COLLAPSIBLE CONTAINER

Abstract

A container (2) for food and/or beverage type items is at least partially defined by two or more wall portions including at least a first sidewall portion, and at least one thin or foldable wall portion (6). The container also includes a base portion and 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 thin wall portion (6) is formed or located between a first sidewall portion and the base, and it is between 0.25 mm and 0.5 mm thick.

Claims

1. A container for food and/or beverage type items, said container is manufactured from polypropylene and/or polyethylene and 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 a lid and 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, 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 between, or is substantially between, 0.25 mm and 0.5 mm thick.

2. (canceled)

3. A container according to claim 1 wherein the thin wall portion of a substantially polypropylene material is 0.25-0.45 mm thick or in cross sectional width.

4. A container according to claim 3 wherein the thin wall thickness is substantially 0.31 mm.

5. A container according to claim 1 wherein the thin wall portion of a substantially polyethylene material is 0.25-0.50 mm thick or in cross sectional width.

6. A container according to claim 5 wherein the wall thickness is substantially 0.35 mm.

7. (canceled)

8. A container according to claim 1 wherein the container is manufactured from polypropylene base material plus plasticiser additives for hot fill, microwave and other food applications.

9-13. (canceled)

14. A container according to claim 1 wherein the thin wall portion is curved or non-linear when in at least the second in-use or expanded condition.

15. A container according to claim 1 wherein the top to bottom length of the thin wall portion is at least 25% greater or longer than the distance between first and second sidewall portions and/or at least 25% greater or longer than the linear distance between a sidewall portion and the base portion when viewed in plan in said second or in-use or expanded condition.

16. A container according to claim 1 wherein the thin wall portion is and/or substantially forms a region of flexion which bends, 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.

17. 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.

18. A container according to claim 16 wherein the second sidewall portion is attached to and/or depends from the base portion.

19. A container according to claim 1 wherein the thin wall portion forms a band around the container.

20-21. (canceled)

22. A container according to claim 19 wherein as force is applied the thinner thin wall portion which extends into the side wall portion at least partially collapses or bends, thereby reducing the internal dimension and the force required to form the container to the second condition.

23-24. (canceled)

25. 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.

26. (canceled)

27. (canceled)

28. A container according to claim 1 wherein the sidewall portions are substantially linear, straight or non-curved when viewed in vertical cross-section.

29. A container according to claim 28 wherein the thin wall portions are more flexible or less rigid than the side wall portions and roll when moving the container between the first and second conditions.

30-34. (canceled)

35. 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 a lid and 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, 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, or is substantially, curved or non-linear when in at least the second in-use or expanded condition and the length of the thin wall portion is at least 25% greater or longer than the linear distance between first and second sidewall portions and/or at least 25% greater or longer than the linear distance between a first sidewall portion and the base portion when in said second or in-use or expanded condition.

36. A method of manufacturing a container comprising features according to claim 1 wherein at least the wall portions of the container are formed from injection moulding.

37. A method according to claim 35 wherein the wall portions, including the sidewall portion and thin wall portions, and/or the base portion are formed from single point injection moulding.

38. A method according to claim 36 wherein the moulding process is single point hot tip injection moulding to form the container.

Description

[0108] Specific embodiments of the invention are now described with reference to the following figures wherein;

[0109] FIG. 1 shows views of a container according to one embodiment of the invention;

[0110] FIGS. 2a-2d shows cross sectional views of containers illustrating how the thin wall portion/area of flexion distorts as the container is collapsed and then returned to its extended state;

[0111] FIG. 3 shows one embodiment of the invention where two different food products can be stored in separate compartments;

[0112] FIGS. 4a and 4b shows one embodiment of the present invention in its extended state;

[0113] FIGS. 5a and 5b show one embodiment of the present invention in its collapsed state;

[0114] FIGS. 6a and 6b shows the present invention in its collapsed state with lid attached;

[0115] FIGS. 7a and 7b show one embodiment of the present invention with one area of flexion and one fixed/side wall;

[0116] FIGS. 8a and 8b shows one embodiment of the present invention with two areas of flexion and three fixed walls;

[0117] FIGS. 9a-10 show one embodiment of the present invention with the container formed to such a profile that an eating utensil can be attached to it;

[0118] FIGS. 11a and 11b show one embodiment of the present invention with a label attached to the base of the container which can be used to pull the pot from its collapsed to its extended state;

[0119] FIGS. 12a and 12b show one embodiment of the present invention with a breather hole molded into the container;

[0120] FIGS. 13a and 13b show one embodiment of the present invention with a breather hole incorporated into the film lid sealing pattern.

[0121] FIG. 14 shows how the polymer molecular chain flows across and not around the areas of flexion when the present invention is manufactured using the single point injection moulding process; and

[0122] FIG. 15 shows one embodiment of the present invention in an oval shape.

[0123] The present invention relates to a single use collapsible plastic packaging container 2 with sealed lid 4 as shown in FIG. 1. The body of the container is primarily constructed from polypropylene or polyethylene with a separate lid 4 sealed to it enabling the package to contain, preserve, protect, store and merchandise the product it contains.

[0124] The container is configured with one or more thin flexible wall portions 6, henceforth referred to as Areas of Flexion which, when force is applied distort, collapse and snap into an inverted position allowing the container to collapse and revert to its extended form whilst remaining stable in either its extended or collapsed state. The side wall portions 8 are relatively inflexible or more rigid compared to the areas of flexion 6. The process of inversion or extension and compression is shown in FIG. 2.

[0125] A flexible film lid 4 can be sealed to one or more walls of the container allowing one or more products A, B to be contained discreetly within, as shown in FIG. 3 where the lid is sealed to the inner sealing rim 10 and an outer sealing rim 12 defining two discreet annular portions or chambers within the container in its collapsed state. The filled package is transported, stored and sold in its collapsed state. The consumer opens the container and pops the container back up into its original extended form, creating the void required for product to be mixed, prepared, dispensed or consumed directly from.

[0126] The present invention relies on the areas of flexion to distort and snap into position making the collapsed and extended container rigid and stable in either state. The material must be thin enough to distort as force is applied and have enough strength to snap into position when manipulated from its collapsed to extended state or vice versa. The present invention can be manufactured in a range of sizes and profiles so the size or proportionality cannot be defined however in all cases the area of flexion or thin wall is 25% or more longer (vertically from top to bottom) than the distance between the adjacent thick walls when viewed in plan as shown in FIG. 2b.

[0127] This arrangement is significantly different to a living hinge arrangement shown in FIG. 3c which is utilised in packaging materials such as toothpaste and sauce caps. Here the thick or side wall portions are inverted to effect the transfer from the open to closed state. The present invention utilises an area of flexion 6 and two adjacent fixed walls to effect a transfer from its extended to collapsed state. The area of flexion 6 rolls rather than hinging. This unique element ensures both adjacent walls remain in the same plain as shown in FIG. 3d, i.e. are not inverted as with a living hinge.

[0128] In one embodiment the present invention is manufactured from Polypropylene base material plus additives for hot fill, microwave and other food applications. The area of flexion on such material is typically between 0.25 mm and 0.45 mm, ideally 0.31 mm.

[0129] In one embodiment the present invention is manufactured from Polyethylene base material plus additives for cold fill and other non-food applications. The area of flexion on such material is typically between 0.25 mm and 0.5 mm, ideally 0.35 mm.

[0130] Someone skilled in the art would recognise that the present invention could also be manufactured from a Polyethylene Terephthalate (PET) based material.

[0131] The present invention, is manufactured by single point injection moulding method.

[0132] The person skilled in the art would recognise that this invention could be manufactured in a vacuum forming process.

[0133] In one embodiment at least part of the film 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.

[0134] In one embodiment the present invention has a breather hole incorporated into the container wall. The lid is partially pealed back to expose the breather hole allowing the vacuum inside the container to be released and container expanded into its extended state.

[0135] In one embodiment the present invention has a breather hole incorporated into the film lid sealing pattern. The lid is partially pealed back to expose the breather hole allowing the vacuum inside the container to be released and container expanded into its extended state.

[0136] In one embodiment the breather hole is sized to control the rate at which air is expelled from the container as pressure/force is generated during the cooking process. Increasing or reducing the size of this hole varies the rate that air is expelled from the container during the cooking process.

[0137] Some products (e.g. Popcorn) create pressure within the container when microwaved. In one embodiment the rate at which air is allowed to escape from the container in the microwave cooking process is restricted by narrowing the breather hole. This generates pressure within the container and sufficient force to move the container from its collapsed to extended state during the microwave cooking process.

[0138] Someone skilled in the art would recognise that other food and non-food products could be prepared this way.

[0139] Typically once used, substantially empty and/or the contents accessed the container can be collapsed to aid disposal and/or storage.

[0140] Someone skilled in the art would appreciate that it is possible to produce such a container with up to seven combinations of rigid walls and areas of flexion.

[0141] Someone skilled in the art would recognise that the container can be moulded in many shapes.

[0142] 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 attached or embedded utensils and/or the like.

[0143] In one embodiment the outer wall is located substantially around the periphery of the container in its collapsed form.

[0144] In one embodiment the foldable portion is located substantially between the outer wall or walls.

[0145] In one embodiment the compartments are substantially concentric with the outer wall. Typically the wall or walls closest to the point at which polymer is injected into the injection forming mould are substantially circular. Single point injection moulding and the substantially circular shape of the container combine to ensure the correct molecular alignment as the polymer flows into the mold. It is critical when injection molding the present invention that the length of the polymer molecular chain flows across and not around the areas of flexion.

[0146] Turning to FIGS. 4a and 4b which show the present invention in its extended state forming a circular bowl with one area of flexion 6 and two rigid side walls 8. The bowl in this example includes a circular base 14, which is also more rigid than the area of flexion 6. The bowl in its collapsed configuration is shown in FIGS. 5a and 5b, and the same embodiment including a lid 4 is shown in FIGS. 6a and 6b.

[0147] FIGS. 7a and 7b show extended and collapsed configurations respectively of a container 2 which has a single thin wall or area of flexion 6 and a single fixed or side wall 8. FIGS. 8a and 8b also show extended and collapsed configurations with two areas of flexion 6, 6 between three fixed or side walls 8, 8, 8.

[0148] Turning to FIGS. 9a and 9b the base wall or side wall portion is configured with apertures or holes 16 formed therein such that a utensil 18, in this example a spoon can be located in and/or attached to the same. The apertures 16 are formed below the base of the container in this example. FIG. 10 shows an embodiment wherein the aperture 16 is in the form of a channel and the utensil (not shown) can be secured by a label 20 positioned over the aperture.

[0149] FIGS. 11a and 11b show how the label 20 can be used to move the container 2 from the collapsed to the expanded configuration, by acting as a tab which can be pulled by the user. The label could be perforated and/or include a frangible portion to allow the same to form two tabs.

[0150] FIGS. 12 a and 12b shows one embodiment of the present invention with a breather hole 22 molded into the container which, when the lid 4 is partially pealed back to expose, allows the vacuum inside the container to be released and container expanded into its extended state. FIGS. 13a and 13b show an embodiment of the present invention with a breather hole 22 incorporated into the film lid 4 sealing pattern. The lid 4 is partially pealed back to expose the breather hole allowing the vacuum inside the container to be released and container expanded into its extended state. It should be noted that by increasing or reducing the size of this hole the rate air is expelled and pressure created within the container, throughout the cooking process, can be controlled.

[0151] Turning to FIG. 14 wherein it is shown how the polymer molecular chain flows across and not around the areas of flexion when the present invention is manufactured using the single point injection moulding process. Finally, FIG. 15 shows one embodiment of the present invention in an oval shape. Someone skilled in the art will recognise the container could be moulded into many shapes.

[0152] FIGS. 16a and 16b illustrate an embodiment wherein a portion 24 of the thin wall portion/area of flexion 6 extends into the thicker side wall 8. The area of flexion 6, effectively the thinner wall section, can be extended into thicker sections of adjacent walls creating areas within the thicker wall sections 8 that flex as the container is formed, reducing the total force required to erect to container. FIG. 6b shows that as force is applied the thinner section 24 in the side wall 8 collapses, reducing the internal dimension and the force required to form the bowl.