Collapsible shape-retaining containers
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Solution Overview
Problem
Conventional collapsible containers face challenges such as occupying excessive space when not in use, difficulty in uniform expansion and collapse, high production costs for watertight designs, and reduced capacity compared to non-adjustable containers.
Innovation Solution
The design features a multi-tiered collapsible container with living hinges allowing for easy expansion and collapse, a thermoplastic overmolded layer for cost-effective watertightness, and flexible-rigid tier combinations to maintain volume adjustability while ensuring maximum capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If containers are made large to have large capacity, then capacity is improved, but storage space is worsened when empty
Solution Approach 1:
The container employs a collapsible wall structure with living hinges that enables the container to dynamically change its volume. When empty, the walls collapse inward to reduce storage space by 50-70%, while when in use, the walls expand to provide full capacity. This dynamic transformation resolves the contradiction between large capacity and compact storage.
Solution Approach 2:
The collapsible design allows the container walls to nest within themselves when collapsed, with the structure folding inward to occupy minimal space. The tiers and wall sections are configured to nest efficiently, enabling the container to transition from a large capacity state to a compact nested state for storage.
2Adaptability or versatility
If capacity adjustable containers are made from two or more separate pieces, then adaptability is improved, but manufacturing cost is worsened due to watertight requirements
Solution Approach 1:
The patent combines multiple components (tiers, wall sections, living hinges) into a integrated molded structure. The living hinges are molded as integral parts connecting the tiers, and the overmolded thermoplastic layer seals all joints and connections in a single manufacturing step. This merging of components maintains capacity adjustability while eliminating the high costs associated with assembling multiple separate watertight pieces.
Solution Approach 2:
The container uses composite construction with a base material structure combined with an overmolded thermoplastic layer. This composite approach provides both the structural flexibility needed for collapsibility and the watertight sealing required for capacity-adjustable containers, achieving adaptability without excessive manufacturing cost.
3Quantity of substance
If collapsible containers are made large, then capacity is improved, but ease of operation is worsened due to difficulty in expanding and collapsing
Solution Approach 1:
The container wall is divided into multiple tiers (first, second, third tiers) connected by living hinges. This segmentation allows the large container to collapse in discrete, manageable sections rather than as a single rigid structure. Each tier can fold independently, making the operation of large containers easier while maintaining full capacity when expanded.
Solution Approach 2:
The container employs flexible wall sections with living hinges that allow easy folding and collapsing. The wall material and hinge design provide the necessary flexibility for large containers to be expanded and collapsed without excessive force, improving ease of operation while maintaining large capacity when needed.
4Adaptability or versatility
If capacity adjustable containers have corners, then adaptability is improved for various uses, but ease of operation is worsened due to non-uniform collapse
Solution Approach 1:
The container is designed with a generally annular (circular) cross-section rather than angular corners. This curved geometry allows the container to collapse uniformly in all directions when compressed, as there are no corners to create stress concentrations or uneven folding patterns. The circular shape maintains versatility for various uses while enabling smooth, uniform collapse operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables containers to efficiently reduce volume by 50-70% for compact storage, maintain watertight integrity, and match content volume effectively, addressing the limitations of existing capacity-adjustable containers.
Implementation Method 1
The collapsible wall section has an upper living hinge adjacent the lower edge of the upper tier, a lower living hinge adjacent the upper edge of the lower tier, and at least two intermediate living hinges
Implementation Method 2
the collapsible container body is overmolded with a matching container component in a mold to join the container body and the container component
Data Source
AI summary
Collapsible containers and a method of their manufacture are disclosed herein. The collapsible containers have one or more collapsible wall sections and a stiff upper and lower tier. The wall sections have living hinges and three or more tiers between the hinges. A thermoplastic elastomer layer may join separately made portions of the container together. The containers may be made by molding and overmolding. The containers include inter alia bulk liquid containers, jugs, tubs, baskets, bottles, and food containers. The method of manufacturing includes placing a container component and a matching container body comprising a stiff first tier, a stiff second tier, and a collapsible wall section in a mold; assembling the container body with the container component to close one end of the container body; and overmolding a thermoplastic layer around the container body and the container component.