HK40007566B - Collapsible shape-retaining containers - Google Patents

Description

Collapsible shape-retaining container

Technical Field

The present invention relates to a shape retaining collapsible container. More particularly, a collapsible container, collapsible bottle, collapsible bucket, collapsible basket, and collapsible food container for holding a bulk liquid are provided.

Background

To have a large capacity, the container must necessarily be large. However, such containers do not necessarily occupy a large volume when not in use. Accordingly, there is a need for a container that can be stored in a compact configuration when not in use.

The container in use will typically have an excess capacity relative to the capacity actually used within the container. These containers may then occupy an excessive amount of space when in use. Therefore, there is a need for a container whose size and capacity can be varied to better match the volume of its contents.

Various types of adjustable volume containers are known in the art, but they have a number of disadvantages. In particular, it has been found that these containers can be difficult to expand or collapse, especially if they are large. Moreover, it has been found that these containers do not fold or expand evenly and easily, especially if they have corners. Therefore, there is also a need for a capacity-adjustable container that expands easily and easily, and folds evenly and easily.

Another disadvantage of previous adjustable-volume containers is that they are difficult to make waterproof economically and efficiently when they must be made of two or more separate parts. Therefore, there is also a need for a cost-effective waterproof volume-adjustable container made of separate components.

Tunable volume containers typically have a smaller volume than an equivalent non-tunable container. There is a need for a capacity-adjustable container that has the same or similar capacity when expanded as compared to a non-adjustable container.

Disclosure of Invention

Various types of collapsible containers are provided according to the present invention. In one embodiment, a collapsible container has a generally annular rigid upper deck and an opening in an upper portion of the upper deck, a rigid lower deck, and collapsible wall sections connected to the upper and lower decks. The collapsible wall section comprises at least a first, a second and a third substantially annular layer of collapsible wall sections. The foldable wall portion also has an upper flap adjacent the lower edge of the upper layer, a lower flap adjacent the upper edge of the lower layer, and at least two intermediate flaps. The layers of the first and second foldable wall parts are connected to each other by one of the intermediate flaps. The layers of the second and third foldable wall parts are connected to each other by the other of the intermediate flaps. The first layer is located above the second layer, and the second layer is located above the third layer. The size of the container volume may be increased by unfolding the foldable wall portion from the folded configuration to the expanded configuration and may be decreased by folding the foldable wall portion from the expanded configuration to the folded configuration. When the foldable wall portion is in the folded configuration, the foldable wall portion is at least partially within one of the upper and lower decks, and the other of the upper and lower decks is at least partially within the foldable wall portion.

In one aspect of the invention, the second layer is adjacent to the first layer and the third layer. In addition, the first and third layers are flexible, while the second layer is rigid. In the folded state, the foldable wall parts are folded along the leaflet between the first and second layers and along the leaflet between the second and third layers.

In another aspect of the invention, the foldable wall portion is folded along the upper leaf and along the lower leaf in the folded position.

In another aspect of the invention, the first, second and third layers are substantially vertical in the expanded configuration and the folded configuration.

In yet another aspect of the invention, the lower layer has a generally annular first portion and a second portion. The first and second portions are secured together by an over-molded thermoplastic layer that at least partially covers the first and second portions. Preferably, one of the first and second portions has a female member and the other of the first and second portions has a corresponding male member which is inserted into the female member. Preferably, the lower layer comprises an inner wall exposed to the interior of the container, the inner wall comprising at least a portion of the male member.

Typically, the second portion has an imperforate base. The collapsible container may have a tap and a tap passage through the lower portion through which the tap extends, for example for use as a beverage container or jug.

The second portion is generally annular. Typically, the container further comprises a bottom layer below the lower layer and a second collapsible wall portion connected to the lower layer and the bottom layer. The second foldable wall section comprises at least fourth, fifth and sixth substantially annular layers of foldable wall sections, a second upper flap adjacent a lower edge of the lower layer, a second lower flap adjacent an upper edge of the lower layer, and at least two intermediate flaps. The layers of the fourth and fifth foldable wall parts are interconnected by one of the intermediate flaps. The layers of the fifth and sixth foldable wall parts are interconnected by the other of the intermediate flaps. The fourth layer is located over the fifth layer and the fifth layer is located over the sixth layer. The size of the container volume can be increased by unfolding the second foldable wall portion from the second folded configuration to the second expanded configuration, and the size of the container volume can be decreased by folding the second foldable wall portion from the second expanded configuration to the second folded configuration. When the second foldable wall portion is in the second folded configuration, the second foldable wall portion is at least partially located within one of the lower layer and the bottom layer, and the other of the lower layer and the bottom layer is at least partially located within the second foldable wall portion.

In another aspect of the invention, the second portion is generally annular. Typically, the container further comprises a bottom layer below the lower layer and a second collapsible wall portion connected to the lower layer and the bottom layer. The second foldable wall section comprises at least a fourth, a fifth and a sixth substantially ring-shaped layer of foldable wall sections, a second upper leaflet adjacent the lower edge of the lower layer, a second lower leaflet adjacent the upper edge of the lower layer, and at least two intermediate leaflets. The layers of the fourth and fifth foldable wall parts are interconnected by one of the intermediate flaps. The layers of the fifth and sixth foldable wall parts are interconnected by the other of the intermediate flaps. The fourth layer is located over the fifth layer and the fifth layer is located over the sixth layer. The size of the container volume can be increased by unfolding the second foldable wall portion from the second folded configuration to the second expanded configuration, and the size of the container volume can be decreased by folding the second foldable wall portion from the second expanded configuration to the second folded configuration. When the second foldable wall portion is in the second folded configuration, the second foldable wall portion is at least partially positioned within one of the lower deck and the bottom deck, and the other of the lower deck and the bottom deck is at least partially positioned within the second foldable wall portion.

In another aspect of the invention, the collapsible container further comprises a rim having an underside, a flexible rim member and a rigid rim underside member. Typically, the container further comprises a lid having a plurality of peripheral flaps for securing the lid to the container. Typically, the upper layer, the lower layer, the foldable wall parts and the flexible edge parts are made of an elastomer, said flexible edge parts being connected to said upper layer. More preferably, the flexible edge means is directly connected to said upper layer. The rigid rim underside member may be made of a non-elastomeric plastic. Each peripheral flap includes a hook for securing the lid to the container, each flap being adjustable from a hooked position in which the hook is on the underside of the rim to an unhooked position.

In another aspect of the invention, a collapsible container further includes a flexible spout having a spout flap. The mouth is capable of being folded down along the mouth flap. The spout is thus at least partially located within the lower layer when the lower layer and the pouring spout are in the folded configuration.

In another aspect of the invention, the container includes a removable lid covering the opening and securable over the opening. Preferably, the lid comprises a plurality of peripheral flaps for securing said lid to the container. Preferably, the lid includes a selectively openable vent. Preferably, the container is water-tight when the removable lid is secured over the opening.

In another aspect of the invention, the container includes a plurality of apertures.

In another aspect of the invention, the container includes a handle attached to the upper layer.

In yet another aspect of the invention, a container volume is defined by the upper and lower layers and the collapsible wall sections.

In another aspect of the invention, the opening is configured to open and close to selectively allow and restrict fluid flow into and out of the container body through the top opening.

In yet another embodiment, a method of manufacturing a collapsible container is provided. The method includes placing a container body having a rigid first layer, a rigid second layer, and a collapsible wall portion into a mold; assembling the container body with mating container parts to close one end of the container body; placing the container assembly into a mold; and over-molding a thermoplastic layer around at least a portion of the container body and around at least a portion of the container component in a mold to bond the container body and the container component. Preferably, the bonding is permanent. Assembly may occur inside the mold or outside the mold.

In another aspect of the invention, the method further comprises folding the foldable wall portion to fold the container body prior to over-molding. The over-molding occurs on the folded container body.

In another aspect of the invention, the method further comprises forming the foldable wall portions from a plurality of peripheral wall portions and a plurality of circumferential lines of reduced material for the hinge between the peripheral wall portions.

In another aspect of the invention, the method further comprises over-molding the foldable wall portion onto the first and second layers

Drawings

Fig. 1 is a top view of a collapsible liquid container according to the invention in a fully expanded state.

Fig. 2 is an enlarged side view of the collapsible container shown in fig. 1.

Fig. 3 is a perspective view showing the handle of the foldable container shown in fig. 1 moved to another position.

Fig. 4 is an enlarged side view of the collapsible container shown in fig. 1 in a fully collapsed state.

Fig. 5 is a perspective view of the collapsible container shown in fig. 1 in a fully collapsed state.

Fig. 6 is a bottom view of the foldable container shown in fig. 1.

Fig. 7 is an inverted perspective view of the collapsible container shown in fig. 1.

Fig. 8 is an inverted perspective view of the collapsible container shown in fig. 1 in a fully collapsed state.

Fig. 8A is an exploded view of the bottom of the collapsible container shown in fig. 1.

Fig. 9 is a front sectional view taken along line 9-9 of fig. 1.

FIG. 10 is an enlarged front cross-sectional view taken along line 10-10 of FIG. 1 of the container of FIG. 1 in a fully collapsed state.

FIG. 11 is an exploded view of the faucet and a partial view of the collapsible container shown in FIG. 1.

Fig. 12 is a perspective view of the container and a partial view of a portion of the collapsible container shown in fig. 1.

FIG. 13 is a front cross-sectional enlarged view taken along line 13-13 of FIG. 1 of the container of FIG. 1 in a first partially folded state.

Fig. 14 is an enlarged front cross-sectional view taken along line 14-14 of fig. 1 of the container of fig. 1 to be in a second partially folded state.

Fig. 15 is a top plan view of a collapsible container or bottle in a fully expanded state in accordance with a second embodiment of the present invention.

Fig. 16 is an enlarged side view of the collapsible container shown in fig. 15.

Fig. 17 is a perspective view of the collapsible container shown in fig. 15.

Fig. 18 is a bottom plan view of the collapsible container shown in fig. 15.

Fig. 19 is an enlarged cross-sectional view of the collapsible container taken along line 19-19 of fig. 15.

FIG. 20 is an enlarged cross-sectional view taken along line 20-20 of FIG. 15, with the upper half of the collapsible container of FIG. 15 in a collapsed state.

FIG. 21 is an enlarged cross-sectional view taken along line 20-20 of FIG. 15, with the lower half of the collapsible container of FIG. 15 in a collapsed state.

Fig. 21A is an enlarged cross-sectional side view of a portion of fig. 21 as shown in fig. 21.

FIG. 22 is a cross-sectional view taken along a longitudinal plane that bisects the collapsible container shown in FIG. 15 in a fully collapsed state.

Fig. 23 is a partially exploded sectional view of the collapsible container shown in fig. 15.

Fig. 24 is a perspective view of the lid of the collapsible container shown in fig. 15.

Fig. 25 is a top plan view of the collapsible container shown in fig. 15 without the lid.

Fig. 26 is a top plan view of a collapsible container or tub in a fully expanded state according to a third embodiment of the present invention.

Fig. 27 is an enlarged side view of the collapsible container shown in fig. 26.

Fig. 28 is a perspective view of the collapsible container shown in fig. 26.

Fig. 29 is a bottom plan view of the collapsible container shown in fig. 26.

FIG. 30 is a cross-sectional side view of the collapsible container shown in FIG. 29 taken along line 30-30.

FIG. 31 is a cross-sectional view of the collapsible container shown in FIG. 29 in a first partially collapsed state taken along line 31-31 of FIG. 29.

FIG. 32 is a cross-sectional view of the collapsible container shown in FIG. 29 in a second partially collapsed state, taken along line 32-32 of FIG. 29, folded more than the first partially collapsed state.

FIG. 33 is a cross-sectional view of the collapsible container shown in FIG. 29 in a fully collapsed state taken along line 32-32 of FIG. 29.

FIG. 34 is a top plan view of a collapsible container or basket in a fully expanded state according to a fourth embodiment of the invention.

Fig. 35 is an enlarged side view of the collapsible container shown in fig. 34.

Fig. 36 is a perspective view of the collapsible container shown in fig. 34.

Fig. 37 is a bottom plan view of the collapsible container shown in fig. 34.

FIG. 38 is an enlarged cross-sectional view taken along line 38-38 of the collapsible container shown in FIG. 34.

FIG. 39 is a view of the collapsible container shown in FIG. 38 in a fully collapsed state.

Fig. 40 is a top plan view of a collapsible food container in a fully expanded state in accordance with a fifth embodiment of the invention.

Fig. 41 is an enlarged side view of the collapsible container shown in fig. 40.

Fig. 42 is a perspective view of the collapsible container shown in fig. 40.

Fig. 43 is a bottom plan view of the collapsible container shown in fig. 40.

Fig. 44 is a cross-sectional view taken along line 44-44 in fig. 40.

FIG. 45 is a view of the collapsible container shown in FIG. 44 in a fully collapsed state.

FIG. 46 is an exploded side enlarged view of the collapsible container shown in FIG. 40

Fig. 47 is a top plan view of the collapsible container shown in fig. 40 without the lid.

Detailed Description

The collapsible container according to the present invention is described in detail herein.

Referring generally to the drawings, a collapsible bulk liquid container 10 is shown in fig. 1-14, a collapsible bottle 110 is shown in fig. 15-25, a collapsible tub 210 is shown in fig. 26-33, a collapsible basket 310 is shown in fig. 34-39, and a collapsible food container is shown in fig. 40-47.

Referring to fig. 1-14, a generally pot-shaped bulk liquid container 10, particularly suitable for containing water or other beverages or liquids, is shown as a multi-layer container including a rigid or rigid upper layer 12 (sometimes described herein as a top layer 12), a rigid or rigid lower layer 14 (sometimes described herein as a bottom layer 14), and a collapsible wall portion 16 connecting the upper layer 12 to the lower layer 14. The combination of the layers 12, 14 and the foldable wall portion 16 form a reservoir housing 18.

The top layer 12 has a handle 20, a top opening 22 (sometimes described herein as opening 22 or main opening 22), and a lid 24. The handle 20 may be pivotally connected to the top layer 12 by means of a male member received in an opening in the top layer 12. The main opening 22 has a rim 30 located below the top layer. The rim 30 may have one or more drainage channels (not shown).

The cap 24 may be secured to the opening 22 by any suitable method, including a threaded engagement between the cap 24 and the opening 2, which may be configured to form a water-tight seal when fully secured or screwed into the opening 22. Suitable gaskets (not shown) may also be employed in this regard. Located above the edge 30, as shown in fig. 3 and 12, are one or more catches 32, each catch 32 having a downwardly extending projection 35. The lid 24 has two notches 34 that allow the lid to rest on the rim 30 when the notches 34 are aligned with the catches 32. The cover 24 also has a projection 36 that engages the catch 32 when the cover 24 is rotated counterclockwise so that the projection 36 passes under the projection 35 to secure the cover 24 to the opening 22. Preferably, the lid 24 has a handle 38 pivotally attached to the lid 24 and a recess 40 in which the handle may rest.

The bottom layer 14 has a base portion 42 and a sidewall portion 44. The base portion 42 has no more than three feet 50, an upstanding peripheral lip 52, and a circumferentially and radially extending flange 54. The side wall portion 44 has a concave portion 56 and a flange 58 extending circumferentially and radially. The male portion 52 extends into and frictionally engages the female portion 56 to form a water-tight seal. Flange 54 abuts flange 58 and includes corresponding steps 59 and 60. The exterior of the combination of flanges 54 and 58 is covered by a stretched elastomeric layer 61, which elastomeric layer 61 holds the base portion 42 and the side wall portion 44 together. Elastomeric layer 61 at least partially covers male portion 52 and female portion 56. Preferably, the base portion 42 and the side wall portion 44 are secured to one another without any adhesive, which could potentially leach odors or toxins into the contents of the container 10.

As shown in fig. 11, the bottom layer 14 also has an opening 64 and a spigot or tap 66. An opening 64 is located in the sidewall portion 44, with a faucet of any suitable design extending through the opening 64. As shown, the faucet 66 is secured to the sidewall portion 44 by a nut 67 and O-ring 67 'on the inside of the sidewall portion 44 and a faucet flange 68 and O-ring 68' on the outside of the sidewall portion 44. The tap 66 has a rotatable and tiltable handle 69, which handle 69 is connected to a spring loaded lever 70 covered by an elastic seal 71. The handle 6 may be rotated for ease of use and compressed when not in use. In practice, the handle 69 extends outwardly in fig. 1, 2, 3, 6 and 7 with the bulk liquid container 10 shown in a fully expanded configuration and inwardly in fig. 4, 5, 8 and 8A with the bulk liquid container 10 shown in a fully collapsed configuration. Any suitable spigot or bolt may be used in accordance with the invention. If desired, the faucet 66 and opening 64 can be eliminated and the liquid can be discharged by merely pouring from the opening 27. A suitable pour spout may also be included along opening 64, such as, for example, pour spout 128 described below.

The collapsible wall section 16 can be collapsed and expanded to vary the overall height dimension of the container housing 18 and thereby vary the available volume of liquid, particularly water or beverages and ice, within the housing 18. The wall portion 16 includes a rigid intermediate layer 72 between two flexible layers 74 and 76. The wall portion 16 has four hinges 78. The flap 78a is positioned between the top layer 12 and the flexible layer 74. The flaps 78b and 78c are located between the layers 72 and 74 and the layers 72 and 76, respectively. The flap 78d is positioned between the bottom layer 14 and the flexible layer 76. Additional layers and hinges may be included in the foldable wall sections, preferably in alternative arrangements where the flexible layers are connected above or below each rigid layer with hinges between the layers.

The container 10 is shown in two stable states or configurations, one fully expanded and one fully collapsed. The fully expanded container 10 is shown in fig. 2, 3, 7 and 9, which illustrate the flaps 78 in their generally unfolded configuration, while the fully folded state of the container 10 is shown in fig. 4, 5, 8 and 10, which illustrates the flaps 78 in a folded configuration. The container 10 provides its maximum volume in its fully expanded state, and in the illustrated embodiment is approximately 270 millimeters (mm) high (with the handle removed) and approximately 325mm in height when the container 10 is at its maximum volume, while in its fully collapsed state, the container 10 is approximately 80mm high (with the handle removed) for the illustrated embodiment, with the maximum height reduced by approximately 70% in its most compact state, which is particularly advantageous for storage and transportation. It is also possible for the container 10 to have at least two partially folded states (not shown) in which only the flaps 78a and 78b are folded or only the flaps 78c and 78d are folded.

The housing 18 in combination with the faucet 66 and the lid 24 is waterproof and is adapted to retain water or other liquid within its interior volume, which is generally defined as the space above the inner bottom surface 80 of the bottom layer 14 and below the top opening 22.

Referring generally to fig. 15-25, the bottle 110 is shown as a multi-layered container including a rigid or rigid upper layer 112 (sometimes described herein as a top layer 112), an upper foldable wall portion 114, a rigid or rigid middle layer 116, a lower foldable wall portion 118, and a rigid or rigid lower layer 120 (sometimes described herein as a bottom layer 120). The layers 112, 116 and 120 and the foldable wall portions 114 and 118 combine to form a reservoir housing 122.

The top layer 112 has a top opening 124, a lid 126 and a mouth 128. Opening 124 has a throat 130, and throat 130 has a plug support or basket 132, which can best be seen in FIG. 25. The cover 12 may be of any suitable construction. As seen particularly in fig. 23 and 24, the cap 126 may have a handle 13, a plug body 136 having a prong 137. The opening 124 may be partially opened by lifting the cap 126, thereby allowing the liquid in the bottle body 110 to flow out around the cap 126. The prongs 137 cooperate with the basket 132 to prevent accidental complete removal of the cap 126, but do not prevent complete removal of the cap 126. The mouth 128 has a flap 138 and the mouth 128 may be folded around the flap 138 as shown in figures 20 and 22.

The upper foldable wall section 114 has three main generally annular layers 140 and four flaps 142. Flaps 142a and 142d are located proximal to rigid or stiff layers 112 and 116. Leaflets 142b and 142c are positioned between layers 140a and 140b and connect layers 140a and 140b, and between layers 140b and 140c and connect layers 140b and 140c, respectively. When the bottle 110 is substantially upright, the tier 1 is substantially vertical. Layer 140 has a sloped top surface 144, a sloped bottom surface 146, an outer surface 148, and an inner surface 150. Preferably, face 144 is substantially parallel to face 146. Preferably, face 148 is substantially parallel and substantially perpendicular to face 150. The thickness 152 between one outer surface 148 and an adjacent inner surface 150 of the layers 140 is significantly greater than the thickness 154 of the foldable wall section 114 between one top surface 144 and the adjacent bottom surface 146, so that the flaps 142 are present at the top and bottom of each layer 140 as shown in fig. 21A. Thus, each leaflet (e.g., 142) may be comprised of a ring-shaped ring of material that is thinner than the upper and lower regions adjacent to the leaflet (e.g., 142). Alternatively, the leaflet (e.g., 142) may be constructed of a material that is more flexible than the material in the areas above and below the leaflet (e.g., 142). Layer 140 is between layers 140 and is arranged in small horizontal steps relative to layers 112 and 116. By having the vertical tier 140 directed vertically, it is possible to maximize the volume of the wall portion 114 and the container 110 for a given container diameter.

The middle layer 116 has a generally annular first portion or top 156, a generally annular second portion or bottom 158, and a stretched elastomeric sleeve or layer 160. The top 156 is connected to the collapsible wall portion 114 and has a generally annular convex portion 162. The base 158 is connected to the collapsible wall portion 118 and has a generally annular concave portion 164. Alternatively, portion 156 is a female portion 164 and portion 158 has a male portion 162. The male portion 52 extends into and frictionally engages the female portion 56 to form a water-tight seal. The exterior of the combined or overlapping male portion 162 and female portion 164 is at least partially covered by an elastomer layer 160. Preferably, portions 156 and 158 are secured together without an adhesive that may leach odors or toxins into the contents of container 110. The intermediate layer 116 also has a circumferential groove 165 for receiving a generally annular mating protrusion 165' of the elastomeric layer 160 to better hold the elastomeric layer 160 in place. The layer 160 is also beneficial in that it makes it easier for the bottle 110 to grip the intermediate layer 116.

The lower foldable wall section 118 has three main generally annular layers 166 and four flaps 168. The tier 166 is generally upright when the bottle 110 is generally upright. Layer 166 has a sloped top surface 169, a sloped bottom surface 170, an outer surface 172, and an inner surface 174. Face 169 and face 170 are preferably substantially parallel. Faces 172 and 174 are preferably substantially parallel and substantially perpendicular. Collapsible wall section 118 is substantially similar to wall section 114; the main difference is that the wall portion 118 is inverted when compared to the wall portion 114.

The bottom layer 120 has a generally annular sidewall 176, a bottom 178, and a skirt 180 for stability.

The bottle 110 is shown in four stable states or configurations. The fully expanded container 110 is shown in fig. 16, 17, 19 and 23, which illustrate the flaps 142 and 168 in their substantially unfolded configuration. Fig. 22 shows the bottle 110 fully collapsed, with the flaps 142a, 142b, 168a, and 168d in the collapsed configuration. The spout 128 is also folded and partially inserted into the middle layer 116. In the fully expanded state, the bottle 110 is about 225mm high (mouth up), about 75mm wide and about 95mm long in the illustrated embodiment, providing its maximum volume, while in its fully collapsed state, about 75mm high (including folded down mouth) or about 67% less in height from its maximum height, the bottle 1 is in its maximum compressed state, which is particularly convenient for storage and transport. Two partially folded states of the bottle 110 are also shown in fig. 20 and 21. In fig. 20, the upper half 182 of the bottle 110, including the top layer 112, the foldable wall portion 118, and the top 156, is in a fully folded state, with the flaps 142a and 142d and the mouth 128 collapsed, but the lower half 184 of the bottle 110 is fully expanded. In fig. 21, the upper half 182 is fully expanded and the lower half 184 is in a fully folded state, with the flaps 168a and 168d collapsed. Other partially folded states are also possible, in which either the upper half 182 or the lower half 184 is partially folded and the other half is fully expanded, partially folded or fully unfolded. If the upper half 182 is partially folded, one of the flaps 168b or 168c is folded. The partially collapsed state is discussed further with reference to the tub 210. The bottle 110 may be closed by a cap 126 and partially folded to minimize headspace above the liquid to reduce carbonation losses when the liquid is carbonated, minimize oxidation if the liquid is oxidation sensitive, or minimize evaporative heat losses if the liquid is hot.

Each layer of the housing 122 is non-porous and the attachment area connecting adjacent layers is water-tight, such that the housing 122 is adapted to retain water or other liquid in an interior volume generally defined as the space above the interior surface of the bottom 178 and below the opening 124.

Referring to fig. 26-33, the collapsible pot 210 is shown as a multi-layered container including a rigid or hard upper layer 21 (sometimes described herein as a top layer 212), a collapsible wall portion 214, and a rigid or hard lower layer 216. The layers 212 and 216 and the foldable wall portion 214 combine to form a reservoir housing 222.

The top layer 212 has a top opening 224, an end wall 226, a side wall 228, and a handle 230. The handle 230 may be covered with a plastic or elastomeric material that is softer than the material of the end wall 226 and the side wall 228. The top layer 212 is generally annular.

The foldable wall part 214 has three main substantially ring-shaped layers 240 and four leaflets 2 42. Flaps 242a and 242d are positioned proximal to the rigid or stiff layers 212 and 216. Flaps 242b and 242c are positioned between layers 240a and 240b and between layers 240b and 240c, respectively. The tier 240 is substantially vertical when the basin 2 is substantially upright. Layer 240 has a sloped top surface 244, a sloped bottom surface 246, an outer surface 248, and an inner surface 250. Collapsible wall portion 214 is substantially similar to wall portion 114 except that it is inverted relative to wall portion 114.

The lower layer 216 has a generally annular portion 256 and a bottom portion 258. The annular portion 256 has two opposing side walls 260 and two opposing end walls 262. The bottom 258 has a foot 264, which may include a soft plastic or elastomeric cover. In addition to the cover, the lower layer 216 may be a unitary piece that has been prepared in a separate stamping operation.

The tub 210 is shown in four stable states or configurations. The tub 210 has many uses, such as serving as a luggage basket, a wash tub, a container for supporting various types of objects. The fully expanded basins 210 (basins having a height of about 300mm, a length of about 525mm, and a width of about 420 mm) are shown in figures 26-30, which show the flaps 242 in their substantially unfolded configuration. Two partially folded states and one fully folded state are shown in fig. 31-33. Fig. 31 shows a partially folded state in which the flaps 242c and 242d are folded. Fig. 32 shows a partially folded state in which the flaps 242b and 242d are folded. Fig. 33 shows the fully folded state (height of the tub is about 120mm, height is about 50% smaller) in which the flaps 242a and 242d are folded. One possible folded state, not shown, is one in which the leaflets 242b and 242c are folded. This possible folding condition is unlikely to occur without specifically manipulating the container to achieve some degree of folding, as downward pressure on the tub 210 will generally cause the flaps 242d to fold first when the flaps 242 have the same thickness, as the flaps 242d provide the least resistance to folding because they have the shortest perimeter. The tub 210 is optionally provided with a lid, not shown, which may be used for storage or transport and which is partially folded to better match the dimensions of the tub 210 with its contents, which is particularly advantageous when trying to make efficient use of the space within a vehicle or storage space, for example.

The basin 210 may be waterproof except for the top opening 224 and the handle 320. Alternatively, any or all of the side walls 228 and 260, end walls 226 and 262, and bottom 258 may have various apertures.

Referring to fig. 34-39, collapsible basket 310 may be used as a laundry basket or for housing a desired object, such as shown as a multi-layered container including a rigid or rigid upper layer 312 (sometimes described herein as top layer 3 12), a collapsible wall portion 314, and a rigid or rigid lower layer 316. The layers 312 and 316 and the foldable wall portion 314 combine to form a reservoir housing 322.

Top layer 312 has top opening 324, end wall 326, side wall 328, handles 330 and 331, and edge 332. The handle 330 may be made of any suitable material including plastic or metal. Handle 330 is pivotally attached to rim 332. Handle 331 is similar to handle 230. The top layer 312 is generally annular. The end wall 326 and the side wall 328 have a plurality of apertures 334. The aperture 334 is optional.

The foldable wall part 314 has three main substantially ring-shaped layers 340 and four leaflets. The flaps 342a and 342d are located proximal to the rigid or stiff layers 312 and 316. Flaps 342b and 342c are positioned between layers 340a and 340b and between layers 340b and 340c, respectively. The tier 340 is generally vertical when the basket 310 is generally upright. Layer 340 has a sloped top surface 344, a sloped bottom surface 346, an outer surface 348, and an inner surface 350. Collapsible wall portion 314 is substantially similar to wall portions 114 and 214.

The lower layer 316 has a generally annular portion 356 and a bottom portion 358. The annular portion 356 has two opposing side walls 360 and two opposing end walls 362. The bottom portion 358 has a foot 364, which foot 364 may comprise a soft plastic or elastomeric cover. In addition to the cover, the lower layer 316 may be a unitary piece that has been prepared in a separate stamping operation.

The basket 310 is shown in two stable states or configurations. The fully expanded basket 310 (having a height of about 260mm, a length of about 500mm, and a width of about 420 mm) is shown in figures 34-38, which illustrate the leaflets 342 in their generally unfolded configuration. Figure 39 shows the fully folded condition (basket height about 120mm, reduced by about 60%) with the leaflets 342a and 342d folded. In addition, the basket 310 has the same partially folded state as the tub 210.

Referring to fig. 40-47, a foldable and microwavable food container 410 is shown as a multi-layered container including a rigid or rigid upper layer 412 (sometimes described herein as a top layer 412), a foldable wall portion 414, and a rigid or rigid lower layer 416. The layers 412 and 416 and foldable wall portion 414 combine to form a reservoir housing 418. The container housing 418 includes a container body 420 and a removable cover 422. As shown, the container body 420 may be made of an elastomeric material, such as silicone, and may be manufactured in a separate molding operation.

Top layer 412 has top opening 424, end wall 426, side wall 428, edge 432, and removable cover 422. The top layer 412 is generally annular. The brim 432 has three components, a rigid top component 434, a rigid middle component 436, and a rigid bottom component 438. The rigid top part 434 and the rigid bottom part 438 provide rigidity to the rim 432, which if made of an elastomeric material is missing from the middle part 436. The middle part 436 may be part of the container body 420 and made from the body 420 in a separate press molding operation. The edge components 434 and 438 form a rigid hook 439 on the underside of the edge 432 and may be joined to the middle component 436 by any suitable method, including ultrasonic welding, over-molding, and adhesives, but is not preferred. Alternatively, side member 438 forms a rigid hook 439 without side member 434. Indeed, the side member 438 may provide sufficient rigidity to the side 432 such that the side member 434 may be omitted. Lid 422 includes lid body 440 peripheral flap 442, hinge 444, peripheral seal 446, cavity 448, vent 450, and recess 451. The outer peripheral flap 442 is connected to the cover 440 by a hinge 444. The flap 442 has one or more prongs 447 for engaging the hook 439 to secure the cover 422 over the opening 424. The seal 446 is preferably made of an elastomeric material and is contained within a cavity 448. Seal 446 preferably has a plurality of fingers 452 extending toward edge 432. Vent 450 has an opening 454 and a plug 456. The plug 456 has a handle 458, a stepped cylindrical body 460, and a hollow end 462. The main body 460 has a first layer 464 for blocking the opening 454 and a second layer 466 for partially opening the vent 450. The end 462 may be forked or hooked to removably retain the plug 456 within the opening 454. The vent 450 allows the contents of the container 410 to be microwaved and allows vapors to escape while the lid 422 is secured over the opening 424.

The foldable wall part 414 has three main substantially ring-shaped layers 470 and four leaflets 4 72. Flaps 472a and 472d are positioned proximal to stiff or rigid layers 412 and 416. Leaflets 4 72b and 472c are positioned between layers 470a and 470b and layers 470b and 470c, respectively. When the container 410 is substantially upright, the layer 470 is substantially vertical. Layer 470 has a sloped top surface 474, a sloped bottom surface 476, an outer surface 478, and an inner surface 480. Collapsible wall section 414 is substantially similar to wall sections 114 and 214.

The lower layer 416 has a generally annular portion 486 and a bottom portion 488. The annular portion 486 has two opposing side walls 490 and two opposing end walls 492. The bottom portion 488 has a plurality of feet 494.

The container 410 is shown in two stable states or configurations. A fully expanded container 410 (approximately 65mm high, 180mm long and 130mm wide with a lid) is shown in fig. 40-44, 46 and 47, which shows the flaps 472 substantially in their unfolded configuration. Fig. 45 shows the fully folded state (container 410 with lid about 32mm high, height reduced by about 50% from fully expanded height) with flaps 472a and 472d collapsed. In addition, the container 410 has the same partially folded state as the tub 210.

A preferred method of manufacturing a collapsible container will now be discussed. The stiff or rigid first layer of the first material is manufactured by any suitable method. The stiff or rigid second layer of the second material is manufactured by any suitable method. The first and second layers may correspond to the top, middle, or bottom layers of any of the containers discussed herein. The first and second materials may be the same or different and may be, for example, polypropylene or a metal. If the first or second material is a plastic, the respective first and/or second layer is preferably extruded by injection molding. The first and second layers are placed in a first mold and a collapsible wall section is compression molded over the ends of the first and second layers in the first mold to form a container body comprising the first and second layers and the collapsible wall section therebetween. The collapsible wall section may have three substantially annular layers. It may correspond to any of the collapsible wall sections discussed herein. The container body has a male or female member at one end. The container body is then placed in a second mold. Assembling together in a second mold a container part having a female or male member opposite a male or female member of the container body includes mating the male and female members together. Prior to assembly, the container body may be fully folded in the second mold. The second mold is closed. Next, a layer of thermoplastic elastomer is overmolded onto at least a portion of the exterior of the combined male and female members and is overmolded onto and in contact with at least a portion of the container body and container parts. After the over-molding, the thermoplastic elastomer layer is under tension, thereby holding the container component and the container body together. The process herein is applicable to the manufacture of collapsible containers generally and specifically containers 10 and 110, according to which elastomeric layers 61 and 160 thereof may be over-molded. The collapsible container of the present invention may provide a height reduction of, for example, 50%, 66%, 70% or more from a fully erected or expanded position to a fully collapsed position.

Of course, in the context of a container according to the present invention, it is to be understood that "rigid", "rigid" and "flexible" are relative terms. Thus, unless further described, reference herein to a layer of wall structure as "stiff" simply means that the layer is stiff enough to apply a force to its adjacent flexible layer sufficient to fold the flexible layer between the relatively folded and unfolded stable positions (optionally so that the flexible layer "snaps" between positions) without folding on itself (i.e., without reversing its vertical orientation relative to the top and bottom of the container). On the other hand, for purposes of the present invention, a layer that is considered "rigid" generally does not even yield or deform significantly in the direction of the force that folds the flexible layer, let alone fold in response to that force or other typical loads associated with normal use of the container. Still further, the rigid layer preferably does not significantly deform in any direction during normal use of the container. A "rigid" layer, which exhibits the latter feature of not being significantly deformed in any direction, is typically formed of a different material than the flexible layer, rather than the same material of a different size or geometric configuration.

While each flexible layer of the various containers described herein is shown as having only two stable positions, it is within the scope of the present invention to provide one or more flexible layers having a plurality of stable partially expanded positions, such as by providing one or more flexible layers having a stepped profile comprising a series of accordion-like pleats of flexible material comprising a peripheral strip of material oriented in alternating directions and connected to an adjacent strip by a hinge such that each pleat may be independently folded and unfolded (not shown), being stable in either state. Furthermore, the wall structure of the container according to the invention need not have the exact shape of the container shown in the drawings, but may have any suitable shape, such as circular, oval, rectangular with rounded corners, or other shapes as desired. For example, a continuous accordion pleat may be stable in a relatively "bowed" direction, with a portion of the circumferential length of the pleat being folded and the remainder of the length being unfolded.

Containers according to the present invention may be made by imparting relative stiffness or rigidity to the top, middle and bottom layers; and any suitable material that imparts relative flexibility to the flexible layer while allowing the layer to be permanently connected to its adjacent layers. For example, in the respective shells or bodies 18, 122, 222, 3 and 420 of the illustrated containers, the top, bottom and/or intermediate layers can be rigid and constructed of polypropylene or other suitable material, and the flexible layer is a thermoplastic elastomer over-molded onto the polypropylene or other suitable material. Alternatively, the top, bottom and/or intermediate layers may be rigid and constructed of metal or nylon or other suitable material, the flexible layer being a silicon material over-molded onto the metal or nylon or other suitable material, with a suitable adhesive or bonding agent being located between the two materials to enhance their attachment. Alternatively, the entire body of the container may be made of an elastomer comprising a thermoplastic elastomer or silicon, and the walls of the top and bottom layers are thicker than the walls of the collapsible wall sections. The layers and foldable wall sections may be attached to each other by any suitable method, including over-molding, ultrasonic welding or adhesive attachment. The connection may be watertight, if desired. The cover and handle may be made of any suitable material, and may even be made of multiple materials.

On the other hand, in a corresponding insertion container, the rigidity is unlikely to be critical (particularly the intermediate layer) given that the rigidity of the non-folded layer of the outer shell will protect the insertion container and its contents, which may be merely stiff rather than rigid, and may be composed of the same resilient material as the flexible layer, but simply thicker and/or more vertically aligned (i.e. less tapered or not tapered at all in its relaxed state) to resist folding under vertical compressive forces.

Furthermore, the structural strength and shape retention provided by the rigid intermediate layers of different materials is only one of many advantages provided by the indoor and outdoor containers of the present invention. Thus, where desired, a component that is only "rigid" and optionally made of the same material as the flexible layer, but formed with a shape, alignment and/or dimensions that resist folding, may replace the "rigid" component of the container of the present invention, not only in the insert, but even in the housing, while still retaining other advantages over existing containers.

In the context of a container according to the invention, it will be understood that the flap is made of the same material as the rigid or stiff member to which it is attached. Typically, the leaflet is thinner than the surrounding material. The leaflet may be made of any suitable material including polypropylene, silicone, and thermoplastic elastomers that allows the leaflet to be repeatedly folded and unfolded.

While the invention has been described with respect to certain embodiments, it will be apparent to those skilled in the art that the invention is capable of numerous variations, modifications and rearrangements, and such variations, modifications and rearrangements are intended to be covered by the following claims.

Claims (22)

1. A collapsible container comprising:

a generally annular, rigid upper layer and an opening in an upper portion of the upper layer;

a rigid lower layer; and

foldable wall sections connected to the upper and lower layers, the foldable wall sections including at least first, second and third generally ring-shaped layers of foldable wall sections, an upper flap adjacent a lower edge of the upper layer, a lower flap adjacent an upper edge of the lower layer, and at least two intermediate flaps, the first and second foldable wall section layers being connected to each other by one of the intermediate flaps, the second and third foldable wall section layers being connected to each other by the other of the intermediate flaps, the first layer being located above the second layer and the second layer being located above the third layer, wherein the size of the container volume can be increased by unfolding the foldable wall sections from a folded configuration to an expanded configuration, and the size of the container volume can be decreased by folding the foldable wall sections from the expanded configuration to a folded configuration, the foldable wall sections being located at least partially within one of the upper and lower layers when the foldable wall sections are in the folded configuration, and the other of the upper and lower layers being located at least partially within the foldable wall sections;

wherein the lower layer comprises a generally annular first portion and a second portion, the first and second portions being secured together without the use of an adhesive by an overmolded thermoplastic layer at least partially covering the first and second portions, the upper and lower layers being of polypropylene material, the collapsible wall portion being a thermoplastic elastomer overmolded onto the upper and lower layers, and the housing of the container comprising the upper layer, lower layer and water-tight collapsible wall portion.

2. A collapsible container as claimed in claim 1, wherein the second layer adjoins the first and third layers, the first and third layers being flexible and the second layer being rigid, and wherein in the collapsed condition the collapsible wall sections collapse along the hinge between the first and second layers and collapse along the hinge between the second and third layers.

3. A collapsible container as claimed in claim 1, in which in the collapsed condition the collapsible wall sections collapse along the upper leaf and along the lower leaf.

4. The collapsible container of claim 1, wherein the first, second, and third layers are substantially vertical in the expanded configuration and the collapsed configuration.

5. A collapsible container as claimed in claim 1, wherein one of the first and second portions has a female member and the other of the first and second portions has a corresponding male member which is inserted into the female member.

6. The collapsible container of claim 5, wherein the lower tier comprises an inner wall exposed to the container interior, the inner wall comprising at least a portion of the male member.

7. A collapsible container as claimed in claim 1, wherein the second portion comprises an imperforate base.

8. The collapsible container of claim 7 further comprising a spigot and a spigot passage through the lower portion, the spigot extending through the spigot passage.

9. A collapsible container as claimed in claim 1, wherein the second portion is substantially annular.

10. The collapsible container of claim 9 further comprising

A bottom layer below the lower layer; and

a second foldable wall section connected to the lower layer and the bottom layer, the second foldable wall section comprising at least a fourth, a fifth and a sixth generally ring-shaped layer of foldable wall sections, a second upper flap adjacent a lower edge of the lower layer, a second lower flap adjacent an upper edge of the bottom layer, and at least two intermediate flaps, the layers of the fourth and fifth foldable wall sections being connected to each other by one of the intermediate flaps, the layers of the fifth and sixth foldable wall sections being connected to each other by the other of the intermediate flaps, the fourth layer being located above the fifth layer and the fifth layer being located above the sixth layer, wherein the size of the container volume can be increased by unfolding the second foldable wall section from the second folded configuration to the second expanded configuration and the size of the container volume can be decreased by folding the second foldable wall section from the second expanded configuration to the second folded configuration, the second foldable wall section being located at least partially within one of the lower layer and the bottom layer, and the other of the lower layer being located at least partially within the second foldable wall section when the second foldable wall section is in the second folded configuration.

11. A collapsible container as claimed in claim 1 further comprising:

a bottom layer below the lower layer; and

a second foldable wall section connected to the lower layer and the bottom layer, the second foldable wall section comprising at least a fourth, a fifth and a sixth generally ring-shaped layer of foldable wall sections, a second upper flap adjacent a lower edge of the lower layer, a second lower flap adjacent an upper edge of the bottom layer, and at least two intermediate flaps, the layers of the fourth and fifth foldable wall sections being connected to each other by one of the intermediate flaps, the layers of the fifth and sixth foldable wall sections being connected to each other by the other of the intermediate flaps, the fourth layer being located above the fifth layer and the fifth layer being located above the sixth layer, wherein the size of the container volume can be increased by unfolding the second foldable wall section from the second folded configuration to the second expanded configuration and the size of the container volume can be decreased by folding the second foldable wall section from the second expanded configuration to the second folded configuration, the second wall section being located at least partially within the one of the lower layer and the bottom layer, and the other of the lower layer being located at least partially within the second foldable wall section when the second foldable wall section is in the second folded configuration.

12. A collapsible container as claimed in claim 1 further comprising a flexible spout, the spout having a spout flap, wherein the spout is foldable down the spout flap and is thus at least partially located within the lower layer when the lower layer and pouring spout are in a folded configuration.

13. A collapsible container as claimed in claim 1 further comprising a removable lid covering the opening and securable over the opening.

14. A collapsible container as claimed in claim 13 wherein the lid includes a selectively openable vent.

15. A collapsible container as claimed in claim 13, wherein the container is waterproof when the moveable cover is secured over the opening.

16. The collapsible container of claim 1 further comprising a plurality of apertures.

17. The collapsible container of claim 1, further comprising a handle attached to the upper layer.

18. A collapsible container as claimed in claim 1 wherein the container volume is defined by the upper and lower layers and the collapsible wall section.

19. A collapsible container as claimed in claim 1, the opening being configured to open and close to selectively allow and restrict the flow of fluid into and out of the container body through the top opening.

20. A method of manufacturing a collapsible container according to any of claims 1 to 19 comprising:

over-molding a thermoplastic elastomer foldable wall portion onto a rigid upper layer supported by polypropylene and a rigid lower layer made of polypropylene to form a container body;

placing the container body into a mold;

assembling the container body with mating container parts to close one end of the container body;

placing the container assembly into a mold; and

over-molding a thermoplastic layer around at least a portion of the container body and around at least a portion of the container part in a mold to bond the container body and the container part, the shell of the container comprising the upper layer, the lower layer, and a foldable wall portion that is water-tight without the use of an adhesive.

21. The method of claim 20, further comprising folding the foldable wall portion to fold the container body prior to over-molding, wherein the over-molding occurs on the folded container body.

22. The method of claim 20, further comprising forming the foldable wall portions with a plurality of circumferential wall portions and a plurality of circumferential lines of thinned material for the hinge between the circumferential wall portions.