WO2016051208A1

WO2016051208A1 - Collapsible plastic container and methods for forming the same

Info

Publication number: WO2016051208A1
Application number: PCT/GB2015/052901
Authority: WO
Inventors: Paul Cheney
Original assignee: Tiddler Inc Llp
Priority date: 2014-10-03
Filing date: 2015-10-05
Publication date: 2016-04-07
Also published as: GB201417493D0; GB2530800A

Abstract

A container (2) for food and/or beverage type items is at least partially defined by two or more wall portions (6), which include at least a first sidewall portion (7), and at least one thin or foldable wall portion (9). The container also has a base portion (5) and optionally a lid (4). It is convertible between a first substantially flattened storage or transport condition and a second in-use or expanded condition by manipulation of the wall portions and/or base. The at least one thin wall portion (9) is formed or located between a first sidewall (6) portion and the base (5), wherein the thin wall portion is connected to at least the first sidewall portion by a hinge (12, 13).

Description

COLLAPSIBLE PLASTIC CONTAINER AND METHODS FOR

FORMING THE SAME

The present invention relates to an improved container for one or more items.

Although the following description refers to containers for food and drink type items, the person skilled in the art will appreciate that the present invention could be used to contain and transport other non-food based items and is not limited to food, drink and beverages.

The packaging for food items in containers which can be heated to thereby cook the contents is known. A particular problem with such containers is that the containers are not suitable, functionally or aesthetically, for serving and consuming the contents. Furthermore, such containers including two or more compartments is also known. For example, ready-made meals such as curries are packed in a container that typically includes a compartment for rice and a compartment for the curry. Once cooked, both the rice and the curry are normally combined on a plate or the contents combined in a single compartment.

The problems with this are that a considerable mess is created in transferring and mixing the foods. Furthermore, it is unlikely that any compartment will be large enough to accommodate the combined items . In addition, these types of containers are unsuitable for foodstuffs where it is desirable to mix the contents part way through the cooking process to combine flavours and the like as again the contents have to be transferred to a larger container. Providing at least one of the items in a larger compartment is undesirable as this increases the transport costs of the container and contents. WO2015/054402 discloses a container that can be moved between a collapsed and expanded configurations using a series of living hinges. A problem with such a product is that a living hinge has force within it and has the potential to be under stress . Therefore a pot or container manufactured from a series of living hinges could collapse, particularly if subject to a small external force or filled with hot liquid.

It is therefore an aim of the present invention to provide an improved container that addresses the abovementioned problems.

It is a further aim of the present invention to provide a method of manufacturing a container that addresses the abovementioned problems.

It is a yet further aim of the present invention to provide a method of combining one or more items in a container that addresses the abovementioned problems.

In a first aspect of the invention there is provided a container for food and/or beverage type items, said container at least partially defined by two or more wall portions, said wall portions including at least a first sidewall portion, and at least one thin or foldable wall portion, said container also including a base portion and convertible between a first substantially flattened storage or transport condition and a second in-use or expanded condition by manipulation of the wall portions and/or base, said at least one thin wall portion being formed or located between a first sidewall portion and the base, wherein the thin wall portion is connected to at least the first sidewall portion by a hinge. Thus a collapsible container is provided that can be converted between a collapsed or storage configuration and an expanded configuration. Typically the thin wall portion is and/or substantially forms a region of flexion. Further typically the thin wall bend, flexes, folds and/or the like at one or more points on the area of the same when moving the container between the first and second conditions.

In a preferred embodiment the container includes first and at least a second sidewall portion wherein said thin wall portion is disposed or located substantially between the side wall portions. Typically the thin wall portion is attached or connected to the first sidewall portion by said hinge. Further typically the second sidewall portion is attached to and/or depends from the base portion.

In one embodiment the thin wall portion depends from the second sidewall portion forming a region of flexion between said first and second sidewall portion and is attached to the bottom of the first sidewall portion via a hinge. Typically the thin wall portion depends from substantially the top of the second sidewall portion.

In one embodiment the hinge connecting the thin wall portion to the first sidewall portion is a living hinge.

In one embodiment the area where the thin wall portion and the second sidewall portion is connected includes some resilience and/or is resiliently biased. Typically the area acts as a spring that substantially holds the container in the first and/or second conditions. Further preferably the container includes a lid wherein at least a portion of the lid being removable to access the items contained therein in use.

Typically at least the sidewall portions are substantially linear, straight or non-curved when viewed in vertical cross-section. Further typically the thin wall portion is substantially curved, non-linear and/or S-shaped when viewed in vertical cross section in at least the second condition. Typically the S-shape is an elongated S-shape.

In one embodiment the thin wall portions are substantially inverted and/or turned upside down when moving the container from the first condition to the second condition.

Typically the thin wall portion is smaller in cross sectional area or diameter when compared to the one or more sidewall portions. Further typically the at least one sidewall portion is thicker or larger in cross section in comparison to the one or more thin wall portions .

Further typically the sidewall portions are more rigid than the thin wall portions. Typically the thin wall portions are more flexible or less rigid than the side wall portions.

Typically, at least part of the thin wall portions flex, distort and/or invert when moving the container between the first and second conditions or configurations.

Thus the container is substantially expandable when moved or manipulated to the second condition. Furthermore the container is substantially collapsible when moved or manipulated from the second condition to the first. Typically the size of the container is increased or expanded in at least one dimension when moved from the first to the second condition. Further typically the flexible or thin wall portions are collapsible such that the volume of the container is smaller in the first condition than the second.

In one embodiment the thin wall portions at least partially define one or more compartments. Typically the thin wall portions, sidewall portions and/or the base portion define one or more compartments when in the first condition. Further typically the sidewall portions, thin wall portions and the base define a single compartment in the second in use condition.

In one embodiment the thin wall portions are connected or substantially attached to the base and/or sidewall portions by one or more flexible portions, sprung portions, fold-lines and/ or the like.

Thus items can be kept separate in different compartments inside a container when in the first condition and by manipulation of the container the contents can be mixed and/or a larger compartment formed.

In one embodiment an outer sidewall is located substantially around the periphery of the container in at least the first condition.

In one embodiment at least a first thin wall portion is located substantially between the outer wall and a second sidewall portion located inside the outer wall portion when in the first condition.

In one embodiment the container includes a second thin wall portion located substantially between a second and third side wall portions. Typically that the walls of a container can be formed by a series of side wall portions with thin wall portions disposed between the same. Further typically the walls of the container comprise alternating sidewall portions and thin wall portions.

In one embodiment the compartments are substantially concentric with the outer sidewall portion. Typically the outer sidewall portion is substantially circular or cylindrical.

In one embodiment at least part of the thin or foldable wall portion and/or regions of flexion are manipulated or moved to substantially extend the walls and/or height of the container in the second expanded in-use condition. Further typically the compartments are combined or consolidated by the movement of the thin wall potions towards the second condition.

In one embodiment at least the wall members comprise a substantially resilient material. In a preferred embodiment at least the wall members comprise polypropylene and/or polyethylene.

Typically the thin wall portions are deformed by manipulation, applying pressure, force, pulling and/or the like to the sidewall portions and/or the base portion. Further typically the wall portions and/or the base portion retain substantially their original shape or form when in at least the second condition.

In one embodiment the regions of flexion form one or more ridges or peaks when in at least the first condition. Typically the side wall members are substantially vertical when in the first and/or second condition. Further typically the wall portions and/or areas of flexion substantially partition the inside of the container into two or more compartments when in at least the first condition.

In one embodiment the ridges abut and/or contact the lid in at least the first condition. Typically one or more of the ridges are attached and/or adhered to at least part of the lid.

In one embodiment at least part of the lid can be selectively removed. Typically at least part of the lid can be removed to open one or more compartments, leaving one or more compartments closed.

Typically once used, substantially empty and/or the contents accessed the container can be collapsed to aid disposal and/or storage.

Further typically the container is a single use and/or disposable container.

In one embodiment the lid, or at least part thereof is detachably attached to at least part of the outer sidewall.

In one preferred embodiment the container includes a circular base portion. Typically the base portion is substantially centrally located.

In one embodiment the container includes a rim portion. Typically the rim portion depends outwardly from the edge of the outer side wall. Further typically the rim depends substantially perpendicularly from the edge of the outer sidewall portion.

In one embodiment the container is expanded or extended from the base potion by pulling the rim and/or outer wall upwards or in combination of alternatively pulling the base downwards, thereby expanding the container in a substantially vertical direction.

In one embodiment the container includes one or more grip members to provide the user with a portion or section to grip or hold and enable the container to be moved from the first to at least the second condition. Typically the grip members are any one or any combination of tabs, labels, flaps and/or the like.

Preferably at least the wall portions of the container are formed from injection moulding. Further preferable the wall portions, including the sidewall portion and thin wall portions, and/or the base portion are formed from hot tip injection moulding. Typically the moulding process is single point hot tip injection moulding to form the container.

In a second aspect of the invention there is provided a container including at least one side wall portion and at least one foldable or thin wall portion, said container formed from hot tip injection moulding.

Preferably the process by which the container is formed is a single point hot tip injection moulding process.

In a third aspect of the invention there is provided a method of forming a container, said container including at least one side wall portion and at least one foldable or thin wall portion wherein the method includes the step of injecting a polymer into a mould.

Preferably the injection is a single point hot tip injection. In a forth aspect of the invention there is provided a container for food and/or beverage type items, said container at least partially defined by an outer wall, a foldable portion and a lid, at least a portion of the lid being removable to access the items contained therein in use and the container is convertible between a first substantially flattened storage or transport condition and a second in-use condition by manipulation of the foldable portion wherein the foldable portion forms one or more compartments inside the container when in the first condition and said outer wall and/or foldable potions are substantially straight or linear when the container is viewed in vertical cross section.

In a further aspect of the invention there is provided a container for food and/or beverage type items, said container at least partially defined by an outer wall, a foldable portion and a lid, at least a portion of the lid being removable to access the items contained therein in use and the container is convertible between a first substantially flattened storage or transport condition and a second in-use condition by manipulation of the foldable portion wherein the foldable portion forms one or more compartments inside the container when in the first condition.

Thus the container is substantially expandable when moved or manipulated to the second condition. Furthermore the container is substantially collapsible when moved or manipulated from the second condition to the first.

Typically the size of the container is increased or expanded in at least one dimension when moved from the first to the second condition. Further typically the foldable portion is collapsible such that the volume of the container is smaller in the first condition than the second. Typically the foldable portion includes a number of members or walls that at least partially define the one or more compartments. Further typically the foldable members are connected or substantially attached by one or more flexible portions, fold-lines and/or the like.

In one embodiment the outer wall is located substantially around the periphery of the container in at least the first condition.

In one embodiment the foldable portion is located substantially between the outer wall.

In one embodiment the compartments are substantially concentric with the outer wall. Typically the outer wall is substantially circular or cylindrical.

In one embodiment at least part of the foldable portion and or members are manipulated or moved to substantially extend the outer wall of the container in the second expanded in-use condition. Typically the foldable portion is manipulated or unfolded to increase the size of the compartments. Further typically the compartments are combined or consolidated by unfolding the foldable potion towards the second condition.

In one embodiment the foldable portion and/or members forming the same comprise a substantially resilient material. Typically the material can be deformed by manipulation, applying pressure and or the like but at least the members retain substantially their original shape or form.

In one embodiment the foldable portion members form one or more ridges or inner walls when in at least the first condition. Typically the foldable portion members thereby partition the inside of the container into two or more compartments when in at least the first condition. Further typically moving one or more members removes the partition and/or moves the container to the second condition.

In one embodiment the lid, or at least part thereof is detachably attached to at least part of the outer wall.

In one embodiment the container includes a base portion. Typically the base portion is substantially centrally located.

In one embodiment the container is expanded or extended from the base potion by pulling the outer wall upwards, thereby expanding the container in a substantially vertical direction. In a yet further aspect of the invention there is provided a method of manufacturing a container, said container including an outer wall, a foldable portion and a lid, at least a portion of the lid being removable to access the items contained therein in use and the container is convertible between a first substantially flattened storage or transport condition and a second in-use condition container by manipulation of the foldable potion wherein the foldable portion forms one or more compartments inside the container when in the first condition, said method including the step of;

- substantially forming at least part of the container from plastics material.

Typically at least part of the foldable portion comprises plastics material.

In a yet further aspect of the invention there is provided method of combining one or more items in a container, said container including an outer wall, a foldable portion and a lid, at least a portion of the lid being removable to access the items contained therein in use and the container is convertible between a first substantially flattened storage or transport condition and a second in-use condition container by manipulation of the foldable potion wherein the foldable portion forms one or more compartments for location or separation of items inside the container when in the first condition, and the method includes the step of;

- manipulating the foldable portion such that the contents of the compartments is combined.

Typically the foldable portion is at least partially unfolded and/or expanded to remove one or more of the partitions forming the compartment. In a further aspect of the invention there is provided a collapsible container.

Specific embodiments of the invention are now described with reference to the following figures wherein;

Figures l a- I d show vertical cross sectional views of container in accordance with the invention;

Figures 2a-2c show front elevated views of a container in accordance with one embodiment of the invention;

Figures 3a and 3b show cross sectional views through the side of a container in accordance with one embodiment of the invention;

Figure 4 shows a perspective view of a container in the collapsed or storage condition;

Figures 5a-5c show perspective views of a container being expanded in accordance with one embodiment of the invention;

Figures 6a and 6b show cross sectional views through the side of a container in accordance with one embodiment of the invention; and

Figures 7a-7c show show perspective views of a container being expanded in accordance with one embodiment of the invention.

The present invention as shown in figures 1 and 2 is a single use collapsible injection molded polypropylene or polyethylene packaging container 2 with a separate lid 4 sealed to it enabling the package to contain, preserve, protect, store and merchandise the product it contains. The container is designed to collapse allowing the container, once filled and lidded, to travel through the manufacturers and retailers supply chain in its collapsed, compressed state. The addition of a molded tab, separate label or other device which is attached to the base 5 of the container allows the consumer to pop the container back up to its original state at point of use, creating the void 8 required to prepare, consume or dispense the product from.

As the container 2 and product within, travels through the manufacturers and retailers supply chain in its compressed form it significantly reduces the overall volume of the package and increases the amount of units that can be stored on a pallet, transported on a vehicle or held on the retailer's shelf. This creates significant financial and environmental savings without sacrificing convenience for the consumer who is able to create the void required to prepare and consume or dispense the product from, at point of use.

The container is constructed from a plurality of wall portions 6 which include thicker or more rigid sidewall portion 7 with one or more thin and/or weakened thin wall sections 9 sandwiched between the thicker or strengthened walls 7. As force is applied to either collapse the container 2 or pop it back up from its collapsed state, the force is transferred through the stronger walls 7 into the weakened section or sections 9 between. This causes the weakened sections to flex, distort, invert and/ or spring into position locking the container in either its collapsed or original state.

The way the thinner section 9 between two thicker section 7 design works, compared to prior art examples which relies solely on the living hinge principle, allows the package to be molded in one shot, at high speed whilst ensuring the package, which can in some instances be filled with hot liquids, remains rigid, stable and safe for the consumer to consume product directly from.

The walls of the collapsed container as shown in figure l a can be configured to form one or more cells 8,10 into which single products or different component parts of a multi part product can be filled. Once the lid is applied single or component parts of a product can be discretely separated, sealed and transported within the one container with these separate elements then mixed by the consumer at point of use.

The material recipe of the container has unique properties that allow the container to be injection molded in one shot, at high speed without the need for co-molding or post molding treatments (unlike a lot of prior art) which is key in enabling cost effective production of the item and making the same economically viable for as a single use packaging item.

The manufacture of the package requires facilitates single point hot tip injection molding. A process which, in conjunction with the design of the container, ensures the correct molecular alignment of the polypropylene or polyethylene polymers the container is manufactured from. This molecular alignment is critical in ensuring the container collapses with minimal force and without rupturing as the container is collapsed or popped back up.

Unlike existing multi use "storage" or utensil products (cup bucket bowl) currently in the marketplace this container is designed to be a single use disposable with a heat sealed lid applied to it. This lid 4 can be hermetically sealed to protect and preserve the product or products contained within. To allow the lid to be sealed to the container the container must be manufactured from polypropylene or polyethylene material. The thick wall 7/thin wall 9/thick wall 7 construction of the pot means and single point hot tip injection molding of the pot enables the pot to be collapsed without the need for any post molding process. Unlike the traditional "living hinge" design widely used throughout the plastics industry which must be flexed shortly after molding to ensure it performs well in use. The removal of this secondary process makes this pot cheaper to produce but also and more importantly, this design ensures the pot 2 is stable when filled with potentially hot liquid. The single living hinge 12 and region of flexion 9 ensures the container pops into place after being inverted into either it upright or collapsed state and the amount of force required to distort and invert the thin wall or series of thin walls when inverting the pot ensures it springs from one state to the other. Once popped into place the inverted thin walls hold the container securely in position.

Figures l c and I d show close up vertical cross section view of the walls 6 of the container 2 and in particular how the region or part 13 of the wall where the thin wall 9 meet the top of a thick wall 7 differs from the hinge, or living hinge, where the top of a tin wall meets the bottom of a thick wall, in that the region 13 acts as a spring or biased portion, holding the container in either its original flattened condition. Figure I d shows how as the pot is collapsed the hinge 12 pivots and the thin wall 9 inverts.

Turning now to figures 3-7 which show an additional embodiment of the invention which discloses a collapsible container, designed to contain beverage, food and non food products, sealed with a lid that is opened and popped up at point of use. When popped up the space created around the product allows the product to be prepared, dispensed or consumed from within the container. As the void required to prepare the product (mix, microwave, rehydrate etc.) is created by the consumer at point of use as the container is popped up, the volume of the pack produced stored and transported through the suppliers network is minimised.

The walls of the collapsed container can be profiled to form one or more cells into which single products or different component parts of a product can be filled. Once the lid is applied single or component parts of a product can be discretely separated, sealed and transported within the one container.

Turning to figure 3a where there is shown a cross section of a collapsible container 2 that includes a lid 4. The container includes a number of walls 6, 6', 6" that define a number of compartments or cells 8, 10 that contain different items. In this example cell 8 contains noodles and cell 10 contains sauce that are kept separate in this collapsed or storage condition/configuration. The container 2 can be expanded to an in-use bowl-like configuration by manipulating the walls to unfold the same and thereby create a larger single compartment as shown in figures lb and 3b and mixing the contents. The joints or hinges 12 between the walls comprise plastics material in this example. The person skilled in the art will recognise that other materials, such as metal foil, could be suitable.

Furthermore, multipoint injection molding techniques allow containers such as this to be made from one or more plastic materials. It is now possible to form the wall of the container from one material and the part that flexes (the area of flexion) from something else, for example silicon rubber. It should be noted that such prior art is more expensive to manufacture than the present invention and not always suitable for microwave cooking of the product within. Figure 4 shows a perspective view of the same container 2 with the lid 4 removed, wherein the shape of the container, defined by the outer wall 6, can be seen as well as the concentric or annular arrangement of the inner walls 6', 6" which define and partition the cells or compartments 8, 10. The inner walls are folded about joints 12 between the wall members in a concertina-like fashion such that the container is shorter along the central longitudinal axis of the container when in the collapsed storage arrangement than when in the longer expanded arrangement. To warm or cook the contents the container 2 can be placed in an oven, such as a microwave oven and/or the like.

Figures 5a-5b show how a substantially collapsed or flat configured container split into compartments can be expanded into a bowl or larger single container by moving and/or manipulation of the walls. In the collapsed or first storage configuration the container and therefore the contents are significantly less expensive to store and/or transport.

Although the present examples are circular or cylindrical containers, there person skilled in the art will appreciate that the present invention could be applied to square or rectangular (cuboidal) containers.

Figures 6 and 7 show further examples of the invention wherein additional annular compartments 10', can be added by the inclusion of a pair of walls 6"', 6"" to form an additional partition or ridge 14. As such, compartments can be selectively combined to mix the contents at different stages or items that are substantially incompatible in storage can be kept separate until ready for use. Furthermore, a large container such as a bowl is formed from which the meal can be consumed. The container can then be collapsed for disposal, storage or reuse.

Claims

1. A container for food and/or beverage type items, said container at least partially defined by two or more wall portions, said wall portions including at least a first sidewall portion, and at least one thin or foldable wall portion, said container also including a base portion and convertible between a first substantially flattened storage or transport condition and a second in-use or expanded condition by manipulation of the wall portions and/or base, said at least one thin wall portion being formed or located between a first sidewall portion and the base, wherein the thin wall portion is connected to at least the first sidewall portion by a hinge.

2. A container according to claim 1 wherein the thin wall portion is smaller in cross sectional area or diameter when compared to the one or more sidewall portions.

3. A container according to claim 1 wherein the container includes first and at least a second sidewall portion wherein said thin wall portion is disposed or located substantially between the side wall portions.

4. A container according to claim 3 wherein the thin wall portion is attached or connected to adjacent sidewall portions by a single living hinge and region of flexion.

5. A container according to claim 4 wherein the second sidewall portion is attached to and/or depends from the base portion.

6. A container according to claim 1 wherein the container includes a lid wherein at least a portion of the lid being removable to access the items contained therein in use.

7. A container according to claim 1 wherein the sidewall portions are substantially linear, straight or non-curved when viewed in vertical cross-section when in the first condition and/or second condition.

8. A container according to claim 1 wherein the thin wall portions are substantially inverted and/or turned upside down when moving the container from the first condition to the second condition.

9. A container according to claim 1 wherein the sidewall portions are more rigid than the thin wall portions.

10. A container according to claim 1 wherein the container includes a second thin wall portion located substantially between a second and third side wall portions.

1 1. A container according to any preceding claim wherein least the wall members comprise polypropylene and/or polyethylene.

12. A container including at least one side wall portion and at least one foldable or thin wall portion, said container formed from hot tip injection moulding.

13. A container according to claim 12 wherein the container is formed is a single point hot tip injection moulding process.

14. A method of forming a container, said container including at least one side wall portion and at least one foldable or thin wall portion wherein the method includes the step of injecting a polymer into a mould.

15. A container for food and/or beverage type items, said container at least partially defined by an outer wall, a foldable portion and a lid, at least a portion of the lid being removable to acces s the items contained therein in use and the container is convertible between a first substantially flattened storage or transport condition and a second in-use condition by manipulation of the foldable portion wherein the foldable portion forms one or more compartments inside the container when in the first condition and said outer wall and/or foldable potions are substantially straight or linear when the container is viewed in vertical cross section.