Molded container case with hinge and method for making same

• US 4,615,464 A
• Filed: 06/05/1985
• Issued: 10/07/1986
• Est. Priority Date: 12/21/1983
• Status: Expired due to Term

• Current Assignee: Custom-Pak, Inc.
• Original Assignee: Custom-Pak, Inc.
• Inventors: Byrns, James E.
• Primary Examiner(s): NOT, DEFINED
• Assistant Examiner(s): Wallace, R. S.
• Application Number:
  US06/741,712
• Time in Patent Office: 489 Days
• Field of Search: 29/434, 29/522 R, 29/557, 29/11, 16/341, 16/342, 220/4 E, 220/4 B, 220/335, 220/338, 220/343, 220/324, 220/469, 292/302, 264/98
• US Class Current: 220/4.23
• CPC Class Codes: B29C 49/0031 Making articles having hollow walls
• CPC Class Codes: B29L 2024/00 Articles with hollow walls
• CPC Class Codes: B29L 2031/7418 Suitcases
• CPC Class Codes: B65D 11/16 with double walls
• CPC Class Codes: B65D 2251/1016 Means for locking the closure in closed position
• CPC Class Codes: B65D 43/165 these elements being assembled by a separate pin-like member
• CPC Class Codes: Y10T 29/24 Hinge making or assembling
• CPC Class Codes: Y10T 29/4984 Retaining clearance for motion between assembled parts
• CPC Class Codes: Y10T 29/49938 Radially expanding part in cavity, aperture, or hollow body
• CPC Class Codes: Y10T 29/4998 Combined manufacture including applying or shaping of fluent material

Abstract

A container case includes a cover, a base and a hinge which pivotally joins the cover and the base on a corresponding side of each. The cover, base and hinge are formed by blow molding. The cover and base are double-walled in construction and identical so that they can be formed from the same mold. Each of the cover and base includes cylindrically-shaped, hollow extensions which form portions of the hinge. When the case is assembled, alternate hinge portions of the cover and base are aligned end-to-end along a common axis and cooperatingly mate to form the full hinge. The hinge is drilled to form openings in the end surfaces of the mating hinge portions which communicate with the interior, hollow areas of the hinge portions to form a single bore through the entire axial length of the hinge. A polyethylene pin is received by the hinge bore to interlock the individual hinge portions. The container case is also provided with a slidable latch having a C-shaped polyethylene bracket which slides on rails or tracks formed on extensions of corresponding sides of the cover and base. The bracket is capable of sliding to overlap mating edge portions of the latch extensions to keep the container case closed.

Claims

1. A method for making a container case including a cover and a base, the cover having a substantially planar top wall and peripheral side walls extending from the top wall, the base having a substantially planar bottom wall and peripheral side walls extending from the bottom wall, each of the top wall, bottom wall, and peripheral side walls having an inner wall and an outer wall, each of the cover and the base having a plurality of separated hinge portions connected between the inner and the outer walls of a peripheral side wall, the inner and outer walls of the cover defining a first hollow space, the inner and outer walls of the base defining a second hollow space, comprising the steps of:

blow molding the cover from a thermoplastic material to form the top and side walls and hollow hinge portions with end surfaces so that the interiors of the hollow hinge portions communicate with the first hollow space;

blowing molding the base from the thermoplastic material to form the bottom and side walls and hollow hinge portions with end surfaces so that the interiors of the hollow hinge portions communicate with the second hollow space;

fitting the hinge portions of the cover and the hinge portions of the base together in an end-to-end arrangement along a common axis;

drilling opening in the end surfaces of the hinge portions to define a central bore; and

inserting a hinge pin into the central bore.

2. A method as recited in claim 1, wherein the inserting step includes inserting a hinge pin that is at least as soft as the thermoplastic material.

3. A method as recited in claim 1, wherein the step of blow molding the cover includes forming a first interior rib that extends above the inner wall of the cover, the first interior rib partially encircling the inner periphery of the cover, and wherein the step of blow molding the base includes forming a second interior rib that extends above the inner wall of the base, the second interior rib partially encircling the inner periphery of the base.

4. A method as recited in claim 1, wherein the step of blow molding the cover and the step of blow molding the base are performed using an identical mold.

5. A method as recited in claim 1, wherein the drilling step is performed after the fitting step.

6. A method as recited in claim 1, wherein the step of blow molding the cover includes blow molding hollow hinge portions that extend at an angle of approximately 45°

from the associated side wall, and wherein the step of blow molding the base includes blow molding hollow hinge portions that extend at an angle of approximately 45°

from the associated side wall.

7. A method as recited in claim 1, wherein the step of blow molding the cover includes blow molding hollow hinge portions with end surfaces that are tapered, and wherein the step of blow molding the base includes blow molding hollow hinge portions with end surfaces that are tapered.

8. A method as recited in claim 7, wherein each blow molding step includes blow molding hollow hinge portions with end surfaces that are tapered, the angle of taper being between about 2°

and about 4°

.

9. A container case including a cover and a base, the cover having a substantially planar top wall and peripheral side walls extending from the top wall, the base having a substantially planar bottom wall and peripheral side walls extending from the bottom wall, each of the top wall, bottom wall, and peripheral side walls having an inner wall and an outer wall, each of the cover and the base having a plurality of separated hinge portions connected between the inner and the outer walls of a peripheral side wall, the inner and outer walls of the cover defining a first hollow space, the inner and outer walls of the base defining a second hollow space, made by a process comprising the steps of:

blow molding the cover from a thermoplastic material to form the top and side walls and hollow hinge portions with end surfaces so that the interiors of the hollow hinge portions communicate with the first hollow space;

blow molding the base from the thermoplastic material to form the bottom and side walls and hollow hinge portions with end surfaces so that the interiors of the hollow hinge portions communicate with the second hollow space;

fitting the hinge portions of the cover and the hinge portions of the base together in an end-to-end arrangement along a common axis;

drilling openings in the end surfaces of the hinge portions to define a central bore; and

inserting a hinge pin into the central bore.