Container hinge

Abstract

A hinge assembly for connecting panels made from an expandable material is disclosed, comprising: a first hinge member having a first plate member configured to be placed on a surface of one of the connecting panels and a first bottom plate configured to be embedded in the expandable material of the connecting panel; and a second hinge member having a second plate member configured to be placed on a surface of the other connecting panel and a second bottom plate configured to be embedded in the expandable material of the connecting panel; wherein the first plate member and the second plate member are configured to engage with each other to facilitate hinged movement of the connecting panels.

Description

Related Applications

[0001] This application claims priority to Australian Provisional Patent Application No. 2022903520 filed on 21 November 2023, the entire contents of which are incorporated herein by reference. [Technical Field]

[0002] FIELD OF THE INVENTION The present invention relates generally to hinges for storage containers, and more particularly to hinges for storage containers that are integral with and formed from expandable material. [Background technology]

[0003] Insulated storage containers are generally used to provide a means for containing items in a controlled thermal environment for storage or transportation. Such containers have a variety of uses, ranging from receiving food products, as well as pharmaceuticals and the like, to maintaining them in a controlled thermal environment to maximize their usable life. The controlled thermal environment can be a heated or cooled environment depending on the items stored in the container. Summary of the Invention [Problem to be solved by the invention]

[0004] Conventional insulated containers have generally been made from polymeric foam materials such as expanded polystyrene (EPS) and expanded polypropylene (EPP). Such materials have known insulating properties and can be efficiently and cost-effectively molded to form a single, monolithic three-dimensional container. Such containers can then be used to store items such as food in a refrigerated or heated state, and by attaching a lid to the opening, an enclosed space can be formed that can maintain a heated environment for an extended period of time.

[0005] However, conventional molded containers suffer from a number of drawbacks. One significant drawback is that they occupy substantially the same volume of space whether or not they contain items. As a result, the container requires a considerable amount of storage space when not in use. This can be a major problem when the container is used to transport goods, as the container requires significant storage space even when empty. As a result, the container may be destroyed or discarded, significantly shortening its useful life.

[0006] Many attempts have been made to provide collapsible containers that can be collapsed to significantly minimize the storage space required to store the container when not in use. Such containers generally include panels having hinges therebetween that facilitate folding of the panels between a collapsed configuration and an erected configuration. Containers made from expandable materials such as expanded polystyrene (EPS) or expanded polypropylene (EPP) present unique challenges in the ability to form such hinges into the body of the material, especially when such containers are intended for multiple uses. Traditionally, such containers have been formed to create thinned areas between the panels for forming hinges. However, multiple uses of the hinge in situations where the container is assembled / reassembled multiple times can cause material failure in the hinge area and significantly compromise the integrity of the container.

[0007] Therefore, there is a need to provide a hinge arrangement for use with containers formed from expandable materials that has sufficient strength to facilitate multiple folding cycles without compromising the integrity of the container.

[0008] The above references and discussion of prior proposals or products are not intended, and should not be construed, as statements or admissions of common general knowledge in this technical field. In particular, the above discussion of the prior art is not related to what is commonly known or well-known to those skilled in the art, but is helpful in understanding the inventive step of the present invention, of which the identification of relevant prior art proposals is only a part. [Means for solving the problem]

[0009] The present invention, in one or more aspects, is as defined in the independent claims. Some optional and / or preferred features of the invention are defined in the dependent claims.

[0010] Thus, in one aspect of the present invention, a first hinge member having a first plate member configured to be disposed on a surface of one of the connecting panels and a first bottom plate configured to be embedded in the expandable material of the connecting panels; a second hinge member having a second plate member configured to be disposed on a surface of the other connecting panel and a second bottom plate configured to be embedded in the expandable material of the connecting panel; Includes: the first plate member and the second plate member are configured to interengage with one another to facilitate hinged movement of the connecting panel. A hinge assembly is provided for connecting the panels made from expandable material. In one embodiment, the first plate member and first bottom plate and the second plate member and second bottom plate are connected by rib members to facilitate integration of the hinge assembly with the expandable material.

[0011] At least one of the first hinge member and the second hinge member may have a wing member extending laterally from at least one end thereof.

[0012] The wing member may be shaped to trap the particles of expandable material during expansion such that the particles fuse together in a space formed between the wing member and the end of the first or second hinge member.

[0013] At least one of the first plate member or the second plate member may include a pin member, and the other of the first plate member or the second plate member may include one or more knuckles that interengage with the pin member.

[0014] The pin member may have a cam profile, and one or more pin members may engage surfaces of the cam profile of the pin member to control the angular position of the first plate member relative to the second plate member.

[0015] In one form, the angular position of the first plate member relative to the second plate member can vary between 0 and 90 degrees. In another form, the angular position of the first plate member relative to the second plate member may vary between 0 and 270°.

[0016] Each first or second hinge member may be formed from a polymeric material such that as the expandable material expands, the expandable material at least partially forms a molecular bond with the polymeric material of the first or second hinge member. The expandable material may be expanded polypropylene (EPP). [Brief explanation of the drawings]

[0017] The present invention can be better understood from the following non-limiting description of preferred embodiments, in which: [Figure 1] 1 is a perspective view of a container employing a hinge assembly according to one embodiment of the present invention. FIG. [Figure 2] 1 shows a perspective view of a first hinge member and a second hinge member of a hinge assembly according to the present invention; [Figure 3] 1 shows a perspective view of a first hinge member and a second hinge member of a hinge assembly according to the present invention; [Figure 4] FIG. 1 illustrates a side view of an assembled hinge assembly according to one embodiment of the present invention. [Figure 5]FIG. 1 illustrates a perspective view of an assembled hinge assembly according to one embodiment of the present invention. [Figure 6] FIG. 10 illustrates a top view of an assembled hinge assembly according to another embodiment of the present invention. [Figure 7] FIG. 10 illustrates a rear view of an assembled hinge assembly according to another embodiment of the present invention. [Figure 8] FIG. 10 is an end view of an assembled hinge assembly according to another embodiment of the present invention. [Figure 9] 1 shows a cross-sectional view of a hinge assembly according to the present invention; [Figure 10] 1 shows a cross-sectional view of a hinge assembly according to the present invention; [Figure 11] 1 shows a cross-sectional view of a hinge assembly according to the present invention; [Figure 12] 1 shows a cross-sectional view of a hinge assembly according to the present invention; DETAILED DESCRIPTION OF THE INVENTION

[0018] Preferred features of the present invention will now be described with particular reference to the accompanying drawings. It should be understood, however, that the features illustrated and described with reference to the drawings should not be construed as limiting the scope of the invention.

[0019] The present invention is intended for use with containers such as those disclosed in Applicant's co-pending PCT International Patent Application No. PCT / AU2020 / 050491. The entire contents of which are incorporated herein by reference.

[0020] In this regard, the hinge structure of the present invention will be described below as being incorporated into a container formed from expanded polypropylene (EPP). However, it will be understood that the hinge structure of the present invention can be incorporated into a container formed from any type of expandable material, including expanded polystyrene (EPS) or other polymeric foam materials such as polyurethane, or any other plastic material capable of providing thermal insulation.

[0021] Referring to FIG. 1, a container 10 having a hinge assembly 20 according to one embodiment of the present invention is shown in an assembled configuration. The container 10 generally includes a base 12 , a pair of opposed end walls 14 , and a pair of opposed side walls 16 . In the illustrated embodiment, the lid member 18 is attached to the upper end of the end wall 14 ; however, in alternative embodiments, the lid member may be attached to the upper end of the side wall 16 . In alternative embodiments, the lid 18 may be a separate piece that is fitted to the container 10 once assembled, or the container 10 may be lidless.

[0022] The base 12 is configured to include a pair of opposed end supports 11 that project upwardly from the base 12 . The end supports 11 extend the width of the base 12 and are integrally formed with the base 12 . The end supports 11 support end walls 14 thereon. The portion of base 12 extending between end supports 11 is generally planar and forms the bottom surface of container 10 when the container is in the assembled configuration as shown.

[0023] The side walls 16 are positioned to extend along opposite side edges of the base 12 . To facilitate folding of container 10 into a flattened configuration for storage, each side wall 16 is attached to opposite side edges of base 12 by a base hinge assembly 20a of the present invention, which is hidden in FIG. In this arrangement, the side walls 16 fold inward, one against the other, over the surface of the base 12 .

[0024] End wall 14 is attached to end support 11 via a base hinge assembly 20a according to the present invention, which is hidden in the embodiment of the invention depicted in FIG. The base hinge assembly 20 a provides a pivotal connection between the lower end of the end wall 14 and the upper end of the end support 11 . This orientation of the base hinge assembly 20a allows the end walls 14, as well as the side walls 16, to fold inwardly relative to the container 10, and prevents the end walls 14 from folding outwardly. It will be appreciated that the end supports 11 are substantially the same height as the combined thickness of the side walls 16 so that the end walls 14 can sit flush against the surfaces of the side walls 16 when the container 10 is in the inverted configuration. Also, because the combined height of the end walls 14 is less than the distance between the end supports 11, the end walls 14 can be folded to extend along the same plane and not overlap.

[0025] In the illustrated container embodiment, a lid member 18 is attached to the end wall 14 via a lid hinge assembly 20b. The lid hinge assembly 20b and the base hinge assembly 20a are similar in construction but are configured differently to accommodate different ranges of movement. As will be explained below, the lid hinge assembly 20b is configured to allow the lid member 18 to move in an arc of approximately 270° relative to the end wall 14. In comparison, the base hinge assembly 20a is configured for 180° of movement, but when overmolded and assembled to the base component it is limited to use at only 90°. This limits the end walls 14 and side walls 16 from moving beyond the 90° required for installation in the disassembled and assembled states, as shown in FIG.

[0026] With respect to 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 projection formed thereon to which the hinge plate 23 of the first hinge member 21 is attached. The hinge plates 23 include pin members 24 having cam profiles that project perpendicularly from the upper edges of the end walls 14 as shown. The end of the cover member 18 has the hinge plate 25 of the second hinge member 22 attached to its upper edge. The hinge plate 25 has a metal pin 26 that protrudes from the end of the cover member 18 and receives the pin member 24 of the first hinge member 21 . In this arrangement, the hinge assembly 20 allows the lid member 18 to move in an arc of approximately 270°. This allows the lid member 18 to be moved between a closed position and an open position, allowing easy access to the interior of the container 10.

[0027] The lid member 18 moves 270° relative to the end wall 14 so that the lid member 18 can fold backward against the end wall 14 when the container 10 is in the collapsed or reclined position. This allows the lid members 18 to seat securely flush against the outer surface of each end wall 14, thereby providing a compact folded container with each folded component supported by the component below and extending substantially parallel to one another. In this arrangement, the inverted containers can be stacked for compact and stable storage.

[0028] 2 and 3, the first hinge member 21 and the second hinge member 22 of the lid hinge assembly 20b are shown separated. The first and second hinge members 21, 22 each have the same configuration and include a plurality of rib members 27 extending from the underside of each hinge plate 23, 25 and terminating in a first bottom hinge plate 28 and a second bottom hinge plate 29. As best seen in FIG. 4, each rib member 27 extends angled downward from each hinge plate 23, 25 such that the first bottom hinge plate 28 and the second bottom hinge plate 29 extend generally parallel to but laterally offset from the respective hinge plates 23, 25.

[0029] As mentioned above, the components of the container 10 are preferably made from an expandable material such as EPP. The components of the base hinge assembly 20a and the lid hinge assembly 20b are preferably made from a polymer that is compatible with the expanded material, and during molding of the container 10, the hinge assemblies 20a, 20b are embedded within the expandable material, such that the hinge assemblies 20a, 20b are bonded to the expandable material during the molding process. During the steam molding cycle, the expanded material is molded around the hinge assemblies 20a, 20b, so that the hinge assemblies 20a, 20b are molecularly bonded to the expanded material to some degree during the overmolding process. The components of the hinge assemblies 20a, 20b are provided with voids formed between the rib members so that as the material expands during the molding process, the expanding material creates undercuts for the hinge components, thereby also creating a mechanical interlock or frictional bond between the hinge assembly components and the expandable material.

[0030] In this regard, as depicted in FIGS. 4 and 5, the first and second hinge members 21, 22 of the lid hinge assembly 20b are configured such that the rib member 27 and bottom plates 28, 29 are encapsulated within the molded material and trap particles of the expandable material during the overmolding process, creating both a molecular bond from the steam heating process and also a rigid mechanical or frictional bond between the molded foam and the rigid plastic material of the components of the lid hinge assembly 20b. This creates a secure, robust engagement between the foam and the rigid components of the hinge assemblies 20a, 20b that is capable of withstanding significant forces during use of the container 10. As shown, first hinge member 21 and second hinge member 22 are positioned within the mold so that respective hinge plates 23 and 25 are positioned adjacent the exterior surfaces of the panels of container 10 .

[0031] As shown in FIGS. 2, 6 and 7, the second hinge member 22 may also include a pair of retention wing members extending laterally from opposite sides of the second hinge member 22. The retaining wing members 30 can function to trap the injected foam particles of the expandable material so that during the steaming process, the particles fuse between the edges of the hinge members 22 and the wing members 30, preventing separation between the embedded hinge members and the expanded material when bending forces are applied to the container during use. This serves to prevent the hinge assembly and container material from separating during use, creating gaps or depressions where dirt, food, or other materials can collect and compromise the safety and quality of the container 10.

[0032] Referring to Figure 8, to accurately position the hinge member 22 within the mold for overmolding with the expandable material, a pin is provided to assist in locating the first hinge member. In this regard, pins are placed in holes 31a and 31b to provide precise locations that restrain hinge member 22 from moving in the X and Y directions as shown. The round central hole 31 a provides a precise location for a pin to restrain the hinge member from moving in the X and Y axes, and the holes 31 b formed in the surface of the hinge plate are elongated to allow for tolerances for thermal expansion, contraction, and warpage while precisely restraining rotation of the hinge member 22 about the Z axis. The flat surfaces on the top of the hinge plates, combined with the friction between the pins in the hinge holes 31a and 31b, constrain the movement of the hinge members in the Z direction during the molding process due to the frictional forces present when the mold is closed. This arrangement also facilitates removal of the pin in the Z direction after overmolding and during the transfer and ejection process. Using this system, the hinge members of the hinge assemblies 20a, 20b can be loaded into the mold either by a human or by a robot. It is also envisioned that a clamp may be employed that attaches to a portion of the hinge member when the mold is closed to prevent movement of the hinge member during the molding process.

[0033] The hinge assembly 20 is configured to provide a clear margin for sealing between the expandable materials to prevent the expandable beads from getting into undesired positions during formation. In this regard, the design of the first and second hinge members of each of the hinge assemblies 20a, 20b positions all sealing surfaces such that core pulls or other mechanisms are not required to move portions of the mold away from areas where foam is not intended to be placed. The plastic material of the hinge members is configured to ensure that particles of the expandable material do not get into areas where they are not wanted and where, during use, the hinge members would hit the expanded material and prevent them from rotating correctly. The shape of the hinge members is optimized to allow particles of expanded material to be injected in the usual way and to flow around the rigid hinge members. This ensures that the expanded material is of the correct thickness (i.e., a few grain sizes) in all areas, avoiding inconsistent build, surface defects, or poor fusion.

[0034] As previously discussed and shown in Figures 9 and 10, the base hinge assembly 20a is depicted. The pin member 44 of the first hinge member 41 is configured with a cam profile. This camming profile of the pin member 44 works in conjunction with the upper rib 50 to resist any upward force from the top panel member of the container 10 which would normally separate the two components of the container and create a gap between them. Such voids adversely affect the temperature control performance of the insulated container.

[0035] As shown in FIG. 11, the hinge assemblies 20a, 20b are configured to cooperate when in the final position as shown. This interlocking is created by the engagement between pin member 44 and ferrule 46, creating a strong connection between the two halves of the rigid hinge assembly and reducing the load on the foam-to-rigid plastic connection when the assembled container is subjected to a shear force in the direction of arrow F.

[0036] Referring to Figure 12, the lid hinge assembly 20b is depicted. The camming profile of pin member 24, as shown, provides interference with the rivet 26 of the clip half of the hinge assembly, which serves a dual function: first, to hold the light foam component of the container panel in the desired position; and second, to make the first hinge member 21 and second hinge member 22 of hinge assembly 20b difficult to separate by accidental means. In this regard, bending the ferrule 26 to separate the pin member 24 therefrom requires the application of significant force and may require a tool, thus ensuring the integrity of the container once assembled.

[0037] It will be appreciated that by providing the hinge assemblies 20a, 20b in two parts, i.e., the first hinge member 21 and the second hinge member 22, each panel 11, 14, 16, 18 of the container 10 can be removed and repaired or replaced if damaged. This two part hinge assembly also allows parts to be molded in any configuration within the tooling required.

[0038] It will be appreciated that the hinge assembly of the present invention is capable of maintaining the panels of the container 10 in a reclined position, an upright container position, and an upright position with the lid open for loading the container. The lid hinge can operate over 270 degrees of motion, and the base hinge can move up to 180 degrees, but once overmolded and assembled to the base component, it is limited to use with only 90 degrees of motion. All other configurations are possible within the allowed range of motion of the hinge. The hinge may be ideally compatible with the foam material used in the overmolding process, but this is not necessary due to the mechanically interlocking design of the rigid hinge and the particles being molded. Additives and other materials can be used to further improve properties such as heat resistance.

[0039] Throughout the specification and claims, the term "comprises" and its derivatives are intended to have an inclusive rather than exclusive meaning unless expressly stated to the contrary or the context dictates otherwise. That is, the term "comprises" and its derivatives will be understood to indicate the inclusion of not only the recited components, steps, or features to which it directly refers, but also other components, steps, or features not specifically recited, unless otherwise specified or the context dictates otherwise.

[0040] Terms indicating directions (such as vertical, horizontal, top, bottom, above, below, etc.) used in the specification and claims are to be construed relationally and based on the premise that a component, item, article, apparatus, device, or equipment is normally considered to be in a particular orientation, with the container at the top.

[0041] Those skilled in the art will recognize that many modifications and variations can be made to the methods of the invention described herein without departing from the spirit and scope of the invention.

Claims

1. a first hinge member having a first plate member configured to be disposed on a surface of one of the connecting panels and a first bottom plate configured to be embedded in the expandable material of the connecting panels; a second hinge member having a second plate member configured to be disposed on a surface of the other connecting panel and a second bottom plate configured to be embedded in the expandable material of the connecting panel; Includes: the first plate member and the second plate member are configured to engage one another to facilitate hinged movement of the connecting panel; A hinge assembly for connecting panels made from an expandable material.

2. 2. The hinge assembly of claim 1, wherein the first plate member and the first bottom plate and the second plate member and the second bottom plate are connected by rib members to facilitate integration of the hinge assembly with the expandable material.

3. 3. The hinge assembly of claim 2, wherein 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. 4. The hinge assembly of claim 3, wherein the wing members are shaped to trap the particles of expandable material during expansion to fuse together in a space formed between the wing member and the end of the first or second hinge member.

5. 5. The hinge assembly of claim 1, wherein one of the first plate member or the second plate member includes a pin member, and the other of the first plate member or the second plate member includes one or more rivets that are mutually engaged with the pin member.

6. 6. The hinge assembly of claim 5, wherein the pin member has a cam profile and the one or more locking members engage surfaces of the cam profile of the pin member to control the angular position of the first plate member relative to the second plate member.

7. 7. The hinge assembly of claim 6, wherein the angular position of the first plate member relative to the second plate member can vary between 0 and 90 degrees.

8. 7. The hinge assembly of claim 6, wherein the angular position of the first plate member relative to the second plate member can vary between 0 and 270 degrees.

9. 9. A hinge assembly as claimed in any one of claims 1 to 8, wherein each first or second hinge member is formed from a polymeric material such that as the expandable material expands, the expandable material forms at least a partial molecular bond with the first or second hinge member.

10. 10. A hinge assembly according to any one of claims 1 to 9, wherein the expandable material is expanded polypropylene (EPP).

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