Note: Descriptions are shown in the official language in which they were submitted.
CA 02634890 2008-06-12
-1-
TITLE
COLLAPSIBLE STORAGE DEVICE
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. Patent Application
No. 11/361,530,
tiled February 23, 2006, which is a continuation-in-part of U.S. Patent
Application No.
11/102,965, filed April 11, 2005, which claims the benefit of U.S. Provisional
Patent Application
No. 60/561,497, filed April 12, 2004. Each of the aforesaid applications is
hereby incorporated
by reference herein in its entirety.
REFERENCE REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
SEQUENTIAL LISTING
[0003] Not applicable.
BACKGROUND OF THE INVENTION
1. Technical Field
[0004] The present invention is directed toward a device for storing objects,
and more
particularly a collapsible storage device.
2. Background Art
[0005] It is sometimes desirable to have a storage device that is convertible
between an
expanded position and a collapsed position. In the expanded position, the
storage device is
capable of retaining objects within an interior space. In the collapsed
position, the storage device
CA 02634890 2008-06-12
-2-
has less or even no storage capability but is more convenient to store because
it takes up less
space.
100061 A collapsible metal box container has a bottom, four sides, and a lid.
The bottom and
tour sides are connected to each other with pin and knuckle hinges. The lid is
connected to one
of the sides with pin and knuckle hinges. Each of the bottom and two opposing
sides is divided
into a pair of opposing triangular segments that are connected to each other
with pin and knuckle
hinges. The box can be folded or unfolded between an expanded box shape and a
substantially
flat or planar collapsed shape.
[0007] A collapsible pasteboard box has a rectangular side wall extending
upwardly from
each of four peripheral edges of a square bottom wall. Each side wall is
articulably connected to
each adjacent side wall along one of four linear vertical hinges and is
connected to the bottom
wall along one of four horizontal hinges. A diagonal hinge in the bottom wall
extends from one
corner to an opposite corner. A diagonal hinge in each of two opposing side
walls extends from
a lower corner of the side wall along the bottom wall to an end point along
the upper edge of the
side wall displaced from an upper corner. The box folds along the hinges
between a flat
collapsed position and a cubic or rectangular prismatic expanded position. The
box has the same
footprint outline in both the collapsed position and the expanded position so
that a lid accepts the
box in both such positions.
[0008] Another collapsible paperboard box has a base portion and a lid
portion. The base
portion has a square bottom wall and four outwardly slanted side walls. Each
side wall is
articulably connected to each adjacent side wall along one of four outwardly
slanted linear
hinges and is connected to the bottom wall along one of four horizontal
hinges. Two opposing
side walls are divided into three generally triangular sections by two
converging fold lines
extending diagonally from each bottom corner toward a central location along a
top edge thereof.
The lid portion is articulably attached to a top edge of a third one of the
side walls along a
horizontal hinge. The base portion folds flat along the hinges and the fold
lines, and the lid also
has a rim portion that folds flat.
CA 02634890 2008-06-12
-~-
[0009] Another collapsible cardboard container has a square bottom, four
rectangular side
walls extending upwardly from the bottom, and an opening opposite the bottom.
A removable
lid is provided to cover the opening with a peripheral flange fitting about
the side walls. Each
side wall is separated into three sections, and at least one of the sections
of each of the four side
walls is divided into a pair of hingedly connected opposing triangular
segments. The container is
folded between a collapsed position and an expanded position by twisting the
side walls to either
t'old or unfold the triangular segments.
[0010] Generally such metal and paperboard containers are not able to contain
fluids
without leaking without the addition of some sort of flexible liner or inner
leak proof container.
However, a flexible liner may be apt to tear and leak, and an inner container
may be
inconvenient and/or minimize or eliminate the benefit of the space saving
purpose of a
collapsible container. To overcome these challenges, some collapsible
containers have been
made of injection molded thermoplastics with living hinges articulably
connecting some adjacent
resilient panels. However, an inherent difficulty with injection molded living
hinge members,
called plastic memory, has made it difficult to make a collapsible container
that will remain in
the desired collapsed and/or expanded position. Because of plastic memory, the
living hinges
have a tendency to return to a relaxed position that is different from the
desired expanded or
collapsed position.
SUMMARY OF THE INVENTION
[0011] In one embodiment, a collapsible container includes a plurality of wall
panels. Each
wall panel is connected to each adjacent wall panel at a hinged connection,
and the wall panels
are arranged so as to articulate at the hinged connections between a collapsed
position and an
expanded position defining a bottom wall and a plurality of side walls
extending upwardly from
the bottom wall. The collapsible container further includes a deformed portion
on a side wall
disposed across a hinged connection. The deformed portion projects toward an
exterior of the
CA 02634890 2008-06-12
-4-
collapsible container to releasably lock the hinged connection in a convexly
bowed position
when the collapsible container is in the expanded position.
[0012] In another embodiment, a collapsible container including a plurality of
wall panels.
Each wall panel is connected to each adjacent wall panel at a hinged
connection, and the wall
panels are arranged so as to articulate at the hinged connections between a
collapsed position and
an expanded position defining a bottom wall and a plurality of side walls
extending upwardly
from the bottom wall. Each of two opposing side walls includes at least two
wall panels defining
a diagonal hinge extending substantially between diagonally opposite corners
of the side wall.
'l'he collapsible container also includes a deformed portion disposed across
at least one of the
diagonal hinges. The deformed portion projects toward an exterior of the
collapsible container to
releasably lock the diagonal hinge in a convexly bowed position when the
collapsible container
is in the expanded position.
[0013] These and other aspects and advantages of the present invention will
become apparent
upon consideration of the following detailed description in which;
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is an isometric view of a collapsible storage device according
to one
embodiment of the invention with a lid over an opening of a collapsible
container in an expanded
position;
[0015] FIG. 2 is an isometric view of the storage device of FIG. I with the
collapsible
container in a collapsed position and ready to be placed in a recessed portion
of the lid;
[0016] FIG. 3 is a vertical cross-sectional view of the storage device of FIG.
2 with the
collapsed collapsible container partly shown fitted into the recessed portion
of the lid;
[0017] FIG. 4 is a fragmentary cross-sectional view taken generally along the
lines 4-4 of
FIG. 1;
CA 02634890 2008-06-12
-5-
[0018] FIG. 5 is a fragmentary cross-sectional view taken generally along the
lines 5-5 of
FIG. 1;
10019] FIG. 6 is an isometric view of an embodiment of a collapsible container
having
arched living hinges;
[0020] FIG. 7 is an isometric view of yet another embodiment of a collapsible
container;
[00211 FIG. 8 is a partial cross-sectional view of the collapsible container
of FIG. 7 in a
collapsed position;
[0022] FIG. 9 is an enlarged isometric inside view in partial cross section of
a single
thickness corner of the collapsible container of FIG. 7;
[0023] FIG. 10 is an enlarged isometric inside view in partial cross section
of a double
thickness corner of the collapsible container of FIG. 7;
[0024] FIG. 11 is an isometric view of a collapsible container according to a
further
embodiment of the invention;
[0025] FIG. 12 is a partial isometric view of a bottom side of the collapsible
container of
FIG. 11;
[0026] FIG. 13 is an enlarged partial isometric view of an interlocking
mechanism on the
collapsible container of FIG. 11;
[0027] FIG. 14 is an enlarged partial isometric cutaway view of an upper
corner on the
collapsible container of FIG. 11 generally along the lines 14-14 of FIG. 11;
[0028] FIG. 15 is an enlarged partial isometric view of still another
interlocking mechanism
on a collapsible container;
[0029] FIG. 16 is an enlarged partial isometric view of a further interlocking
mechanism on a
collapsible container of the invention;
CA 02634890 2008-06-12
-6-
[0030] FIG. 17 is an isometric view of a collapsible container according to
yet another
embodiment of the present invention in a fully expanded position;
[0031] FIG. 18 is an isometric view of the collapsible container of FIG. 17 in
a fully
collapsed position;
[0032] FIG. 19 is an enlarged partial isometric cutaway view of a latch
assembly on the
collapsible container of FIG. 17 generally along lines 19-19 of FIG. 17;
[0033] FIG. 20 is an enlarged bottom partial view of the latch assembly shown
in FIG. 19;
[0034] FIG. 21 is an enlarged partial isometric view of a latch assembly
according to another
embodiment of the invention;
[0035] FIG. 22 is an enlarged bottom partial view of a latch assembly
according to yet a
further embodiment of the invention;
[0036] FIG. 23 is an enlarged fragmentary cross-sectional view taken generally
along the
line 23-23 of FIG. 17;
[0037] FIG. 24 is an isometric view of another lid adapted for use with a
collapsible
container of the present invention;
[0038] FIG. 25 is an isometric view of the collapsible container of FIG. 17 in
a collapsed
position and secured in the lid of FIG. 24;
[0039] FIG. 26 is a fragmentary cross-sectional view taken generally along the
lines 26-26 of
FIG. 24;
[0040] FIG. 27 is a fragmentary cross-sectional view taken generally along the
lines 27-27 of
FIG. 25;
[0041] FIG. 28 is a fragmentary cross-sectional view taken generally along the
lines 28-28 of
FIG. 25;
CA 02634890 2008-06-12
-7-
10042] FIG. 29 is a fragmentary cross-sectional view taken generally along the
lines 29-29 of
1'IG. 25;
10043] FIG. 30 is a partial isometric view of the lid of FIG. 24 on the
collapsible container of
FIG. 17;
[0044] FIG. 31 is a partial isometric view of the latch of FIG. 30 in a non-
use position;
[0045] FIG. 32 is an enlarged partial cross-sectional view of the lid, latch,
and collapsible
container of FIG. 31 along the lines 32-32 in a latched or use position;
[0046] FIG. 33 is an enlarged partial front view of the latch of FIG. 32;
[0047] FIG. 34 is an isometric view of a collapsible container according to a
further
embodiment in a fully expanded position;
[0048] FIG. 35 is an isometric view of yet another lid adapted for use with a
collapsible
container of the present invention;
[0049] FIG. 36 is an isometric view of a collapsible container according to
yet a further
embodiment in a fully expanded position;
[0050] FIG. 37 is an enlarged partial isometric view of an anti-fold lock on
the collapsible
container of FIG. 36 in a first position; and
[0051] FIG. 38 is an enlarged partial isometric view of the anti-fold lock of
FIG. 37 in a
second position.
DETAILED DESCRIPTION
[0052] Referring now to FIGS. 1-3, a single unit storage device 20 according
to the present
invention includes a collapsible container 22 and a lid 24. The container 22
includes resilient
wall panels connected by flexible hinges that are convertible between an
expanded position as
shown in FIG. I and a collapsed position as shown in FIG. 2. The container 22
and lid 24 in one
CA 02634890 2008-06-12
-8-
embodiment are made of a thermoplastic, such as polypropylene, polyethylene,
or other
polyoletin, nylon, or other resilient polymeric material. In another
embodiment, the container 22
and the lid 24 are made of organic or biodegradable polymers, such as
polyesters based on lactic
acid (for example, PLA). The container 22 includes a bottom wall 26 and four
side walls 28, 30,
32, and 34 extending upwardly from the outer periphery of the bottom wall.
Each of the bottom
wall 26 and the side walls 28, 30, 32, and 34 is substantially square in
shape, although one or
more of the walls may have a different shape. Each of the bottom wall 26 and
the side walls 28
and 32 includes a pair of complimentary triangular panels 26a, 26b, 28a, 28b,
and 32a, 32b,
respectively, wherein the panels of each pair are hingedly joined to form the
respective wall.
Each of the side walls 30 and 34 comprises a single panel 30a and 34a,
respectively. Each panel
26a, 26b, 28a, 28b, 30a, 32a, 32b, and 34a is connected to adjacent panels by
one of living
hinges 36a, 36b, 36c, 36d, 36e, 36f, 36g, 36h, 38a, 38b, and 38c such that the
container 22 may
be converted from the expanded position of FIG. I to the substantially flat
collapsed position of
FIG. 2. This conversion is accomplished by moving the panel 30 and the panel
34 in opposite
directions (as seen in FIG. 1) so that corners 42a and 42b converge toward one
another.
Continued opposite movement of the panels 30a and 34a results in rotation of
the panel 30a
clockwise and rotation of the panel 34a counterclockwise (as seen in FIG. 1)
90 with respect to
each other, during which time the panels 26a and 26b, 28a and 28b, and 32a and
32b collapse
inwardly toward one another in a folding motion about the hinges 38b, 38a, and
38c,
respectively. This collapsing is afforded by movement of the panels 26a, 26b,
28a, 28b, 30a,
32a, 32b, and 34a about the living hinges 36a-h and 38a-c. Eventually, the
panels 26a, 26b, 28a,
28b, 30a, 32a, 32b, and 34a collapse into the configuration shown in FIG. 2.
The collapsed
container 22 may be expanded by reversing the process. Another method of
converting the
container 22 to the collapsed position is to push bottom hinge 38b upwardly
and hinges 38a and
38b inwardly, which causes the same folding/collapsing motion of the panels
26a,b; 28a,b; and
32a,b, as described.
CA 02634890 2008-06-12
-9-
(0053] [n the expanded position, the bottom wall 26 and side walls 28, 30, 32,
and 34 of the
container 22 define an interior space 44, and upper edges 46 of the side walls
28, 30, 32, and 34
detine an opening 48 into the interior space. The interior space 44 of the
expanded container 22
may be tilled through opening 48 with a product (not shown). The force of the
product
contained within the interior space 44 pressing outwardly against the side
walls 28, 30, 32, and
34 and bottom wall 26, and hinges 38a-c assists in maintaining the container
22 in the expanded
position by preventing the panels 26a,b, 28a,b, and 32a,b from collapsing
inwardly, and in
another embodiment, one or more latching mechanisms are used to maintain the
container in the
expanded position. The lid 24 is adapted to cover the opening 48 to completely
enclose the
interior space 44.
[0054] The lid 24 has an interior, or product side 50 and an exterior, or
stacking side 52
opposite the product side. The lid 24 includes a cover plate 54, a peripheral
flange 56 with an
outwardly-flared skirt 58, a tapered lead-in 60, and a retaining wall 62 with
an inwardly-turned
lip 64 along the upper edge of the retaining wall. The flange 56 and lead-in
60 define a groove
66 extending around the outer periphery of the cover plate 54 on the product
side 50 of the lid
24. The cover plate 54 is adapted to cover the opening 48 of the container 22
when the container
is in the expanded position with the upper edge 46 of the side walls 28, 30,
32, and 34 fitting into
the peripheral groove 66 of the lid 24 so that the product side 50 is facing
any product contained
in the interior space 44. The tapered lead-in 60 and flared skirt 58 help
guide the upper edge 46
of the side walls 28, 30, 32, and 34 into the groove 66 as the lid 24 is being
placed over the
opening 48. The lead-in 60 extends below the flared skirt 58 with a gentle
enough taper to
readily catch the side walls 28, 30, 32, and 34 and urge them outwardly if
they are bowed
inwardly. For this purpose, the lead-in 60 is preferably tapered inwardly and
toward the center
of the lid 24 from the groove 66 a distance greater than any anticipated
inward bowing of the
side walls 28, 30, 32, and 34. The lead-in 60 is preferably formed by the
opposite side of a
recessed channel 68 in the cover plate 54 inwardly spaced from the outer
periphery of the cover
plate; however, any form of tapered lead-in structure could be used. In one
embodiment, the
CA 02634890 2008-06-12
-10-
recessed channel 68 extends continuously around the cover plate 54, and in
another embodiment,
the recessed channel extends intermittently around the cover plate. Structural
and aesthetic relief
indentations 70 in the cover plate 54 provide added structural integrity and
aesthetic design to the
lid 24. The retaining walls 62 protrude upwardly from and extend
intermittently around the
cover plate 54 to form a recess 72 on the stacking side 52 of the lid 24. The
recess 72 is adapted
to receive the container 22 in either the collapsed position or the expanded
position so that the
container can be stacked onto the stacking side 52 of the lid 24. The
container 22 lies
substantially flat within the recess 72 when in the collapsed position as
partially depicted in
dashed lines at 74 in FIG. 3. The lip 64 presses resiliently against the edges
of at least one of the
side walls 28, 30, 32, and 34 of the collapsed container 22 that is fitted
within the recess 72 to
releasably restrain the container within the recess by means of a snap-fit. A
thumb tab 76
extending outwardly from the flange 56 provides a convenient mechanism for
prying the lid 24
away from the container 22, both when the container is stacked within the
recess 72, and when
the lid is covering the opening 48.
[0055] Referring now to FIGS. 4 and 5, each living hinge 36a-h and 38a-c
according to one
embodiment of the present invention includes a notch 78 and a flexible hinge
portion 80 as best
seen in FIG. 4. The hinge portion 80 is slightly off center from the panel
axis, which provides a
measure of directionality to the hinge, and which conveniently lends itself to
describing the
hinges in the container 22 as being either interior hinges or exterior hinges.
An interior hinge is
a living hinge in which the hinge portion 80 is offset toward the interior
space 44 of the
expanded container 22. An exterior hinge is a living hinge in which the hinge
portion 80 is
offset away from the interior space 44 of the expanded container 22. Hinges
36a-h are interior
hinges, and hinges 38a-c are exterior hinges. This placement of interior and
exterior living
hinges allows the hinge portion 80 of each of the hinges 36a-h and 38a-c to be
rotated away from
the notch 78 when converting the container 22 from the expanded position to
the collapsed
position as shown in FIGS. 4 and 5, which minimizes any interference between
the panels on
opposite sides of the hinge portion as those panels are rotated about the
hinge portion. In another
CA 02634890 2008-06-12
-11-
embodiment, any or all of the hinges may be formed by fold lines that are
defined in the walls of
the container 22 by other methods.
100561 In an embodiment shown in FIG. 6, a collapsible container 100 has a
fold geometry
similar to the collapsible container 22 and has arched living hinges. Each
vertical corner hinge
36a, 36b, 36c, and 36d is an out-of-plane arched hinge. The bottom wall 26
(not shown) and
opening 48 are generally square, and each side wall 28, 30, 32, and 34 has a
straight upper edge
46 and straight bottom edge 47. In this embodiment, the opening 48 is larger
than the bottom
wall 26 so that the arched vertical corner hinges 36a-d are always inside a
vertical projection of
the opening 48 in order to facilitate easy ejection of the container 100 from
a non-segmented
mold. In another embodiment, the opening 48 is the same size as the bottom
wall 26, and the
arched vertical hinges 36a-d bow outwardly of the vertical projection of the
opening. Other
embodiments may have different combinations of arched hinges such as: having
all of the hinges
be out-of-plane arched hinges, having at least one of the hinges be an out-of-
plane arched hinge
with the remaining hinges being straight hinges, having at least one in-plane
arched hinge and at
least one straight hinge, and having a combination of in-plane arched hinges,
out-of-plane arched
hinges, and straight hinges. In another embodiment according to the present
invention, the
diagonal hinges 38a-c are in-plane arched hinges, and in another embodiment,
the diagonal
hinges 38a-c are out-of-plane arched hinges. In any embodiment including
arched living hinges,
the amount of non-linearity between the ends of the hinge may be sufficient to
cause the arched
hinges to be bi-modal, having a stressed mode when the hinges are folded and
an unstressed
mode when the hinges are not folded. The arched hinges may be formed by an
edge having a
single arcuate segment, by an edge having a plurality of distinct arcuate or
linear segments,
and/or by other non-linear shapes.
[0057] In yet another embodiment of the present invention shown in FIGS. 7-10,
a leak
resistant plastic container 200 that is injection molded as a single piece
from polyethylene has
the same fold geometry as the container 22 and includes three-dimensional side
wall panels and
variable width hinges. As best seen in FIGS. 8-10, each of the side walls 26,
30, and 34 includes
CA 02634890 2008-06-12
-12-
a diagonal offset, or step 202, located at transition points between a two-
layered thickness of
panels and a four-layered thickness of wall panels when the container is in
the collapsed position.
Fach of the vertical corner hinges 36a and 36c (best seen in FIG. 10) is an
inside living hinge
including a hinge web 204 having a width designed to accommodate the combined
thicknesses of
wall panels 28a,b, 32a,b between wall panels 34a and 30a in the collapsed
position. Each of the
horizontal hinges 36e-h is an inside hinge having a cutaway portion on an
exterior side thereof to
reduce stresses therein when the container 200 is in the collapsed position.
The diagonal hinges
38a, 38b, and 38c are outside hinges and include a hinge web 206 smaller than
hinge web 204 to
reduce the thickness of the hinges when in the collapsed position. The
vertical corner hinge 36d,
horizontal hinges 36h and 36g, and diagonal hinge 38a converge at a single
thickness corner 208,
shown in FIG. 9, which is also the same as single thickness corner 210. The
vertical corner
hinge 36c, horizontal hinges 36g and 36f, and diagonal hinge 38b converge at a
double thickness
corner 212, which is also the same as double thickness corner 214. When the
container 200 is in
the expanded position, the diagonal hinge 38b twists along the length thereof
from each corner
212 and 214, where the panels 26a and 26b are level with each other, toward an
intersection with
the step 202, where the panels 26a and 26b are offset from each other.
Protrusions, such as feet
216, are disposed on an exterior surface of the panels 26a, 26b and have
different heights to
compensate for the offset of the panel 26a from the panel 26b at the step 202
so that the
expanded container 200 sits stably when placed on a flat support surface. Each
side wall 28, 30,
32, and 34 is slightly trapezoidal having an upper edge 46 that is slightly
longer than the bottom
edge 47 in order to provide a draft angle along the side edges of each side
wall of between
approximately 0.75 and 1.5 for molding purposes. In order to form the square
opening 48, the
side walls 28 and 32, in one embodiment, have smaller draft angles than side
walls 30 and 34 in
order to adjust for the offset caused by the steps 202 in the wall panels 30a
and 34a. In another
embodiment, each side wall 28, 30, 32, and 34 has the same draft angle. In
order to
accommodate the draft angles, the diagonal hinges 38a and 38c extend from
single thickness
corners 208 and 210, respectively, and terminate at a position slightly
laterally offset from the
upper corners 42a and 42b, respectively, which allows the side wall panels to
collapse without
CA 02634890 2008-06-12
-13-
overlapping. A lip 218 extends along an exterior side of the upper edges 46
for snap-fit retention
of a lid (not shown) when the container 200 is in the expanded position. In
one embodiment,
each of the wall panels 26a,b, 28a,b, 30a, 32a,b, and 34a has a substantially
constant thickness.
In another embodiment, one or more of the wall panels 26a,b, 28a,b, 30a,
32a,b, and 34a have
varying thicknesses to accommodate structural and manufacturing purposes, such
as offsetting
warpage caused by bending of the completed container or by cooling of recently
formed panels.
In a further embodiment, the wall panels are formed of polypropylene having a
thickness
between about 0.01 and about 0.04 inches (about .25 - about 1.02mm), and the
hinges are
lormed of polypropylene having a thickness between about 0.001 and about 0.015
inches (about
.025 - about .38mm). In a still further embodiment, the wall panels have a
thickness between
about 0.001 and about 0.5 inches (about.025mm - about 13mm), and the hinges
have a thickness
between about 0.0001 and about 0.3 inches (about .0025mm - about 7.6mm).
[0058] In FIGS. 11-14, another collapsible container 300 according to the
present invention
is shown. The collapsible container 300 is similar to the collapsible
containers 22 and 200 in that
opposing side walls 28 and 32 are divided into opposing triangular wall panels
28a, 28b, and
32a, 32b by diagonal hinges 38a and 38c, respectively, bottom wall 26 (best
seen in FIG. 12) is
divided into two triangular wall panels 26a and 26b by a diagonal hinge 38b,
and side walls 30
and 34 are each defined by a single wall panel 30a and 34a, respectively. The
diagonal hinge
38b is an out-of-plane arched hinge that is arched convexly away from the
interior space 44
when the collapsible container 300 is in the fully expanded position. In
addition, a leg 302
extends downwardly from each of the side walls 28, 30, 32, and 34 beyond the
bottom wall 26 to
form a cavity or space between the bottom wall and a supporting surface, such
as a tabletop (not
shown), when the container 300 is laid on the supporting surface in the
expanded position, which
provides space for the diagonal hinge 38b to arch downwardly out of the plane
of the bottom
wall 26. Arching the diagonal hinge 38b convexly or downwardly locks the hinge
in a position
that helps maintain the collapsible container 300 in the expanded position,
because, in this
embodiment, the diagonal hinge folds towards the interior space 44 to collapse
the container into
CA 02634890 2008-06-12
-14-
the substantially flat position. Steps 202 formed in the side walls 30 and 34
and the bottom wall
26 are adapted to allow the collapsible container 300 to collapse
substantially flat over different
numbers of wall panel layers in the collapsed position as previously described
herein (best
shown, for example, in FIG. 8). A locking mechanism 306 (best shown in FIG.
13) is located at
opposite vertical corners to automatically lock the collapsible container 300
in the expanded
position when the collapsible container is converted from the collapsed
position to the expanded
position. The locking mechanism 306 includes a first interlocking portion 306a
extending from
the wall panel 28b and a second interlocking portion 306b extending from the
wall panel 30a
along the respective upper edges 46 thereof. The first interlocking portion
306a includes a
female recess that releasably interlocks with a male projection on the second
interlocking portion
306b when the collapsible container 300 is converted into the expanded
position. In one
embodiment, the female recess is circular and the male projection is a
complementary circular
shape coplanar with the female recess that resiliently snap-fits therein. As
shown in FIG. 14, a
lip 308 extending along an outer periphery of the upper edge 46 of the
container 300 has a slit
3 10 therethrough located at the corners of the collapsible container
extending inwardly to the
respective vertical corner hinges 36b and 36d, which allows the corners to
fold more easily into
the collapsed position.
[0059] In FIG. 15, a collapsible container 350 according to the present
invention includes
another locking mechanism 352 having a first interlocking socket portion 352a
carried on an
exterior side of a wall panel 354 that releasably interlocks with a second
interlocking ball portion
352b carried on an exterior side of an adjacent side wall panel 356 when the
wall panels pivot
around an intermediate vertical corner hinge 358 from an angle of about 0 to
an angle of about
90 as shown by the arrows A. FIG. 16 shows yet another locking mechanism 360
suitable for
use with a collapsible container of the present invention, such as the
collapsible container 350,
having a first interlocking arm 360a and a second interlocking arm 360b. The
first interlocking
arm 360a extends from side wall panel 362 past vertical corner hinge 364, and
the second
interlocking arm 360b extends from adjacent side wall panel 366 past the
vertical corner hinge.
CA 02634890 2008-06-12
-15-
"rhe first interlocking arm 360a automatically resiliently interlockingly
engages the second
interlocking arm 360b as the wall panels 362 and 366 pivot along the vertical
corner hinge 364
trom an angle of about 0 to an angle of about 90 . A tab 368 at the end of
the first interlocking
arm 360a extends beyond the second interlocking arm 360b to allow a user to
unlatch the
interlocking arms for disengagement. Each of the locking mechanisms 306, 352,
360 may be
used with any collapsible container of the invention, such as the collapsible
container 300, to
supplement or replace the latch 306, for example, to maintain the collapsible
container in the
expanded position.
[00601 Turning now to FIGS. 17-20, a container 400 according to another
embodiment of the
invention is collapsible and includes hold-open latches 402 and hold-closed
latches 404
integrally formed therewith that automatically secure the container in an open
expanded position,
shown in FIG. 17, and in a substantially flat collapsed position, shown in
FIG. 18. The
collapsible container 400 has eight wall panels 26a,b, 28a,b, 30a, 32a,b, and
34a, which are
hingedly joined by vertical corner hinges 36a-d, horizontal corner hinges 36e-
h, and diagonal
hinges 38a-c to be articulable between an open expanded position defining a
substantially square
bottom wall 26 and four upstanding side walls 28, 30, 32, and 34 and a flat
collapsed position in
a manner generally similar to that described for the collapsible container 22,
except that side
walls 28, 30, 32, and 34 are substantially trapezoidal to form arched out-of-
plane vertical corner
hinges similar to those described for the container 100. Further, the hinges
are all substantially
similar to the corresponding variable width hinges described previously for
the container 200. In
this embodiment, the container 400 is made of a single mass of resilient
thermoplastic, such as
polypropylene, and all the hinges 36a-h and 38a-c have a thickness less than
about 0.015 inches
(about 0.38 mm) to reduce the effect of plastic memory therein and still have
sufficient durability
to cycle many times without breaking or splitting. In one embodiment, the wall
panels 26a,b,
28a,b, 30a, 32a,b, and 34a have a thickness between about 0.005 inches (about
0.13 mm) and
about 0.5 inches (about 13 mm), and the hinges 36a-h and 38a-c have a
thickness between about
0.001 inches (about 0.025 mm) and about 0.015 inches (about 0.38 mm). In
another
CA 02634890 2008-06-12
-16-
embodiment, the wall panels 26a,b, 28a,b, 30a, 32a,b, and 34a have a thickness
of about 0.025
inches (about 0.64 mm), and the hinges 36a-h and 38a-c have a thickness of
about 0.005 inches
(about 0. 13 mm).
(0061] The hold-open latches 402, which automatically releasably lock the
container 400 in
the open expanded position, are located on two diagonally opposite vertical
corners 406a, 406b
along top edge 46 of the wall panels at the opening 48. As best seen in FIGS.
19 and 20, each of
the hold-open latches 402 includes a hooked interlocking member 408 and a
groove interlocking
member 410. The hooked interlocking member 408 has a hook member 412 disposed
at a distal
end of an extension member 414 that protrudes angularly from an exterior
surface of the wall
panel 34a spaced from the generally vertical corner hinge 36d. The hook member
412 has a
horizontal portion 412a that extends substantially perpendicularly radially
away from the
generally vertical corner hinge 36d and a vertical portion 412b that extends
downwardly from the
horizontal portion substantially parallel with and spaced from the generally
vertical corner hinge.
The vertical portion 412b points toward the generally vertical corner hinge
36d, and the
horizontal portion 412a points toward the bottom wall 26. The groove
interlocking member 410
has a groove portion 416 at a distal end of an extension member 418 that
protrudes angularly
from an exterior surface of the wall panel 28b at the generally vertical
corner hinge 36d. The
groove portion 416 is defined by and between an interference member 420 spaced
from a stop
member 422. The interference member 420 has a horizontal portion 420a and a
vertical portion
420b that engage with the horizontal portion 412a and vertical portion 412b,
respectively, of the
hook member 412. The hook member 412 and the groove portion 416 are spaced
substantially
radially outwardly from the generally vertical corner hinge 36d. Opposing
leading edges of the
hook member 412 and the interference member 420 are angled so as to
resiliently slide past each
other and automatically interlock as the wall panels 28b, 34a articulate about
the generally
vertical corner hinge 36d into a substantially perpendicular relation, and the
hook member 412
abuts against the stop member 422 to prevent the wall panels 28b, 34a from
rotating substantially
beyond perpendicular. In one embodiment, the stop member 422 is arranged so
that the wall
CA 02634890 2008-06-12
-17-
panels 34a and 28b can extend between about 1 and about 20 beyond the
perpendicular so that
the leading edge of the hook member 412 can completely slide past the leading
edge of the
interference member 420 and interlock slightly beyond a 90 angle. A
horizontal flange or upper
lip 424 protrudes outwardly along the top edge 46 of each of the wall panels
28b, 30a, 32a, and
34a and tapers to no width or a very small width a short distance from
respective adjacent top
corners 42a, 42b, preferably at or before the location of the end of the
respective diagonal hinges
38a, 38c and steps 202. The horizontal flange 424 buttresses the respective
hooked interlocking
members 408 and groove interlocking members 410 to prevent the wall panels
28b, 34a and 30a,
32a from extending substantially beyond perpendicular with respect to each
other. In addition, a
gusset 426 extending between each horizontal flange 424 and the respective
hooked interlocking
member 408 and groove interlocking member 410 provides additional
reinforcement thereto. In
this embodiment, the steps 202 are wavy rather than linear in order to provide
a visual cue to a
user that the steps are not hinges.
[0062] A hold-closed latch 404 is disposed adjacent to each hold-open latch
402. Each hold-
closed latch 404 includes a retention member that is spaced from the
respective wall panel (e.g.,
28b) and engages a portion of an adjacent wall panel (e.g., 28a or 30) and/or
an adjacent hinge
(e.g., 36e) when in the flat collapsed position. In the embodiment shown in
detail in FIG. 19, the
retention member includes a pad 428 that is spaced from and substantially
parallel to the wall
panel 28b and frictionally engages the wall panel 28a and/or 30a in the
collapsed position. An
edge of the pad at a cutout or notch 430 resiliently snap-fits with an end
portion of the hinge 36e
as the container 400 articulates into the flat collapsed position. The pad 428
is disposed entirely
within the bounds of the wall panel 28b because the diagonally opposite corner
of the wall panel
28a is displaced from a peripheral edge of the wall panel in the flat
collapsed position due to the
curvature of the generally vertical corner hinges 36a and 36d, which thereby
reduces the size of
the outline of the container 400 in the collapsed position. In another
embodiment, the pad 428
aligns with the corner and does not have or require the cutout notch 430, and
the hold-closed
latch 404 includes a clip member that overlaps a diagonally opposite corner
portion of the wall
CA 02634890 2008-06-12
-18-
panel 28a in the collapsed position. In further embodiments, the hold-closed
latch 404 may
include adhesives, and/or hook-and-loop fasteners.
(0063] In operation, the hold-open latches 402 actuate as the wall panels 28b,
34a and 30a,
32a articulate between included angles of about 0 and about 90 , and the hold-
closed latches
actuate as the wall panels 28a, 28b and 32a, 32b articulate between included
angles of about 180
and about 0 . For example, as the wall panels 28b and 34a rotate about the
generally vertical
hinge 36d from about a 0 angle in the flat collapsed position to about a 90
angle in the
expanded position, the hooked interlocking member 408 and the groove
interlocking member
410 rotate toward each other and automatically resiliently engage so as to
maintain the wall
panel 28b substantially perpendicular with the wall panel 34a. The wall panels
28b and 34a are
articulated slightly beyond 90 to fully interlock the hook member 412 and the
groove portion
416, and then are allowed to relax back toward the substantially perpendicular
state. To
disengage the hold-open latches 402, a user may simply urge the collapsible
container 400
toward the flat collapsed position, which causes the hooked interlocking
member 408 to
automatically resiliently disengage from the groove interlocking member 410.
Then, as the wall
panels 28a and 28b rotate about the diagonal hinge 38a from about a 180 angle
in the expanded
position to about a 0 angle in the flat collapsed position, a portion of the
horizontal hinge 36e
near the corner of the wall panels 28a, 30a approaches and frictionally
engages the edge of the
pad 428 in the cutout portion 430 to hold the wall panels 28a and 28b folded
at the substantially
0 angle. To disengage the hold-closed latches 404, the user may simply urge
the container 400
back toward the expanded position, or the pads 428 may be pried away to
release the horizontal
hinge 36e. In one embodiment, the pad 428 is pivotally spaced from the wall
panel 28b by a
strut 432 (best shown in FIG. 18) such that pressing on one end of the pad
pivotably disengages
the other end of the pad from the horizontal hinge 36e. In the present
embodiment, the hold-
open latches 402 make an audible cue, such as a clicking sound, or "pop," and
a tactile sensation,
such as a "snap," when they engage and disengage, and the hold-closed latches
404 make an
audible cue when they engage. (Only the hold-open and hold-closed latches near
corner 406a are
CA 02634890 2008-06-12
-19-
described in detail herein, it being understood that the hold-open and hold-
closed latches near
corner 406b are substantially identical with respect to corresponding portions
of the
corresponding wall panels.)
[0064] In one embodiment, the container 400 is injection molded as a unitary
mass of
polypropylene in or near the expanded position, which allows the hold-open
latches 402 to be
lormed without special moving mold parts that would require a secondary
sliding action during
the mold process. Further, this molding technique also produces a container
that is substantially
leak proof. When molded in the expanded position, the mold parts that define
the hooked
interlocking member 408 and the groove interlocking member 410 form a gap
therebetween so
that the interlocking members are molded in an operable condition, i.e., a
condition that allows
the interlocking members to lock and unlock, without requiring a subsequent
step of cutting the
interlocking members apart or removing excess material.
[0065] In other embodiments, other types of hold-open latches may be used with
the
container 400 (or any of the collapsible containers disclosed herein) to
supplement or replace the
hold open latches 402. For example, a hold-open latch is shown in FIG. 21 that
includes two
opposing clip members 440a and 440b, in which each clip member has only a
horizontal portion
extending perpendicularly outwardly from the respective wall panels 34a and
28b. The clip
member 440a has a resilient upwardly pointing outer interlocking member 442a
and a resilient
downwardly pointing inner interlocking member 442b. The clip member 440b has a
resilient
downwardly pointing outer interlocking member 444a and a resilient upwardly
pointing inner
interlocking member 444b. As the wall panels 34a and 28b rotate from an
included angle of
about 0 to about 90 , the clip member 440a snaps into interlocking engagement
with the clip
member 440b, wherein the upwardly pointing outer interlocking member 442a
releasably
interlocks with the downwardly pointing outer interlocking member 444a, and
the downwardly
pointing inner interlocking member 442b releasably interlocks with the
upwardly pointing inner
interlocking member 444b. In FIG. 22, yet another embodiment of a hold-open
latch for use
with any of the containers disclosed herein, such as 400, includes a vertical
interlocking portion
CA 02634890 2008-06-12
-20-
including opposing clip members 450a, 450b. The clip member 450a has a
vertical channel
disposed at an end of an extension member 414 and defined between two inwardly-
turned hooks
452a and 452b. The clip member 450b has two vertical outwardly-turned hooks
454a, 454b
disposed at an end of the extension member 418. "The inwardly-turned hooks
452a, 452b receive
and interlock with the outwardly-turned hooks 454a, 454b to maintain the
container 400 in the
expanded position. A further embodiment of a hold-open latch includes an
elastic strap (not
shown) extended across one or more of the corners 42a,b and/or 406a,b, which
urges the
container 400 (or 22) toward the expanded position and causes the container to
spring open when
released from the collapsed position. Yet a further embodiment of a hold-open
latch is a clip
(not shown) that folds down over one or more of the diagonal hinges 38a-c to
stiffen and
maintain the container in the expanded position.
[0066] Referring again to FIGS. 17 and 18, a bracket 460a,b is disposed on an
exterior side
of each side wall 30, 34 of the collapsible container 400. Further, the
brackets 460a,b include
spaced apart detents 462a,b and 462c,d, respectively, and posts 464a,b,
respectively. In the
present embodiment, the brackets 460a,b also include one or more flanges 466
that stabilize the
brackets 460a,b. For example, in FIG. 17 the brackets 460a,b are secured to
the respective side
walls 30, 34 by tlanges 466 disposed on side edges of the brackets and an
additional flange 466
is connected to the side walls and to a generally centered upper portion of
the brackets. In one
embodiment, the brackets 460a,b are adapted for use as handles for the
container 400. In another
embodiment described hereinafter, the brackets 460a,b are also adapted to
facilitate attachment
of a lid to the container.
[0067] In the present embodiment, the brackets 460a,b are disposed on side
walls 30 and 34
so that they do not interfere with the other side walls when the container 400
is folded into the
collapsed position. However, in a different embodiment, the brackets 460a,b
are disposed on
side walls 28 and 32 and are adapted to allow the container 400 to fold into a
substantially flat
collapsed position, for example, by being substantially flush with the
horizontal flange 424.
CA 02634890 2008-06-12
-21-
[0068] "rhe collapsible container 400 of FIG. 17 also includes stabilizers,
such as 470a or
470b, for stabilizing the container in an open expanded position. In one
embodiment, the
stabilizers 470a,b are deformed portions in the side walls 28 and 32,
respectively. The stabilizers
function to prevent or resist the side walls from folding inwardly when fully
expanded. In the
einbodiment of FIG. 17, the stabilizers 470a,b are circular and are disposed
across the diagonal
hinges 38a,c, wherein the center of the circular stabilizers are generally
disposed at a mid-point
of the diagonal hinges. In other embodiments, the stabilizers can take on any
other shape, such
as, oval, triangular, rectangular, star shaped, tear-drop, or any other
symmetrical or non-
symmetrical shape. Further, the center of the stabilizers 470a,b may be
disposed at any point
along the diagonal hinges 38a,c, and/or the center of the stabilizer may be
offset from the
respective diagonal hinge.
[0069] FIG. 23 shows a cross-section generally along lines 23-23 of the
stabilizer 470a of
FIG. 17. In operation, when the container 400 is fully expanded, the
stabilizer 470a projects out
of the plane of the side wall 28 and takes on a shallow, dome-like form that
releasably locks the
diagonal hinges 38a,c in a convexly bowed position, thereby resisting or
preventing the hinges
from unwantedly folding inwardly until the stabilizers are pushed-in. The
stabilizer 470b
operates in the same manner as the stabilizer 470a. The stabilizers 470a,b are
pushed towards
the interior of the container 400 to unlock the diagonal hinges 3 8a,c and
allow the container 400
to transition towards the collapsed position. Further, the stabilizers 470a,b
provide a visual
target that indicates a good location to push to begin the collapsing process
of the container 400.
[0070] Similar to the lid 24 of FIGS. 1-3, another embodiment of a lid 480 is
shown in FIGS.
24-33 for covering the mouth 48 of the container 400 in the expanded position
and receiving the
entire container in the flat collapsed position. The lid 480 has an interior
or product side 482,
and an exterior or stacking side 484. The product side 482 includes a
generally square, central
plate 486 for covering the mouth 48 of the container 400. The exterior side of
the central plate
486 defines a recess surrounded by a peripheral collar portion 488, which is
dimensioned to
receive the bottom footprint of the expanded container 400 to facilitate
stacking of an expanded
CA 02634890 2008-06-12
-22-
container thereon. Inner walls 490, such as a wall section 490a and posts 490b
and 490c include
one or more projections or snap-fit detents for securing the container 400 in
the lid 480 in the flat
collapsed position. For example, as seen more clearly in FIGS. 26-29, the wall
section 490a
includes snap-tit detents 492a, 492b, and posts 490b and 490c include snap-fit
detents 492c and
492d, respectively, which resiliently engage edges of the wall panels of the
collapsible container
400 in the collapsed position.
10071] A channel 494 is defined around the outer periphery of the central
plate 486 between
the peripheral collar portion 488 and a peripheral tlange 496, which defines a
sidewall around an
outermost periphery of the lid 480. The channel 494 receives the sidewalls 28,
30, 32, 34 of the
container 400, which helps stabilize the container in the expanded position
and in one
embodiment also forms a liquid-tight seal therewith. The peripheral flange 496
includes an
outwardly turned rim portion 498, which helps guide the upper lip 424 of the
side walls 28, 30,
32, 34 into the channel 494.
[0072] In the present embodiment, the lid 480 receives and retains the
collapsible container
400 in the flat collapsed position with a tapered corner of the container
disposed adjacent the
wall section 490a (as best seen in FIG. 25). The tapered corner is formed due
to the curvature of
the generally vertical corner hinges. The snap-fit detent 492a on the wall
section 490a is adapted
to secure a first side wall of the container (as seen in FIG. 27) and the snap-
fit detent 492b on the
wall section 490a is adapted to secure a second side wall of the container (as
seen in FIG. 28).
The snap-fit detents 492c, 492d on the posts 490b,c, respectively, are adapted
to secure the
container 400 in the collapsed position (as seen in FIG. 29). When the
container 400 is in the
expanded position, the posts 490b, 490c press outwardly against an inside
surface of one or more
of the container side walls 28-34 to help maintain the container 400 in the
expanded position
when the upper lip 424 of the container is received in the channel 494.
[0073] As best seen in FIGS. 24, 25, and 30-33, hold down latches 500a,b
extend beyond the
outwardly turned rim 498 on opposite sides of the lid 480. Each hold down
latch 500a,b has a
hinge 502 disposed between a lever 504 and the outwardly turned rim 498 that
allows the lever
CA 02634890 2008-06-12
-23-
to articulate toward and away from the side walls of the container when the
upper lip 424 of the
container 400 is disposed inside the channel 494 in the expanded position as
shown in FIG. 32.
A flexible finger 506 with a hook 508 extends from opposite side edges of the
lever 504, and a
cam member 510 extends from the lever toward the container 400. In one
embodiment, the hold
down latches 500a,b include one or more detents 512 extending from a distal
end of the lever
502 for releasably locking the hold down latch in a non-use position shown in
FIG. 31. The lid
480 further includes corner tabs 514a,b that facilitate prying the lid from
the container 400 in the
expanded position to gain access to the interior of the container. The corner
tabs 514a,b also
Facilitate prying the lid from the container 400 when the container is the
flat collapsed position
and retained by the lid 480. Further, the channel 494 in one embodiment
includes a recess 516
that is shaped to receive and hold the hold open latches 402 together when the
lid 480 is disposed
on the container 400 in the expanded position.
[0074] FIGS. 30-33 illustrate some possible interactions between the hold down
latch 500b
and the bracket 460a. (The hold down latch 500a and bracket 460b interact in a
substantially
similar manner.) When the lid 480 is disposed on the upper lip 424 to cover
the opening 48, the
lever 504 may be rotated toward the container 400 such that the hooks 508 on
the fingers 506
interlockingly snap-fit outwardly under the detents 462a,b. The lever 504 may
also be rotated
away from the container 400 and secured adjacent to the lid 480 in a non-use
position by an
interference fit formed by the detents 512 and the channel 494 on the exterior
side 484 of the lid
(as seen in FIG. 31). In one embodiment, the cam member 510 pries against the
post 464a as the
lever 504 is articulated downwardly to pull the lid 480 tightly onto the upper
lip 424 of the
container 400.
[0075] FIG. 34 shows another embodiment of a collapsible container 520 that is
similar in
structure and function to the collapsible container 400 of FIG. 17 with
differences as noted
hereinafter. The container 520 includes hold open latches 402 and hold closed
latches 404
similar to the latches shown in FIGS. 19-20. However, other embodiments of
hold open and
hold closed latches can be used, such as the hold open and hold closed latches
of FIGS. 21 and
CA 02634890 2008-06-12
-24-
22. In addition, the container 520 includes tear drop shaped stabilizers
470c,d, which function
similarly to the circular stabilizers 470a,b illustrated in FIGS. 17 and 23. A
center of the
stabilizers 470c,d is offset from a mid-point of the diagonal hinges 38a,c.
Further, the container
520 includes brackets 460c,d similar to the brackets 460a,b, except that the
brackets 460c,d
include detents 462e,f and 462g,h, respectively, and posts 464c,d,
respectively. The posts 464c,d
project downwardly and outwardly from the upper lip 424 of the container 520
at an acute angle.
In one embodiment, posts 464c,d provide handles for the container 520 when in
the expanded
position. In addition, the posts 464c,d are flexible portions of the brackets
460c,d, respectively,
that are adapted to compress inwardly toward the respective side walls 30, 34
to facilitate the
container 520 folding into the flat collapsed position. In particular, the
flexible posts 464c,d on
the container 520 compress inwardly when the container in the collapsed
position is received in a
lid, such as the lid 480 or the lid 530 of FIG. 35, so that the container 520
is retained in a
substantially parallel orientation with the lid.
[0076] Referring to FIG. 35, a lid 530 is adapted for use with any of the
collapsible
containers described herein, such as the container 520 of FIG. 34, for
example. The lid 530 is
similar to the lid 480 and is adapted to cover the collapsible container 520
in the expanded
position and receive the container in the collapsed position in a generally
similar manner, but
with some differences as described hereinafter. A wall section 490d and a post
490e project
from the collar portion 488 on the interior side 482 of the lid 530. The wall
section 490d is
similar to the wall section 490a and includes snap-fit detents 492e,f that
retain side walls of the
collapsible container 520 in the collapsed position. The post 490e is similar
to the posts 490c,d
and is a generally L-shaped wall that is disposed along a diagonally opposite
corner from the
wall section 490d and further includes snap-fit detents 492g,h. The post 490e
and snap-fit
detents 492g,h are adapted to retain a generally perpendicular or square
corner of the collapsible
container 520 in the collapsed position and to press outwardly against the
container side walls in
the expanded position. The lid 530 includes one or more projections or ribs
532 disposed along
the channel 494 that form an interference fit with the upper lip 424 of the
container 520 in the
CA 02634890 2008-06-12
-25-
expanded position to further secure the lid 530 to the container. In one
embodiment, the lid 530
is adapted for use with the collapsible container 520 (FIG. 34), and a
peripheral flange 496
disposed on the lid is angled at a substantially similar angle as the posts
464c,d to be compatible
therewith.
[0077] In a further embodiment, the lids 480 and/or 530 are a cork-type lid
having a sealing
member (not shown), such as the tapered lead-in 60 of the lid 24 that seals
against the inner
surface of the side walls 28, 30, 32, and 34.
[0078] Now referring to FIG. 36, a collapsible container 550 according to a
further
embodiment is similar to the collapsible container 100 of FIG. 6 and includes
features from the
collapsible container 400 of FIG. 17 (as indicated by the same reference
numbers) with some
differences, which are noted hereinafter. The container 550 includes an anti-
fold lock 552 that is
disposed proximate to the hinge 36a. The anti-fold lock 552 includes a tab 554
connected to the
container 550 adjacent the upper lip 424 at a hinge 556. In one embodiment,
the tab 554
includes connectors 558, 560 that are disposed on opposite sides of the tab,
and the container 550
includes connectors 562, 564 that are disposed on adjacent side walls 28, 30,
respectively. The
connector 558 on the tab 554 is adapted to engage connector 562 on the side
wall 28, and the
connector 560 on the opposite side of the tab is adapted to engage connector
564 on the side wall
30. The connectors 558-564 may be any type of suitable engagement mechanisms,
for example,
protrusions that form an interference fit therebetween, opposing male and
female interlocking
members such as a tongue and groove, adhesive strips, and/or opposing hook and
loop fasteners.
In addition, the container 550 includes a bracket 566 that is similar to the
brackets 460a,b of FIG.
17. Further, the collapsible container 550 may include an anti-fold lock 552
that is disposed
proximate to the hinge 36c (as seen in FIGS. 37 and 38). The anti-fold locks
552 proximate to
the hinges 36a,c are similar in structure and function.
[0079] Shown most clearly in FIGS. 37 and 38, the anti-fold lock 552
articulates about the
hinge 556 between a first position where the tab 554 is positioned adjacent
the side wall 32 (as
seen in FIG. 37) and a second position where the tab 554 is positioned
adjacent the side wall 34
CA 02634890 2008-06-12
-26-
(as seen in FIG. 38). In the first position, the connector 558 on the tab 554
engages the
connector 562 on the side wall 32. In particular, the tab 554 is secured
across the diagonal hinge
38c and acts as a tie and/or stiffener between the hinge 36c and the connector
562 on the side
wall 32, which thereby prevents the relative motion of the wall panels 32a,b
about the diagonal
hinge 38c. Specifically, the anti-fold lock 552 in the first position prevents
the diagonal hinge
38c from folding inwardly and stabilizes the container 550 in the expanded
position. In one
embodiment, the tab 554 is injection molded as part of the container 550 and
is made of the same
material as the container, such as a resilient polymeric material. In this
embodiment, the resilient
characteristics of the tab 554 further serve to prevent the diagonal hinge 38c
from folding when
the anti-fold lock 552 is in the first position. In the second position, the
connector 560 on the tab
554 engages the connector 564 on the side wall 34 to secure the anti-fold lock
552 against the
side wall 34 in a non-use position and to allow the diagonal hinge 38c to fold
inwardly so that
the container 550 can transition toward the collapsed position.
[0080] In another embodiment, the anti-fold lock 552 does not include the
connector 560 and
the container 550 does not include the connector 564 on the side wall 34. In
this embodiment,
the tab 554 frictionally engages an edge of the bracket 566 at a notch 568
when the anti-fold lock
552 is in the second position and secured adjacent the side wall 34. The anti-
fold lock 552 that is
disposed proximate the hinge 36a can be similarly adapted to frictionally
engage a bracket 566
on the side wall 30 without including the connectors 560, 564.
[0081] In yet another embodiment, the container 550 is adapted for use with a
lid, such as the
lid 530 of FIG. 35. In this embodiment, the anti-fold locks 552 are
substantially parallel with the
side walls 28-34 in the first and second positions so that the anti-fold locks
552 do not interfere
with the placement of the lid 530 on the upper lip 424 of the container 550.
Alternatively or in
conjunction, the anti-fold locks 552 are spaced a distance from the upper lip
424 so that the lid
530 can be placed on the container 550 without engaging the anti-fold locks.
[0082] In yet other embodiments (not shown), the collapsible containers
disclosed herein,
such as the containers 400, 520, and 550 may include one or more handles, pour
spouts, and/or
CA 02634890 2008-06-12
-27-
hangers. 1'he container may have a non-skid surface on an exterior side of the
bottom wall 26,
suc11 as with texture or adhesive. Denesting bumps may be added to an exterior
or interior side
ol'any of the side walls 28-34 near the upper edge 46 to keep the container
when in the expanded
position from sliding too tightly into another container that is also in the
expanded position. The
lids, such as lids 480 and 530 may include appropriately arranged detents to
snap onto the
bottom wall 26 of the container when in the expanded position to keep the lid
with the container
and to provide additional support for the bottom wall. The container and/or
lid may also be
fabricated out of materials including foam for insulation, susceptor materials
for
microwaveability, aluminum, and/or other metals.
[0083] Other embodiments of the invention including all the possible different
and various
combinations of the individual features of each of the foregoing described
embodiments are
specifically included herein.
INDUSTRIAL APPLICABILITY
[0084] A storage device having a collapsible container and lid according to
the present
invention may be used to store any of many types of items or substances. The
collapsible
container and lid may have any convenient size ranging from very small to very
large. A
specific potential use contemplated for the storage device is for the
containment and storage of
food products (not shown). The food products may be stored within the interior
of the
collapsible container when in the expanded position, and the lid is used to
close the collapsible
container. When no food products are stored in the storage device, the
collapsible container may
be collapsed to the collapsed position and placed within a recess in the lid
to provide for
convenient storage of the entire storage device in a compact form. The hold-
open and hold-
closed latches and the arched living hinges on the container help the
container overcome
problems associated with plastic memory in the hinges by helping maintain the
container in both
the expanded position and the collapsed position and still have a unitary
thermoplastic container
that is substantially leak proof at the living hinges. Further, brackets can
be included to serve as
CA 02634890 2008-06-12
-28-
handles for the container. Still further, hold down latches on the lid can
interact with the
brackets on the container to further secure the lid on the container in the
expanded position. In
another aspect of the collapsible container, stabilizers are disposed across
hinges of the container
to releasably lock the hinges in a bowed position that helps maintain the
container in the
expanded position. In another embodiment, anti-fold locks are disposed on the
container to
secure hinges against folding toward a collapsed position.
[0085] Numerous modifications to the present invention will be apparent to
those skilled in
the art in view of the foregoing description. Accordingly, this description is
to be construed as
illustrative only and is presented for the purpose of enabling those skilled
in the art to make and
use the invention and to teach the best mode of carrying out the same. The
exclusive right to all
modifications within the scope of the impending claims is reserved.
