Hinge of container

Abstract

Disclosed is a hinge combination for connecting a plurality of panels made of an expandable material, comprising: a first hinge member having a first panel configured to be located on a surface of one of the connecting panels and a first bottom panel configured to be embedded in the expandable material of the connecting panels; the second hinge piece is provided with a second plate piece and a second bottom plate, the second plate piece is configured to be located on the other surface of the connecting plate, and the second bottom plate is configured to be embedded in the expandable material of the connecting plate; wherein the first plate and the second plate are configured to engage with each other to facilitate hinge movement of the connecting plate.

Description

[0001] Related applications

[0002] This application claims priority from Australian Provisional Patent Application No. 2022903520, filed on November 21, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present invention generally relates to a hinge for a storage container, and more particularly to a hinge for a storage container that is integrated in an expandable material and is made of an expandable material. Background Art

[0004] Thermally insulated storage containers are commonly used to provide a means of storing items in a controlled thermal environment for ease of storage or transport. These containers have a variety of applications, from receiving food and pharmaceuticals to maintaining them in a controlled thermal environment to maximize their usable lifespan. This controlled thermal environment can be heated or cooled, depending on the item being stored.

[0005] Traditional insulated containers are typically made from polymer foam materials, such as expanded polystyrene (EPS) or expanded polypropylene (EPP). These materials have known insulating properties and can be molded in an efficient and cost-effective manner to form a single, three-dimensional container. This container can then be used to store items, such as food, that can be refrigerated or heated, and a lid can be installed over its opening to create an enclosed space within which a thermal environment can be maintained for extended periods.

[0006] However, traditional single-piece molded containers have a number of drawbacks. One significant drawback is that they occupy essentially the same volume of space regardless of whether they contain items. Consequently, they require considerable storage space when not in use. This can be a significant problem when the containers are used to transport goods, as they require considerable storage space even when empty. This can lead to the containers being destroyed or discarded, significantly shortening their useful life.

[0007] There have been a number of attempts to provide collapsible containers which can be collapsed when not in use to significantly reduce the storage space required to store the container. Such containers typically comprise a plurality of panels with hinges between the panels to facilitate folding of the panels between the collapsed and assembled forms. In containers made from expandable materials such as expanded polystyrene (EPS) or expanded polypropylene (EPP), the ability to form such hinges within the body of the material presents particular challenges, particularly where such containers are intended to be used multiple times. Traditionally, such containers have been formed so as to form an area of ​​reduced thickness between the panels to form the hinge. However, where the container is to be assembled / reassembled multiple times, the repeated use of the hinge may result in failure of the material in the hinge area, thereby seriously compromising the integrity of the container.

[0008] Therefore, there is a need to provide a hinge arrangement for a container made of an expandable material that has sufficient strength to facilitate multiple folding cycles without compromising the integrity of the container.

[0009] The above references and descriptions of prior art solutions or products are not intended to, and should not be construed as, statements or admissions of common knowledge in the prior art. In particular, the above discussion of the prior art is not relevant to what is generally known or familiar to those skilled in the art, but rather facilitates understanding of the inventive steps of the present invention, of which the identification of relevant prior art solutions is only a partial one. Summary of the Invention

[0010] One or more aspects of the present invention are defined in the independent claims. Some optional and / or preferred features of the present invention are defined in the dependent claims.

[0011] A hinge assembly for connecting a plurality of panels made of expandable material, comprising:

[0012] a first hinge member having a first plate member and a first base plate, wherein the first plate member is configured to be located on a surface of one of the connecting plates, and the first base plate is configured to be embedded in the expandable material of the connecting plate;

[0013] a second hinge member, the second hinge member having a second plate member and a second bottom plate, the second plate member being configured to be located on the other surface of the connecting plate, and the second bottom plate being configured to be embedded in the expandable material of the connecting plate;

[0014] Wherein, the first plate and the second plate are configured to engage with each other to facilitate the hinge movement of the connecting plate.

[0015] In one embodiment, the first plate and the first bottom plate, and the second plate and the second bottom plate are connected by a plurality of rib members to facilitate integration of a hinge assembly with the expandable material.

[0016] At least one of the first hinge member and the second hinge member has a wing member extending laterally from at least one end thereof.

[0017] The wing member is shaped to capture particles of the expandable material during expansion, so that the particles of the expandable material fuse together in a space formed between the wing member and an end of the first or second hinge member.

[0018] One of the first plate or the second plate includes a pin, and the other of the first plate or the second plate includes one or more steering knuckles mounted on the pin to interengage therewith.

[0019] The pin has a cam profile, and the one or more steering members engage a surface of the cam profile of the pin to control the angular position of the first plate relative to the second plate.

[0020] In one embodiment, the angular position between the first plate and the second plate can be varied between 0-90°.

[0021] In another embodiment, the angular position between the first plate and the second plate can be varied between 0-270°.

[0022] The first or second hinge members are each made of a polymeric material such that when the expandable material expands, the expandable material will at least partially form a molecular bond with the first or second hinge member.

[0023] The expandable material is expanded polypropylene (EPP). BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The present invention will be more readily understood from the following non-limiting description of a preferred embodiment, in which:

[0025] Figure 1 is a perspective view of a container using a hinge assembly according to an embodiment of the present invention;

[0026] Figure 2 and Figure 3 A perspective view showing a first hinge member and a second hinge member of a hinge assembly according to the present invention;

[0027] Figure 4 and Figure 5 Shows a side view and a perspective view of the assembled hinge assembly of the present invention according to one embodiment;

[0028] Figure 6 and Figure 7Shows a top view and a rear view of the assembled hinge assembly of the present invention according to another embodiment;

[0029] Figure 8 is an end view of an assembled hinge assembly of the present invention according to yet another embodiment;

[0030] Figures 9-11 shows a cross-sectional view of a hinge assembly according to the present invention; and

[0031] Figure 12 A cross-sectional view showing a hinge assembly according to the present invention DETAILED DESCRIPTION

[0032] The preferred features of the present invention will now be described with reference to the accompanying drawings. However, it will be appreciated that the features illustrated and described with reference to the accompanying drawings should not be construed as limiting the scope of the present invention.

[0033] The present invention is intended for use with containers, such as those disclosed in the applicant's co-pending PCT application number PCT / AU2020 / 050491, the entire contents of which are incorporated herein by reference.

[0034] In this regard, the hinge arrangement of the present invention is described below as being incorporated into a container formed from expanded polypropylene (EPP). However, it will be appreciated that the hinge arrangement of the present invention may be incorporated into a container formed from any type of expandable material, including other polymer foam materials, such as expanded polystyrene (EPS) or polyurethane, or any other plastic material capable of providing thermal insulation.

[0035] refer to Figure 1 , a container 10 having a hinge assembly 20 according to one embodiment of the present invention is shown in assembled form. The container 10 generally includes a base 12, a pair of opposing end walls 14, and a pair of opposing side walls 16. In the illustrated embodiment, a lid member 18 is attached to the upper ends of the end walls 14; however, in an alternative embodiment, the lid member can be attached to the upper ends of the side walls 16. In another embodiment, the lid 18 can be a separate component that can be mounted on the assembled container 10, or the container 10 can be without a lid.

[0036] The base 12 is configured to include a pair of opposed end supports 11 that extend upwardly from the base 12. The end supports 11 extend across the width of the base 12 and are integral with the base 12. The end supports 11 support the end wall 14 thereon. The portion of the base 12 that extends between the end supports 11 is substantially planar, and this surface forms the bottom surface of the container 10 when the container is in the assembled configuration shown in the figures.

[0037] Each side wall 16 is located along an opposite side edge of the base 12. To facilitate folding the container 10 into a folded configuration for storage, each side wall 16 is mounted to an opposite side edge of the base 12 by a base hinge assembly 20a of the present invention. Figure 1 In this arrangement, the side walls 16 are folded inwardly to rest one above the other on the surface of the base 12 .

[0038] The end wall 14 is mounted to the end support 11 by a base hinge assembly 20a according to the present invention, which is Figure 1 In the illustrated embodiment of the invention, a base hinge assembly 20a provides a pivotal connection between the bottom edge of the end wall 14 and the top edge of the end support 11. This arrangement of the base hinge assembly 20a allows the end wall 14 to fold inward relative to the container 10, similarly to the side walls 16, while preventing the end wall 14 from folding outward. It will be appreciated that because the height of the end support 11 is substantially the same as the combined thickness of the plurality of side walls 16, when the container 10 is in the folded state, the end wall 14 will sit flat on the surface of the side walls 16. Furthermore, because the combined height of the end walls 14 is less than the distance between the end supports 11, the plurality of end walls 14 can fold to extend in the same plane without overlapping.

[0039] In the embodiment of the container shown, a plurality of lid components 18 are connected to a plurality of end walls 14 by a plurality of lid hinge assemblies 20b. The lid hinge assemblies 20b and the base hinge assembly 20a are similar in configuration, but are configured differently to accommodate different degrees of movement. As described below, the lid hinge assembly 20b is configured to allow the lid component 18 to move through an arc of approximately 270° relative to the end wall 14. In contrast, the base hinge assembly 20a is configured to move through 180°, but can only be used at 90° after being overmolded and assembled to the base assembly. This limits the movement of the end walls 14 and side walls 16 beyond 90°, which is required to be in a disassembled state and an assembled state, as shown. Figure 1 shown.

[0040] Regarding the lid hinge assembly 20b, this assembly includes a first hinge member 21 and a second hinge member 22. The upper edge of the end wall 14 has a mounting protrusion formed thereon, to which a hinge plate 23 of the first hinge member 21 is connected. As shown, the hinge plate 23 includes a pin 24 having a cam profile that protrudes vertically above the upper end of the end wall 14. The end of the lid member 18 has a hinge plate 25 mounted on the second hinge member 22 at its upper end. The hinge plate 25 has a plurality of knuckles 26 that extend from the end of the lid member 18 to receive the pin 24 of the first hinge member 21. In this arrangement, the hinge assembly 20 allows the lid member 18 to move through an arc of approximately 270°. This enables the lid member 18 to move between a closed position and an open position, thereby facilitating access to the interior of the container 10.

[0041] Due to the 270° movement of the lid member 18 relative to the end wall 14, when the container 10 is in the collapsed or compact position, the lid member 18 can be folded back relative to the end wall 14. This ensures that the lid member 18 is flush with the outer surface of the corresponding end wall 14, thereby providing a compact collapsed container in which the collapsed members are each supported by a bottom member, and each member extends substantially parallel to each other. In this arrangement, the collapsed containers can be stored in a stack that is both compact and stable.

[0042] Reference Figure 2 and Figure 3 , the first hinge member 21 and the second hinge member 22 of the lid hinge assembly 20b are shown separately. Each of the first hinge member 21 and the second hinge member 22 has a similar configuration and includes a plurality of rib members 27 extending from the bottom surface of the respective hinge plate 23, 25, which terminate in a first bottom hinge plate 28 and a second bottom hinge plate 29. Figure 4 As shown, each rib member 27 extends in a downward manner and angles away from the respective hinge plate 23, 25 such that the first and second bottom hinge plates 28, 29 extend substantially parallel to, but laterally offset from, the respective hinge plates 23, 25.

[0043] As described above, the components of the container 10 are preferably made of an expandable material, such as EPP. The components of the base hinge assembly 20a and the lid hinge assembly 20b are made of a polymer that is preferably compatible with the expandable material, so that during the formation of the container 10, the hinge assemblies 20a, 20b are embedded in the expandable material, so that the hinge assemblies 20a, 20b are bonded to the expandable material during the formation process. Because the expandable material is molded around the hinge assemblies 20a, 20b during the steam molding cycle, there is a degree of molecular bonding between the hinge assemblies 20a, 20b and the expandable material during the overmolding process. Because the components of the hinge assemblies 20a, 20b form gaps between the multiple rib components, as the material expands during the molding process, the expandable material will undercut the hinge components, thereby also forming a mechanical interlocking function or frictional engagement between the components of the hinge assembly and the expandable material.

[0044] In this regard, Figure 4 and Figure 5As shown, the first and second hinge components 21, 22 of the lid hinge assembly 20b are configured such that the rib members 27 and base panels 28, 29 are encapsulated within the molded material and capture particles of expandable material during the overmolding process to create molecular bonding from the steam heating process and a rigid mechanical or frictional engagement between the molded foam and the rigid plastic material of the lid hinge assembly 20b components. This creates a strong and rigid bond between the foam and the rigid components of the hinge assembly 20a, 20b that can withstand considerable forces during use of the container 10. As shown, the first and second hinge components 21, 22 are positioned within the mold such that the respective hinge plates 23, 25 are positioned adjacent the exterior surfaces of the panels of the container 10.

[0045] like Figure 2 、 Figure 6 and Figure 7 As shown, the second hinge member 22 may further include a pair of securing wing members 30 extending laterally from opposite sides of the second hinge member 22. The securing wing members 30 may function to capture foam particles injected into the expandable material, allowing the particles to fuse between the hinge member 22 and the edges of the wing members 30 during the steaming process, thereby preventing separation between the embedded hinge member and the expandable material when bending forces are applied to the container during use. This function prevents separation of the hinge assembly and the container material during use, which could potentially form gaps and grooves therein, in which dirt, food, and other matter could accumulate and compromise the safety and quality of the container 10.

[0046] Reference Figure 8 A pin is provided to assist in positioning the first hinge component, used to precisely locate hinge component 22 in the mold for overmolding with the expandable material. In this regard, a pin is placed in holes 31a and 31b to provide a precise location, constraining hinge component 22 in the X and Y directions as shown. The circular center hole 31a provides an accurate location for receiving the pin, constraining the hinge component's movement in the X and Y axes, while the hole 31b formed in the hinge plate surface is elongated to allow for thermal expansion, contraction, and warpage tolerances while precisely limiting hinge component 22's rotation about the Z axis. The flat surface on the top of the hinge plate, combined with the friction between the pins received in hinge holes 31a and 31b, restricts hinge component movement in the Z direction during the molding process due to frictional forces when the mold is closed. This arrangement also facilitates removal of the Z-direction pin after overmolding and during transfer and ejection. Using this system, the hinge components of hinge assemblies 20a and 20b can be loaded into the mold manually or robotically. It is also envisioned that clamps could be used to connect to parts of the hinge when the mold is closed to prevent the hinge from moving during the molding process.

[0047] The hinge assembly 20 is configured to provide a clear sealing margin between the expandable material to avoid the expandable beads from entering unwanted locations during the forming process. In this regard, the design of the first and second hinge members of each hinge assembly 20a, 20b allows all of the sealing surfaces to be positioned so that no core pulling or other mechanisms are required to remove portions of the mold from areas where foam is not intended to enter. The plastic material of the hinge members is configured to ensure that particles of the expandable material do not enter unwanted areas, which could cause the hinge members to collide with the expandable material during use and not rotate properly. The shape of the hinge members is optimized to allow particles of the expandable material to be injected in a normal manner and flow around the rigid hinge member. This also ensures that the expandable material is sufficiently thick (i.e., several particle diameters) in all areas to avoid manufacturing inconsistencies, surface defects or poor fusion.

[0048] As mentioned above, Figure 9 and Figure 10 FIG. 2 shows a base hinge assembly 20 a. The pin 44 of the first hinge member 41 is configured with a cam profile. The cam profile of the pin 44 works in conjunction with the upper rib 50 to resist any upward force from the upper panel of the container 10 that would normally separate the two components of the container and create an air gap between them. Such an air gap would be detrimental to the temperature control performance of the insulated container.

[0049] like Figure 11 As shown, the hinge assemblies 20a, 20b have been configured to interlock in their final positions as shown. This interlocking is caused by the engagement between the pin 44 and the knuckle 46, which creates a secure connection between the two halves of the rigid hinge assembly and reduces the load on the foam-rigid plastic connection when shear forces are applied to the assembled container in the direction of arrow F.

[0050] Reference Figure 12 , shows a lid hinge assembly 20b. As shown, the cam profile of pin 24 creates an interference fit with knuckle 26 of the clamping half of the hinge assembly, which serves a dual function: first, it serves to hold the lightweight foam component of the container panel in the desired position; second, it makes it less likely that the first hinge member 21 and the second hinge member 22 of hinge assembly 20b will accidentally separate. In this regard, a tool may be required to apply considerable force to bend knuckle 26 in order to separate pin member 24 from it, thereby ensuring the integrity of the assembled container.

[0051] It will be appreciated that by providing a two-part hinge assembly 20a, 20b, namely a first hinge member 21 and a second hinge member 22, each panel 11, 14, 16, 18 of the container 10 can be disassembled and repaired or replaced if damaged. This two-part hinge assembly also allows the parts to be molded in any configuration within the mold as desired.

[0052] It will be appreciated that the hinge assembly of the present invention is capable of maintaining the panels of the container 10 in a folded position, an upright container position, and an upright position with the lid open for loading the container. The lid hinge is capable of operating through over 270 degrees of motion, while the base hinge can move 180 degrees, but can only be used with 90 degrees of motion after being overmolded and assembled to the base assembly. All other configurations are also possible within the range of movement allowed by the hinge. The hinge is best compatible with the foam material used in the overmolding process, but this is not necessarily required due to the mechanical interlocking design of the rigid hinge and molded particles. Additives and other materials can be used to further enhance properties such as heat resistance.

[0053] Throughout the specification and claims, the term "include" and its derivatives are intended to be open-ended rather than closed-ended, unless explicitly stated or the context requires otherwise. That is, the term "include" and its derivatives refer not only to the components, steps, or features that are directly listed, but also to other components, steps, or features that are not explicitly listed, unless explicitly stated or the context requires otherwise.

[0054] Directional terms used in the specification and claims, such as vertical, horizontal, top, bottom, upper, and lower, are to be construed as relative terms and are based on the premise that a component, article, item, device, apparatus, or apparatus is generally considered in a particular orientation, generally with the container uppermost.

[0055] It will be appreciated that those skilled in the art can make various changes and modifications to the methods of the present invention described herein without departing from the spirit and scope of the invention.

Claims

1. A hinge assembly for connecting a plurality of panels made of expandable material, comprising: a first hinge member having a first plate member and a first base plate, wherein the first plate member is configured to be located on a surface of one of the connecting plates, and the first base plate is configured to be embedded in the expandable material of the connecting plate; a second hinge member, the second hinge member having a second plate member and a second bottom plate, the second plate member being configured to be located on the other surface of the connecting plate, and the second bottom plate being configured to be embedded in the expandable material of the connecting plate; Wherein, the first plate and the second plate are configured to engage with each other to facilitate the hinge movement of the connecting plate.

2. The hinge assembly according to claim 1, characterized in that: The first plate and the first bottom plate, and the second plate and the second bottom plate are connected by a plurality of rib members to facilitate integration of a hinge assembly with the expandable material.

3. The hinge assembly according to claim 2, characterized in that: At least one of the first hinge member and the second hinge member has a wing member extending laterally from at least one end thereof.

4. The hinge assembly according to claim 3, characterized in that: The wing member is shaped to capture particles of the expandable material during expansion, so that the particles of the expandable material fuse together in a space formed between the wing member and an end of the first or second hinge member.

5. Hinge assembly according to one of the preceding claims, characterized in that One of the first plate or the second plate includes a pin, and the other of the first plate or the second plate includes one or more steering knuckles mounted on the pin to interengage therewith.

6. The hinge assembly according to claim 5, characterized in that: The pin has a cam profile, and the one or more steering members engage the cam profile surface of the pin to control the angular position of the first plate relative to the second plate.

7. The hinge assembly according to claim 6, characterized in that: The angular position between the first plate and the second plate may vary between 0-90°.

8. The hinge assembly according to claim 6, characterized in that: The angular position of the first plate relative to the second plate can vary between 0-270°.

9. Hinge assembly according to one of the preceding claims, characterized in that The first or second hinge member is each made of a polymer material such that when the expandable material expands, the expandable material will at least partially form a molecular bond with the first or second hinge member.

10. Hinge assembly according to one of the preceding claims, characterized in that The expandable material is expanded polypropylene (EPP).

Images