Collapsible Shape-Retaining Containers

Abstract

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.

1 . A collapsible container comprising
 a generally annular, stiff upper tier having a lower edge and an opening in an upper portion of the upper tier;   a stiff lower tier having an upper edge; and   a collapsible wall section connected to the upper tier and the lower tier, the collapsible wall section comprising at least first, second and third generally annular collapsible wall section tiers, an upper living hinge adjacent the lower edge, a lower living hinge adjacent the upper edge, and at least two intermediate living hinges, the first and second collapsible wall section tiers connected to each other by one of the intermediate living hinges, the second and third collapsible wall section tiers connected to each other by the other of the intermediate living hinges, the first tier located above the second tier and the second tier located above the third tier, wherein the size of the container volume can be increased by unfolding the collapsible wall section from a collapsed configuration to an expanded configuration and can be decreased by folding the collapsible wall section from the expanded configuration to the collapsed configuration, the collapsible wall section being at least partially located within one of the upper and lower tiers and the other of the upper and lower tiers being at least partially located within the collapsible wall section when the collapsible wall section is in the collapsed configuration, wherein the lower tier comprises a generally annular first portion and a second portion, the first and second portions being secured together by an overmolded elastomeric layer at least partially covering the first and second portions, the second portion having a male member extending into and frictionally engaging the first portion.   
     
     
         2 . The collapsible container of  claim 1  wherein the second tier is adjacent the first and third tiers, the first and third tiers are flexible and the second tier is stiff; and wherein in the collapsed state the collapsible wall section is folded along the one of the intermediate living hinges between the first and second tiers and along the other of the intermediate living hinges. 
     
     
         3 . The collapsible container of  claim 1  wherein in the collapsed state the collapsible wall section is folded along the upper living hinge and along the lower living hinge. 
     
     
         4 . The collapsible container of  claim 1  wherein the first, second and third tiers are substantially vertical in the expanded configuration and in the collapsed configuration. 
     
     
         5 . (canceled) 
     
     
         6 . (canceled) 
     
     
         7 . The collapsible container of  claim 1  wherein the lower tier comprises an interior wall exposed to the interior of the container, the interior wall comprising at least a portion of the male member. 
     
     
         8 . The collapsible container of  claim 1  wherein the second portion comprises an imperforate base. 
     
     
         9 . The collapsible container of  claim 7  further comprising a faucet and a faucet passageway through the lower section, the faucet extending through the faucet passageway. 
     
     
         10 . The collapsible container of  claim 1  wherein the second portion is generally annular. 
     
     
         11 . The collapsible container of  claim 10  further comprising
 a bottom tier below the lower tier and 
 a second collapsible wall section connected to the lower tier and the bottom tier, the second collapsible wall section comprising at least fourth, fifth and sixth generally annular collapsible wall section tiers, a second upper living hinge adjacent the lower edge of the lower tier, a second lower living hinge adjacent the upper edge of the bottom tier, and at least two intermediate living hinges, the fourth and fifth collapsible wall section tiers connected to each other by one of the intermediate living hinges, the fifth and sixth collapsible wall section tiers connected to each other by the other of the intermediate living hinges, the fourth tier located above the fifth tier and the fifth tier located above the sixth tier, wherein the size of the container volume can be increased by unfolding the second collapsible wall section from a second collapsed configuration to a second expanded configuration and can be decreased by folding the second collapsible wall section from the second expanded configuration to the second collapsed configuration, the second collapsible wall section being at least partially located within one of the lower and bottom tiers and the other of the lower and bottom tiers being at least partially located within the second collapsible wall section when the second collapsible wall section is in the second collapsed configuration. 
 
     
     
         12 . The collapsible container of  claim 1  further comprising:
 a bottom tier below the lower tier; and 
 a second collapsible wall section connected to the lower tier and the bottom tier, the second collapsible wall section comprising at least fourth, fifth and sixth generally annular collapsible wall section tiers, a second upper living hinge adjacent the lower edge of the lower tier, a second lower living hinge adjacent the upper edge of the bottom tier, and at least two intermediate living hinges, the fourth and fifth collapsible wall section tiers connected to each other by one of the intermediate living hinges, the fifth and sixth collapsible wall section tiers connected to each other by the other of the intermediate living hinges, the fourth tier located above the fifth tier and the fifth tier located above the sixth tier, wherein the size of the container volume can be increased by unfolding the second collapsible wall section from a second collapsed configuration to a second expanded configuration and can be decreased by folding the second collapsible wall section from the second expanded configuration to the second collapsed configuration, the second collapsible wall section being at least partially located within one of the lower and bottom tiers and the other of the lower and bottom tiers being at least partially located within the second collapsible wall section when the second collapsible wall section is in the second collapsed configuration. 
 
     
     
         13 . The collapsible container of  claim 1  further comprising a rim having an underside, a flexible rim component and a rigid rim underside component. 
     
     
         14 . The collapsible container of  claim 13  further comprising a lid having a plurality of peripheral flaps for securing the lid to the container. 
     
     
         15 . The collapsible container of  claim 13  wherein the upper tier, lower tier, collapsible wall section and the flexible rim component are made of an elastomer, the flexible rim component connected to the upper tier. 
     
     
         16 . The collapsible container of  claim 15  wherein the rigid rim underside component is made of a non-elastomeric plastic. 
     
     
         17 . The collapsible container of  claim 13  wherein each of the peripheral flaps comprise a hook for securing the lid to the container, each flap adjustable from a hooked position in which the hook is hooked to the underside of the rim to an unhooked position. 
     
     
         18 . The collapsible container of  claim 1  further comprising a flexible spout, the spout having a spout living hinge, wherein the spout is foldable downwardly along the spout living hinge and the spout is thereby at least partially located within the lower tier when the lower tiers and pour spout are in the collapsed configuration. 
     
     
         19 . The collapsible container of  claim 1  further comprising a removable lid covering and securable over the opening. 
     
     
         20 . The collapsible container of  claim 19  wherein the lid comprises a plurality of peripheral flaps for securing the lid to the container. 
     
     
         21 . The collapsible container of  claim 19  wherein the lid comprises a selectively openable vent. 
     
     
         22 . The collapsible container of  claim 19  wherein the container is watertight when the removable lid is secured over the opening. 
     
     
         23 . The collapsible container of  claim 1  further comprising a plurality of apertures. 
     
     
         24 . The collapsible container of  claim 1  further comprising a handle, the handle attached to the upper tier. 
     
     
         25 . The collapsible container of  claim 1  wherein the container volume is defined by the upper and lower tiers and the collapsible wall section. 
     
     
         26 . The collapsible container of  claim 1 , further comprising a second opening in the lower tier, the second opening configured to be opened and closed to selectively allow and restrict the flow of fluid into and out of the container through the second opening. 
     
     
         27 . A method of manufacturing a collapsible container comprising:
 placing a container body comprising a stiff first tier, a stiff second tier, and a collapsible wall section in a mold;   assembling the container body with a matching container component to close one end of the container body;   placing the container component in the mold; and   overmolding a thermoplastic layer around at least a portion of the container body and around at least a portion of the container component in the mold to join the container body and the container component.   
     
     
         28 . The method of  claim 27  further comprising collapsing the collapsible wall section to collapse the container body before overmolding, wherein the overmolding occurs on the collapsed container body. 
     
     
         29 . (canceled) 
     
     
         30 . (canceled) 
     
     
         31 . The collapsible container of  claim 1  wherein the lower tier is composed of polypropylene and the first and second portions form a watertight seal. 
     
     
         32 . The collapsible container of  claim 1  wherein the first portion has a first radially extending flange and the second portion has a second flange radially extending outwardly of the male member, the elastomeric layer in contact with the first and second flanges. 
     
     
         33 . The collapsible container of  claim 1  wherein the overmolded elastomeric layer covers a substantially annular portion of the first portion and a substantially annular portion of the second portion. 
     
     
         34 . The collapsible container of  claim 33  wherein the overmolded elastomeric layer is stretched over the substantially annular part of the first portion and the substantially annular part of the second portion.