Fold flat foam storage bin

Abstract

An organizational bin formed from molded foam and capable of being folded flat into a planar configuration for transportation and unfolded to provide a useful volume for use by a consumer. The bin has a base and four walls, all of which are integrally formed and coupled to each other by living hinges. The base includes a series of living hinges extending outwardly from a midpoint. The living hinges are positioned to allow base to fold outwardly relative to with walls pivoting relative to each other so that bin folds into a flat configuration. A flat folded bin will reduce shipping costs by more than five times by reducing the volume bin occupies when shipped and also significantly reduces the carbon footprint of shipping the bin.

What is claimed is: 
     
         1 . An organizational bin, comprising:
 a base having a plurality of corners and a first set of living hinges extending from a midpoint of the base to each of the plurality of corners; and   a plurality of walls integrally formed with the base and each other to define a cavity therein, wherein each wall is coupled to the base by a second set of living hinges and integrally coupled to each adjacent wall of the plurality of walls by a third set of living hinges.   
     
     
         2 . The organizational bin of  claim 1 , wherein the base and the plurality of walls are formed from a molded foam material. 
     
     
         3 . The organizational bin of  claim 2 , wherein the molded foam material is ethylene-vinyl acetate (EVA) foam. 
     
     
         4 . The organizational bin of  claim 1 , wherein the organizational bin is a rectangular cube. 
     
     
         5 . The organizational bin of  claim 1 , wherein the plurality of walls are four walls. 
     
     
         6 . The organizational bin of  claim 1 , wherein the first set of living hinges, the second set of living hinges, and the third set of living hinges are arranged to allow the base to fold outwardly relative to the cavity. 
     
     
         7 . The organizational bin of  claim 2 , wherein third set of living hinges are arranged so that two of the plurality of walls that are adjacent to each other can fold into contact with each other and two of the plurality of walls can pivot into a planar orientation. 
     
     
         8 . The organizational bin of  claim 2 , wherein the third set of living hinges are arranged so that the two of the plurality of walls that are adjacent to each other can only fold into contact with each other and the two of the plurality of walls can only pivot into a planar orientation. 
     
     
         9 . The organizational bin of  claim 1 , wherein the first set of living hinges, the second set of living hinges, and the third set of living hinges are formed by a molded foam material. 
     
     
         10 . The organizational bin of  claim 9 , wherein the first set of living hinges, the second set of living hinges, and the third set of living hinges are formed by a thinner web of the molded foam material forming the base and the plurality of walls. 
     
     
         11 . A method of manufacturing an organizational bin, comprising:
 molding a foam material to form an organizational bin component; and   shaping the organizational bin component to form a base having a plurality of corners and a first set of living hinges extending from a midpoint of the base to each of the plurality of corners and a plurality of walls integrally formed with the base and each other to define a cavity therein, wherein each wall is coupled to the base by a second set of living hinges and integrally coupled to each adjacent wall of the plurality of walls by a third set of living hinges.   
     
     
         12 . The method of  claim 11 , wherein the foam material is an expansion foam. 
     
     
         13 . The method of  claim 12 , wherein the foam material is ethylene-vinyl acetate (EVA) foam. 
     
     
         14 . The method of  claim 11 , wherein the organizational bin is a rectangular cube. 
     
     
         15 . The method of  claim 11 , wherein the plurality of walls are four walls. 
     
     
         16 . The method of  claim 11 , wherein the first set of living hinges, the second set of living hinges, and the third set of living hinges are arranged to allow the base to fold outwardly relative to the cavity. 
     
     
         17 . The method of  claim 12 , wherein the third set of living hinges are arranged so that two of the plurality of walls that are adjacent to each other can fold into contact with each other and two of the plurality of walls can pivot into a planar orientation. 
     
     
         18 . The method of  claim 12 , wherein third set of living hinges are arranged so that the two of the plurality of walls that are adjacent to each other can only fold into contact with each other and the two of the plurality of walls can only pivot into a planar orientation. 
     
     
         19 . The method of  claim 11 , wherein the first set of living hinges, the second set of living hinges, and the third set of living hinges are formed by the foam material. 
     
     
         20 . The method of  claim 19 , wherein the first set of living hinges, the second set of living hinges, and the third set of living hinges are formed by a thinner web of the foam material forming the base and the plurality of walls.