render the strength of the panels inadequate.

[05] Therefore, it is now desired to provide a foldable container as an alternative to previously available designs. The example embodiments have been provided with a view to addressing at least some of the difficulties that are encountered with current foldable containers whether those difficulties have been specifically mentioned above or will otherwise be appreciated from the discussion herein.

SUMMARY [06] According to the present invention there is provided an integrally-formed foldable container and a method of manufacturing a foldable container as defined by the claims.

[07] An exemplary foldable container according to the present disclosure comprises a plurality of panels. At least some of these panels are mutually joined by a respective living hinge. By offsetting a first living hinge relative to a second living hinge, so that in the collapsed configuration they remain parallel but not aligned, the foldable container may be fully convertible. That is to say, the foldable container is convertible between a collapsed configuration and an assembled configuration.

[08] According to an example, there is provided an integrally-formed foldable container manually configurable between a collapsed configuration and an assembled configuration, the foldable container comprising a bottom panel. The foldable container further comprises a first panel, a second panel and tab which are moveable about the bottom panel to change the foldable container between the collapsed configuration and the assembled configuration; wherein: the tab is joined to the first panel by a first living hinge defining a first fold line, and the tab is configured to couple the first panel and the second panel when the foldable container is in the assembled configuration; the second panel is joined to the bottom panel by a second living hinge defining a second fold line; wherein the first fold line and the second fold line are generally parallel and offset relative to each other when the foldable container is in the collapsed configuration.

[09] The resulting foldable container is manually convertible between the assembled configuration and the collapsed configuration by rearranging the plurality of panels. By folding (or ‘rotating’) the tab about the offset first fold line, the tab may be brought into a position which does not conflict with the position of the second panel. In the collapsed configuration the foldable container is generally flat, whereas in the assembled configuration the container defines an at least partially enclosed space.

[10] More particularly, in some examples the foldable container is assembled into the shape of a box or at least part of a box. The box may have any suitable shape such as, for example, cuboid. That is, the container may have substantially rectangular panels which can be arranged to form a cuboid box. According to other examples, the foldable container has a triangular prismatic shape. That is, the foldable container may have a shape corresponding to a prism with triangular end faces. Suitably at least one of the end faces may be defines by a triangular panel.

[11] According to some examples, the first panel may define a side of the foldable container and the second panel may define a front of the foldable container. According to other examples, the first panel may define a front of the foldable container the second panel may define a side of the foldable container.

[12] According to some examples, the first fold line is offset relative to the second fold line in a third direction which is substantially perpendicular to the first fold line and the second fold line. For example, the first fold line may be offset along the bottom panel or the first panel.

[13] According to some examples, the tab is joined to the second panel by a further living hinge. That is to say, the tab is not readily detachable from the second panel. The tab may thus be joined to the second panel permanently and couple to the second panel continuously. According to other examples, the tab is attachable to the second panel when the foldable container is in the assembled configuration in order to couple the first panel and the second panel. According to such examples, the tab is detachable from the second panel.

[14] According to some examples, the first fold line and the second fold line are offset by a distance which is not less than a panel thickness of the first panel or the second panel. By relatively offsetting the first fold line and the second fold line by the panel thickness or more, it may be ensured that the tab does not prevent the foldable container from being fully convertible, i.e. is configurable between the collapsed configuration and the assembled configuration. In particular, the tab may be prevented from interfering with the position of the second panel when bringing the container into the assembled configuration.

[15] According to some examples, in the collapsed configuration the tab and the first panel are generally parallel and in the assembled configuration the tab and the first panel are generally perpendicular.

[16] According to some examples, the first living hinge is formed towards an edge of the first panel. That is to say, the first living hinge is formed in the vicinity of the edge of the first panel, or ‘edge region’, but does not necessarily extend from the edge. According to some more particular examples, the first living hinge extends beside or along the entire edge of the first panel. According to other more particular examples, the first living hinge extends beside or along part of the edge of the first panel.

[17] According to some examples, the foldable container comprises a third panel and a second tab. The second tab is joined to the first panel by a further living hinge and configured to couple the third panel and the first panel when the foldable container is in the assembled configuration. The third panel may define a rear panel of the foldable container.

[18] According to some examples, a top panel is joined to the third panel. The top panel comprises a closure means by which the top panel is attachable to the first panel or the second panel.

[19] According to some examples, the foldable container is formed from a single material.

[20] According to some examples, the foldable container is formed from a thermoplastic material, for example polypropylene. Polypropylene is considered a particularly suitable choice due to the known properties of this material, which include stress-induced polymerisation at the living hinges in response to stresses exerted thereon by flexing said hinges.

[21] An exemplary method of manufacturing a foldable container according to the present disclosure is provided. The foldable container is manually configurable between a collapsed configuration and an assembled configuration. The method comprises the following steps: forming a mould cavity and inserting a retractable core, the mould cavity defining the shape of the foldable container; filling the mould cavity with a shot of moulding material; extracting the foldable container by opening the mould and removing the retractable core; wherein the foldable container comprises a bottom panel, a first panel, a second panel, and a tab; wherein the tab is joined to the first panel by a first living hinge defining a first fold line, and the tab is configured to couple the first panel and the second panel when the foldable container is in the assembled configuration; the second panel is joined to the bottom panel by a second living hinge defining a second fold line. The method further comprises the forming of the foldable container in the mould cavity in a partially-collapsed configuration. The method also comprises forming the first living hinge so that, when the foldable container is in the collapsed configuration, the first fold line is generally parallel to and offset relative to the second fold line.

[22] According to some examples, a container as specified above is formed using the method of manufacturing.

[23] According to some examples, the tab is configured to sit against the bottom panel when the foldable container is in the collapsed configuration.

[24] According to some examples, the moulding material is a thermoplastic material. According to a particular example, the moulding material is a polypropylene. Given that the foldable container is moulded in a partially-collapsed configuration, stress-induced polymerisation may occur when bringing the foldable container into the collapsed configuration and the assembled configuration.

[25] In some examples, the foldable container has a cuboid shape. That is, the foldable container may have substantially rectangular faces. The faces may be, for example, square. In other examples, the foldable container has a triangular prismatic shape. That is, the foldable container may have a shape corresponding to a prism with triangular end faces.

[26] The container is manually convertible between an assembled configuration and a collapsed configuration. In the assembled configuration the foldable container has a box shape, and in the collapsed configuration the foldable container is substantially flat. Suitably, the foldable container comprises a plurality of panels which are movable relative to each other about living hinges. By rearranging the panels, the foldable container may be brought into the assembled configuration or the collapsed configuration.

[27] Where the foldable container has a triangular prismatic shape, the container may have five panels so that each face of the container may be formed by a respective panel. Where the foldable container has a cuboid shape, the container may have six panels so that one panel forms one face of the container. In other examples, the foldable container may have a different number of panels.

[28] In some examples, the container comprises an additional panel for locking the foldable container when the container is closed in the assembled configuration. This additional panel, which may alternatively be referred to as a closure panel, may be joined by to the top panel or a side panel.

[29] The foldable container comprises a bottom panel, a front panel, and a pair of side panels.

[30] The bottom panel may have two longitudinal edges, and may have two lateral edges. The longitudinal edges may be opposing edges and, similarly, the lateral edges may be opposing edges. The bottom panel may have a substantially rectangular shape delimited by the longitudinal edges and the lateral edges.

[31] In some examples, the longitudinal edges may be longer than the lateral edges. In other examples, the lateral edges may be longer than the longitudinal edges. In further examples, the longitudinal edges and the lateral edges may have identical lengths.

[32] The front panel may be joined to the bottom panel at a first longitudinal edge of the bottom panel by a first living hinge. Conveniently, the front panel is rotatable relative to the bottom panel about the first living hinge.

[33] In the exemplary embodiments, a first side panel is joined to the bottom panel at a first lateral edge of the bottom panel by a second living hinge. A second side panel may be joined to the bottom panel at a second lateral edge of the bottom panel by a third living hinge. Conveniently, each side panel is rotatable relative to the bottom panel about its respective living hinge.

[34] Where the foldable container has a triangular prismatic shape, the side panels may have a substantially triangular shape. Where the foldable container has a cuboid shape, the side panels may have a rectangular shape.

[35] The foldable container comprises a pair of intermediate portions. Conveniently, the intermediate portions are arranged to correlate the orientation of the front panel and the side panels.

[36] A first intermediate portion is joined to the first side panel by a third living hinge, and the first intermediate portion is joined to the front panel by a fourth living hinge. Conveniently, rotating the front panel about the first living hinge causes the intermediate portion to rotate the first side panel about the second living hinge. Similarly, a rotation of the first side panel causes a rotation of the front panel.

[37] A second intermediate portion is joined to the second side panel by a fifth living hinge, and the second intermediate portion is joined to the front panel by a sixth living hinge. Analogous to the first intermediate portion, the second intermediate portion is arranged such that a rotation of the front panel causes a corresponding rotation of the second side panel and vice versa.

[38] The intermediate portions may be substantially flat, and may each have a substantially triangular shape. Each intermediate portion may have three edges, i.e. two legs and a base. The base of the intermediate portion may be joined to the front panel, one of the legs may be joined to one of the side panels, and there may be a free leg.

[39] Conveniently, the intermediate portions are arranged such that when the front panel is collapsed, the side panels are collapsed as well; and when the front panel is upright, i.e. substantially perpendicular to the bottom panel, then the side panels are also upright. Suitably, the intermediate portions have the shape of an isosceles right triangle, joined to the front panel at the base of the triangle and the side panel at one of the legs of the triangle.

[40] The foldable container comprises a rear panel which may be joined to the bottom panel at a second longitudinal edge of the bottom panel by a seventh living hinge. Conveniently, the rear panel is rotatable relative to the bottom panel about the seventh living hinge.

[41] Where the foldable container has a triangular prismatic shape, the side panels may not be connected to the rear panel.

[42] Where the foldable container has a cuboid shape, the side panels may be connected to the rear panel. Suitably, the foldable container may comprise a second pair of intermediate portions. A third intermediate portion may be joined to the first side panel by an eighth living hinge, and the third intermediate portion may be joined to the rear panel by a ninth living hinge. Conveniently, rotating the rear panel about the seventh living hinge causes the intermediate portion to rotate the first side panel about the second living hinge. Similarly, a rotation of the first side panel causes a rotation of the rear panel.

[43] In one example, there is provided an integrally-formed foldable container, the foldable container comprising: a bottom panel having two longitudinal edges, and two lateral edges; a front panel joined to the bottom panel at a first longitudinal edge by a living hinge, a pair of side panels, each side panel being joined to the bottom panel at a respective lateral edge by a living hinge, wherein the front panel and side panels are each rotatable relative to the bottom panel; a pair of intermediate portions for mechanically linking the front panel to the side panels, each intermediate portion joined to an edge of a respective side panel by a respective living hinge, and both intermediate portions joined to the front panel by respective living hinges; a rear panel joined to the bottom panel at a second longitudinal edge by a living hinge.

[44] Each intermediate portion may be rotatable between a first configuration and a second configuration. Conveniently, the intermediate portion may be in the first configuration when the foldable container is in an assembled configuration, and may be in the second configuration when in the collapsed configuration. Suitably, in the first configuration a free leg of each intermediate portion may extend along a direction which is orthogonal to the side panels, and in the second configuration the free leg may by parallel to the side panels.

[45] Where the foldable container has a cuboid shape, a top panel may be provided. Suitably, the tap panel is joined to the rear panel by a tenth living hinge. Conveniently, the top panel is rotatable relative to the rear panel about the tenth living hinge.

[46] The foldable container may comprise a second pair of intermediate portions for mechanically linking the rear panel to the side panels. Each intermediate portion of the second pair may be joined to an edge of the respective side panel by a respective living hinge. Both intermediate portions of the second pair may be joined to the rear panel by respective living hinges.

[47] An intermediate portion may be joined to an edge of a side panel by a living hinge.

[48] The foldable container may comprise a closure panel. Where the foldable container has a cuboid shape, the closure panel may be joined to the top panel by a living hinge. Where the foldable container has a triangular prismatic shape, the closure panel may be joined to the rear panel by a living hinge.

[49] An intermediate portion may have a shape of a right isosceles triangle. That is, the intermediate portion may have three edges, and at least two of these edges have identical length.

[50] The bottom panel may have two longitudinal edges and two lateral edges. The front panel may be joined to a first longitudinal edge, the rear panel may be joined to second longitudinal edge, and the side panels may be joined to the lateral edges.

[51] The integrally-formed foldable container may be formed from a single choice of material. One material or a plurality of materials may be chosen, and arranged uniformly in every portion of the container. In one example, the foldable container may have a uniform plastics composition.

[52] In one example, there is provided a method of manufacturing a foldable container. In one example, the method comprises providing an injection moulding machine having an injection system and a mould.

[53] In one exemplary embodiment there is provided an integrally-formed foldable container (100), the foldable container comprising: a bottom panel (110), a front panel (120) and a rear panel (130),the front panel and rear panel joined to the bottom panel by respective living hinge (122, 132), a pair of side panels (140, 150), each side panel being joined to the bottom panel by a respective living hinge (142, 152); a pair of intermediate portions (180, 190) for mechanically linking the front panel to the side panels, each intermediate portion joined to a respective side panel by a respective living hinge (182, 192), and both intermediate portions joined to the front panel by respective living hinges (184, 194). Preferably, each intermediate portion is rotatable between a first configuration and a second configuration; and in the first configuration a free leg of each intermediate portion is orthogonal to the side panels, in the second configuration the free leg of each intermediate portion is parallel to the side panels. Preferably, the foldable container further comprises a top panel. Preferably, the foldable container further comprises a second pair of intermediate portions for mechanically linking the rear panel to the side panels, each intermediate portion of the second pair joined to an edge of the respective side panel by a respective living hinge, and both intermediate portions of the second pair joined to the rear panel by respective living hinges. Preferably, each intermediate portion is joined to an edge of a respective side panel. Preferably, the foldable container further comprises a closure panel joined by a living hinge to the top panel, the bottom panel or a side panel. Preferably each intermediate portion has a shape of a right isosceles triangle. Preferably, the bottom panel has two longitudinal edges and two lateral edges; the front panel being joined to a first longitudinal edge, the rear panel joined to a second longitudinal edge, and the side panels joined to the lateral edges. Preferably, the foldable container is formed from a single material.

[54] In one exemplary embodiment, there is provided a method of manufacturing a foldable container, the method comprising: forming a mould cavity and inserting a retractable core, the mould cavity corresponding to a foldable container in a partially collapsed configuration, wherein the foldable container comprises a bottom panel, a front panel joined to the bottom panel at a living hinge, and a pair of side panels, each side panel joined to the bottom panel at a respective living hinge; and a pair of intermediate portions, the pair of intermediate portions joined to the pair of side panels by living hinges, and each intermediate portion joined to the front panel at a respective living hinge; filling the mould cavity with a shot of moulding material; and extracting the foldable container by opening the mould and removing the retractable core. Preferably the moulding material is a thermoplastic material. Preferably the thermoplastic material is a polypropylene. Preferably, the method comprises forming a push-fit locking mechanism for coupling the closure panel and the front panel.

BRIEF DESCRIPTION OF DRAWINGS [55] For a better understanding of the invention, and to show how example embodiments may be carried into effect, reference will now be made to the accompanying drawings in which:

Fig. 1 shows a perspective view of an integrally-formed foldable container in an assembled configuration, and opened;

Fig. 2 shows a perspective view of the foldable container in an assembled configuration, and locked;

Fig. 3 shows a perspective view of the foldable container in an assembled configuration, closed and not locked;

Fig. 4 shows	a	perspective	view	of	the
configuration;
Fig. 5 shows	a	perspective	view	of	the
configuration;
Fig. 6 shows	a	perspective	view	of	the

configuration;

foldable container in a partially collapsed foldable container in a partially collapsed foldable container in a partially-collapsed

Fig. 7 shows a perspective view of the foldable container in a collapsed configuration;

Fig. 8 shows a perspective view of the foldable container in a partially collapsed configuration and having a rear panel, a top panel and a closure panel aligned;

Fig. 9 illustrates a method of manufacturing an integrally-formed foldable container;

Fig. 10 shows a perspective view of another example of a foldable container in the collapsed configuration;

Fig. 11 shows the foldable container of Fig. 10 in a partially-assembled configuration; and

Fig. 12 shows the foldable container of Figs. 10 and 11 in the assembled configuration.

DESCRIPTION OF EMBODIMENTS [56] It is an aim to provide an improved foldable container. An example foldable container is formed integrally, durable and simple to manufacture. At least some examples are lightweight and sufficiently sturdy to provide protection to an object contained within.

[57] At least some of the following example embodiments provide an improved foldable container. The example foldable container is integrally-formed, simple to manufacture and convenient for a user. At least some examples may be used to safely store an object. Many other advantages and improvements will be discussed in more detail herein.

[58] Fig. 1 shows an example of an integrally-formed foldable container 100 in an assembled configuration, and opened.

[59] The container 100 has a base and a lid. In this example, the container is formed from a plurality of panels. A panel is a relatively thin piece forming part of an outer shell of an object, such as a container or a box. The panel may be substantially flat, and may have a substantially polygonal shape, such as triangular or rectangular.

[60] In this example, the base comprises a bottom panel 110, a front panel 120 (or ‘second panel’), a rear panel 130, and a pair of side panels 150 (or ‘first panels’).

[61] In Fig. 1 the container is shown in an assembled configuration. Suitably, in the assembled configuration a receptacle is formed by the foldable container 100. In this example, the base is arranged such that the front panel, rear panel and side panels are substantially perpendicular to the bottom panel.

[62] In this example, the lid comprises a top panel 160 and a closure flap 170. Fig. 1 shows the container 100 in an opened configuration. That is, in Fig. 1 the lid is not arranged to close or lock the container.

[63] The front panel 120 and the rear panel 130 are located at opposing sides of the container and form a front face and a rear face, respectively. In this example, the front panel and the rear panel have substantially identical shapes and sizes, and are parallel to each other. In other examples, the front panel and the rear panel may have different shapes, sizes or may not be parallel to each other. For example, the container may be slanted from front to back and may have a front panel which is larger than the rear panel.

[64] The container 100 comprises a pair of side panels 140, 150 which are located at opposing sides of the container. A first side panel 140 is located on the right-hand side of the container when viewed from the front, forming a first or right side face of the container. A second side panel 150 is located on the left-hand side when viewed from the front, forming a second or left side face.

[65] In this example, the side panels 140, 150 have substantially identical shapes and sizes, and are parallel to each other. In other examples, the side panels may have different sizes or may not be parallel. For example, the container may be slanted from left to right and may have a left side panel 150 which is larger than the right side panel 140.

[66] The container 100 has a length as defined by the front panel 120 or the rear panel 130, and a width as defined by the side panels. In this example, the container has a length which is larger than the width. In use, an elongate object, e.g. spectacles, may be placed into so that the objects elongate dimension coincides with the lengthwise direction of the container. In other examples, the container may have different dimensions and elongate objects would be stored differently. For example, an elongate object may extend along the width of the container.

[67] The container 100 has a uniform height. That is, the front panel 120, rear panel 130, and side panels 140, 150 are arranged to extend perpendicularly and for approximately the same distance from the bottom panel 110. In other examples, the container may be slanted or inclined and the height of the container may, therefore, change across the container.

[68] The container 100 has a shape which is substantially cuboid. Suitably, the faces of the container are substantially rectangular, and the container has a substantially rectangular crosssection is provided. In other examples, the container 100 may, for example, have a triangular prismatic shape. That is, the container may have a triangular end faces and triangular crosssection.

[69] Conveniently, the container 100 may be closed.

[70] Fig. 2 shows a perspective view of the container 100 in a closed configuration.

[71] In the closed configuration, the top panel 160 is arranged to seal the receptacle formed in the assembled configuration, i.e. the volume enclosed by the bottom panel 110, front panel 120, rear panel 130 and the side panels 140, 150.

[72] Suitably, in this example the top panel 160 has a shape and a size that substantially correspond to the shape and size of the bottom panel 110.

[73] In this example, the container 100 may be locked to ensure that the container remains in the closed configuration.

[74] Fig. 3 shows a perspective view of the container in a locked configuration.

[75] The foldable container 100 is arranged to safely retain an object. Suitably, the container is configurable to prevent an accidentally opening of the container. Conveniently, in the locked configuration, the top panel 160 is arranged to seal the receptacle and the closure flap 170 is arranged to engage the front panel 120. Thereby, the closure flap 170 may be arranged to press against the front panel 120, and to pull the top panel 160 against the base.

[76] The closure flap 170 and the front panel 120 may additionally be arranged to couple together by any suitable means. Thereby the container 100 may be additionally secured in the locked configuration.

[77] Suitably, the closure panel 170 and the front panel 120 may couple mechanically or magnetically. In one example, the closure panel 170 and the front panel 120 are arranged to engage in a push-fit, which may lock the closure panel 170 in place against accidental displacements and thereby may prevent unintentionally opening the container 100. That is, the foldable container 100 may comprise a push-fit locking mechanism for coupling the closure panel and the front panel.

[78] The foldable container 100 is convenient to store. Suitably, the foldable container is convertible from the assembled configuration to the collapsed configuration. In the collapsed configuration the container is generally flat and may take up minimal space.

[79] Fig. 4 shows a perspective view of the foldable container 100 in a partially collapsed configuration.

[80] Suitably, the panels 110, 120, 130, 140, 150, 160 170 of the foldable container 100 may be rearranged to convert the container from the assembled configuration to the flat configuration. Conveniently, some panels are joined by living hinges and can be rotated relative to each other. That is, two panels may be joined at a living hinge, which is a flexible portion of the same material constituting the panels, and the living hinge is arranged to deform when one of the two panels is rotated relative to the other panel about the direction along which the living hinge extends.

[81] In this example, the bottom panel 110 has two longitudinal edges 112, 114 and two lateral edges 116, 118. The longitudinal edges are opposing edges, and similarly the lateral edges are opposing edges.

[82] The front panel 120 is joined to the bottom panel 110 at a first longitudinal edge 112 by a first living hinge 122. Similarly, the rear panel 130 is joined to the bottom panel 110 at a second living hinge 132. Conveniently, the front panel 120 and the rear panel 130 are each rotatable relative to the bottom panel 110 about their respective living hinge 122, 132.

[83] The side panels 140, 150 are joined to the bottom panel 110 at the lateral edges 116, 118 by third and a fourth living hinge 142, 152, respectively. Conveniently, the side panels 140, 150 are each rotatable relative to the bottom panel 110 about their respective living hinge 142, 152.

[84] The top panel 160 is joined to the rear panel 130 at a longitudinal edge of the rear panel 130 by a fifth living hinge 162. Conveniently, the top panel 160 is rotatable relative to the rear panel 130 about the fifth living hinge 162. Similarly, the closure panel 170 is joined to a longitudinal edge of the top panel 160 by a sixth living hinge 172, and is rotatable about the sixth living hinge relative to the top panel 160.

[85] Conveniently, the panels constituting the base of the foldable box 100 may be rearranged collectively. That is, it is not necessary to rotate each panel 120, 130, 140, 150 individually, and hold the panel in position when assembling the container. Instead, it may be sufficient to rearrange one or two of the panels. Thereby assembling and collapsing of the foldable container may be made more convenient for a user, and it may become easier to retain the foldable box 100 in the collapsed or assembled configuration.

[86] Suitably, the foldable container 100 comprises intermediate portions (or ‘tabs’) which are arranged to mechanically link to adjacent panels. Thereby rotation of one panel may cause rotation of another panel so linked.

[87] In some examples, the foldable container 100 may comprise two intermediate portions 180, 190. For example, where the foldable container has a triangular prismatic shape. In this example, the foldable container 100 comprises four intermediate portions 180, 185, 190, 195.

[88] In this example, the four intermediate portions 180, 185, 190, 195 each have a shape corresponding to a right isosceles triangle.

[89] The first intermediate portion 180 is arranged to link the front panel 120 and the first side panel 140. Suitably, the first intermediate portion 180 is joined to an edge of the first side panel by a seventh living hinge 182 and rotatable relative to the first side panel. Similarly, the first intermediate portion 180 is joined to the front panel 120 by an eighth living hinge 184 and rotatable relative to the front panel 120. In this example, the eighth living hinge 184 extends along an inner surface of the front panel.

[90] The second intermediate portion 190 is arranged to link the front panel 120 and the second side panel 150. Suitably, the second intermediate portion is joined to the first side panel by ninth living hinge 192; and to the front panel by a tenth living hinge 194.

[91] When rotating the front panel 120 relative to the bottom panel, the intermediate portions 180, 190 cause the side portions 140, 150 to rotate as well. In particular, lowering the front panel causes the side panels to be lowered, as is shown in Fig. 4. According to the present example, the side panels are lowered onto the bottom panel as the foldable container assumes its collapsed configuration.

[92] Connecting the rear panel 130 to the side panels 140, 150, the third and fourth intermediate portions 185, 195 are arranged similarly to the first and second intermediate portions 180, 190, respectively. A detailed description is therefore omitted.

[93] The third intermediate portion 185 is joined to the first side panel 140 by an eleventh living hinge 187, and to the rear panel 130 by a twelfth living hinge 189. Similarly, the fourth intermediate portion 195 is joined to the second side panel 150 by a thirteenth living hinge 197, and to the rear panel by a fourteenth living hinge 199.

[94] Figs. 5, 6 and 7 show a perspective view of the foldable box 100 in increasingly collapsed configurations, with Fig. 7 showing a fully collapsed configuration.

[95] In the collapsed configuration, the side panels 140, 150 rest on the bottom panel 110. The first pair of intermediate portions 180, 190 rests on the front panel 120, and the second pair of intermediate portions 185, 195 rests on the rear panel 130.

[96] The foldable container 100 is integrally formed. In order to enable the foldable container to be brought into a fully collapsed configuration and a fully assembled configuration, the foldable container is provided with a pair of living hinges which, when the foldable container is in the fully collapsed configuration, are parallel but offset relative to each other.

[97] In particular, the seventh living hinge 182 defines a first fold line 183 which is offset relative to a second fold line 113 defined by the first living hinge 122. More particularly, the first fold line 183 is offset along the bottom panel 110 by a distance corresponding approximately to the panel thickness. The resulting side panel 140 is therefore narrower than the bottom panel. Accordingly space is created between the side panel and the front panel. This space is available to be occupied by the intermediate portion 180. In particular, in the assembled configuration this provides sufficient space for the intermediate portion so that the foldable container may be assembled fully, i.e. the front panel, rear panels and side panels are substantially perpendicular to the bottom panel, with a corresponding arrangement provided between the side panel 140 and the rear panel 130.

[98] Similar to the front panel 120, the rear panel 130 is joined to the bottom panel 110. Accordingly, the rear panel defines a fold line 188 which is offset relative to another fold line 133 defined by the living hinge 132. Therefore a corresponding space is created between the rear panel and the front panel which the intermediate portion 185 may occupy, thus allowing the foldable container to assume a fully assembled configuration. To improve the collapsible nature of the box, the offset of the fold lines may be increased by providing ledges protruding outwardly from the generally planar panels. Thus the ledges by increasing the offset provide increased space within which to fit the stacked panels when the box is collapsed.

[99] An exemplary manufacturing process for involves injection moulding. Injection moulding is a known manufacturing process known for producing plastics articles. Injection moulding has numerous advantageous over other manufacturing processes, and is particularly suitable for high-volume production of substantially identical copies of a product.

[100] Injection moulding involves injecting a shot of material in a molten form into a mould cavity formed by a mould. The shot of material hardens in the mould cavity, thereby taking the form of the mould cavity. Finally, the mould is opened and the article removed.

[101] Generally features should not overhang one another in the direction along which the mould opens, as otherwise it may prove difficult to remove the article without damaging it. The foldable box 100, however, has numerous features which overlap. Conveniently, the foldable container may be provided in a partially collapsed configuration. Thereby the overlapping features may be arranged suitably for injection moulding.

[102] Fig. 8 shows a perspective view of the foldable container 100 in a partially collapsed configuration.

[103] The configuration shown in Fig. 8 is suitable for injection moulding the container 100. Being provided in a partially collapsed configuration, the panels of the container 100 are arranged suitable for injection moulding. In particular, undercut features are reduced compared to configurations in which the container is closed or completely collapsed. Conveniently, the rear panel 130, the top panel 160 and the closure panel 170 are aligned.

[104] In one example, the mould comprises a pair of plates. Each plate is provided with a cavity in face of the plate. Pressing both plates together forms the mould cavity which comprises the individual cavities of both plates.

[105] In this example, each plate of the mould may comprise a cavity arranged for forming a longitudinal half of the foldable box 100. That is, the mould may open along a direction substantially parallel to the longitudinal direction of the foldable box 100.

[106] Suitably, a retractable core may be inserted into the mould along a direction substantially perpendicular to the direction along which the mould opens. Conveniently, the retractable core has a shape corresponding to the volume enclosed by the base of the foldable box 100.

[107] The retractable core may be removed from the base of the formed box without damage to the box. This is, because the front panel 120, rear panel 130 and side panels 140, 150, as well as the intermediate portions joining them, are flexible relative to the bottom panel 110.

[108] Notably, it may be difficult to form the foldable box 100 in a configuration other than a partially collapsed configuration. That is, because in a closed configuration the volume enclosed by the base is not accessible to the retractable core, and any gaps between the front panel 120 and rear panel 130 and their respective intermediate portions become too small [109] In one example, there is provided a method of injection moulding an integrally-formed foldable box 100.

[110] Fig. 9 illustrates a method of injection moulding an integrally-formed foldable box 100.

[111] In one example, the method comprises providing an injection moulding machine having an injection system and a mould.

[112] The method comprises forming a mould cavity and inserting a retractable core into the mould (S200). The mould cavity corresponds to the foldable container in a partially collapsed configuration.

[113] The foldable container comprises a bottom panel, a front panel joined to the bottom panel at a living hinge, and a pair of side panels, each side panel joined to the bottom panel at a respective living hinge. The foldable container further comprises a pair of intermediate portions, the pair of intermediate portions joined to the pair of side panels by living hinges, and each intermediate portion joined to the front panel at a respective living hinge.

[114] The method further comprises filling the mould cavity with moulding material (S202). That is, advancing a shot of moulding material into the mould cavity. In one example, the method further comprises operating the injection system to advance the shot of moulding material into the mould cavity.

[115] In some examples, the material may be a suitable choice of thermoplastic or thermosetting polymers. Conveniently, use of plastics may result in an integrally-formed container 100 that is both sturdy and lightweight. Such a material choice may be highly suitable for mass production of containers and particularly of protective cases.

[116] The method further comprises curing the foldable container in the partially collapsed configuration (S204). In practice this may correspond to retaining the moulding material in the closed mould cavity while the moulding material hardens during a cooling process.

[117] The method further comprises extracting the foldable container from the injection moulding machine by opening the mould and removing the retractable core (S206).

[118] In one example, the method further comprises forming push-fit locking mechanism. Complementary features of the push-fit locking mechanism may be provided on the front panel and a closure panel, and may be arranged to engage for locking the container. In some examples, the closure panel is joined to a side panel by a living hinge. In this example, the closure panel is joined to the top panel by a living hinge.

[119] Overall appearance of a product may be among the product’s most important selling points. Conveniently, the described method may be used to manufacture a container 100 having a high-quality appearance. Additional manufacturing steps may be included to modify the appearance of the container.

[120] Figs. 10 to 12 illustrate another example of an integrally-formed foldable container 300. Conveniently, the foldable container 300 may be manufactured by means of injection moulding in either a flat configuration or a partially-assembled configuration as described above with reference to the earlier.

[121] The container 300 comprises a bottom panel 310, a first panel 320 (or ‘front panel’), a second panel 330 (or ‘side panel’), and a tab 340. According to the present example, the bottom panel and the first panel are substantially rectangular, while the second panel has a right triangular shape.

[122] The first panel 320, the second panel 330 and the tab 340 are moveable about the bottom panel 310 to change the foldable container 300 between the collapsed configuration and the assembled configuration. The collapsed configuration is illustrated in Fig. 10, while Fig. 12 shows the assembled configuration, and Fig. 11 shows a partially-assembled configuration. In its collapsed configuration the container 300 is substantially flat, whereas in its assembled configuration the container has a substantially triangular-prismatic shape.

[123] The tab 340 is joined to the first panel 320 by a first living hinge 342 defining a first fold line 344. In the informal figures, the living hinge areas are shown in black material to contrast against the white panels. However, the container is formed substantially from a single as herein described and the formal figures may show the container in a single colour. As herein described, the living hinge means the tab is foldable (or ‘rotatable) about the first fold line, thereby changing the tab between a configuration in which the tab is parallel to the first panel to a configuration in which the tab is perpendicular to the first panel.

[124] The second panel 330 is joined to the bottom panel 310 by a second living hinge 332 defining a second fold line 334. Similar to the arrangement described with respect to the tab 340, the second panel is foldable about the second fold line to change the second panel from being parallel to the bottom panel to being perpendicular to the bottom panel. In doing so, the second panel is lifted from a collapsed configuration beside the bottom panel. This is in contrast to the example discussed above where the side panel 140 was lifted from the bottom panel 110.

[125] The tab 340 is configured to couple the first panel 320 and the second panel 330 when the foldable container is in the assembled configuration. That is to say, the first panel and the second panel are configured to cooperate. According to the present example, the tab and the second panel are configured to cooperatively engage using a push fit mechanism. Suitably, the tab is provided with an aperture 336 configured to receive and retain a protrusion 336 formed on the second panel. It will be appreciated that the aperture and protrusion may be formed on either the tab or panel. Moreover, the protrusion may be integrally moulded or may be a separate part assembled to the panel or tab. Suitable coupling means are envisaged as rivet and studs, press buttons, metal snapper couplings, or magnetic couplings. However, other suitable coupling means are also envisaged to secure and unsecure the tab and panel to each other.

[126] The first fold line 344 and the second fold line 334 are generally parallel and offset relative to each other when the foldable container is in the collapsed configuration.

[127] The offset distance corresponds to approximately the panel thickness, by which the tab is offset into the first panel. That is to say, the first living hinge is formed towards an edge of the first panel, but without extending from said edge. This arrangement provides for the tab to fold inside the volume enclosed by the bottom panel, the first panel and the second panel, as illustrated in Fig. 11. In the assembled configuration the tab is therefore largely hidden within the enclosed volume of the foldable container.

[128] The tab 340 is relatively small compared to the first panel 320. The tab therefore extends beside part of the edge of the first panel along which it is provided. Equally, the first living hinge extends beside part of the edge of the first panel along which it is formed.

[129] The foldable container 300 comprises a third panel 350 (or ‘top panel’). The top panel, in use, provides a lid for closing the volume enclosed by the bottom panel, the first panel and the second panel.

[130] A closure flap 360 is provided on the third panel 350. The closure flap provides for a closure means by which the closure flap is attachable to the first panel. Suitably, the closure flap and the first panel are provided with cooperating components of a push fit mechanism, as described above.

[131] In summary, exemplary embodiments of an integrally-formed foldable container have been described. The described exemplary embodiments provide for an improved foldable container allowing straightforward manufacturing and high-quality finish. Additionally, the described exemplary embodiments are lightweight and convenient to use.

[132] The integrally-formed foldable container may be manufactured industrially. An industrial application of the example embodiments will be clear from the discussion herein.

[133] Although preferred embodiment(s) of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes may be made without departing from the scope of the invention as defined in the claims.

Claims

1. An integrally-formed foldable container (100, 300) manually configurable between a collapsed configuration and an assembled configuration, the foldable container comprising:

a bottom panel (110, 310); and a first panel (140, 320), a second panel (120, 330) and a tab (180, 340) which are moveable about the bottom panel to change the foldable container between the collapsed configuration and the assembled configuration;

wherein:

the tab is joined to the first panel by a first living hinge (182, 344) defining a first fold line (183, 346), and the tab is configured to couple the first panel and the second panel when the foldable container is in the assembled configuration;

the second panel is joined to the bottom panel by a second living hinge (112, 334) defining a second fold line (113, 336);

the first fold line and the second fold line are generally parallel and offset relative to each other when the foldable container is in the collapsed configuration.

2. The foldable container according to claim 1, wherein the tab is joined to the second panel by a further living hinge.

3. The foldable container according to claim 1, wherein the tab is attachable to the second panel when the foldable container is in the assembled configuration in order to couple the first panel and the second panel.

4. The foldable container according to any previous claim, wherein the first fold line and the second fold line are offset by a distance which is not less than a panel thickness of the first panel or the second panel.

5. The foldable container according to any previous claim, wherein in the collapsed configuration the tab and the first panel are generally parallel and in the assembled configuration the tab and the first panel are generally perpendicular.

6. The foldable container according to any previous claim, wherein the first living hinge is formed towards an edge of the first panel.

7. The foldable container according to claim 6, wherein the first living hinge extends along the entire edge of the first panel along which it is formed.

8. The foldable container according to claim 6, wherein the first living hinge extends along part of the edge of the first panel along which it is formed.

9. The foldable container according to any previous claim, further comprising a third panel and a second tab; wherein the second tab is joined to the first panel by a further living hinge and configured to couple the third panel and the first panel when the foldable container is in the assembled configuration.

10. The foldable container according to claim 9, further comprising a top panel joined to the third panel, the top panel comprising a closure means by which the top panel is attachable to the first panel or the second panel.

11. The foldable container according to claim 10, wherein the closure means comprises a closure flap, and wherein the closure flap and either the first panel or the second panel are provided with cooperating push-fit features configured to engage and disengage.

12. The foldable container according to any previous claim, wherein the foldable container is formed from polypropylene.

13. A method of manufacturing a foldable container manually configurable between a collapsed configuration and an assembled configuration, the method comprising:

forming a mould cavity and inserting a retractable core, the mould cavity defining the shape of the foldable container;

filling the mould cavity with a shot of moulding material;

extracting the foldable container by opening the mould and removing the retractable core;

wherein the foldable container comprises a bottom panel (110, 310), a first panel (140, 320), a second panel (120, 330), and a tab (180, 340); wherein the tab is joined to the first panel by a first living hinge (182, 344) defining a first fold line (183, 346), and the tab is configured to couple the first panel and the second panel when the foldable container is in the assembled configuration; the second panel is joined to the bottom panel by a second living hinge (112, 334) defining a second fold line (113, 336);

forming the foldable container in the mould cavity in a partially-collapsed configuration, and forming the first living hinge so that, when the foldable container is in the collapsed configuration, the first fold line is generally parallel to and offset relative to the second fold line.

14. The method according to claim 13, wherein the tab is configured to abut against the bottom panel when the foldable container is in the collapsed configuration.

15. The method as claimed in claim 13 or 14, forming a container according to any one of claims 2 to 12.