Abstract: A mould for forming a collapsible container from an expandable material, the container comprising, at least a base and two pairs of a side walls extending at right angles from opposing sides of the base, the mould comprising: a first mould member and a second mould member movable with respect to each other between an open and a closed moulding position to define a mould cavity; and a plurality of anvils mounted on a rear surface of at least one of the first mould member and/or second mould member, each anvil being movable so as to be extended into the mould cavity so as to form one or more hinges in the expandable material at predetermined locations within the mould cavity; wherein the mould cavity defined by the first mould member and the second mould member is a three-dimensional representation of an inside-out configuration of the assembled container.

Abstract: There is disclosed a mould for forming a collapsible container from an expandable material, the container comprising, when assembled, at least a base and a two pairs of a side walls extending at right angles from opposing sides of the base, the mould comprising: a first mould member and a second mould member movable with respect to each other between an open and a closed moulding position to define a mould cavity; a control means for delivering expandable material into said mould cavity and for delivering steam to facilitate expansion of the expandable material within said mould cavity to form said container; and a plurality of anvils mounted on a rear surface of at least one of the first mould member and/or second mould member, each anvil being movable so as to be extended into the mould cavity so as to form one or more hinges in the expandable material at predetermined locations within the mould cavity; wherein the mould cavity defined by the first mould member and the second mould member is a three-dimensi

Abstract: There is described a method of creating a hinge in a body of expandable material, said body being substantially flat and having at least two planar regions connected by said hinge to facilitate folding of the planar regions about said hinge, comprising: expanding said expandable material to form said body; creating a region of excess expandable material in said body adjacent said hinge; and compressing said region of excess expandable material into the hinge of said body after the expandable material has fused to create a hinge having a concentrated volume of expanded material when compared to said at least two planar regions of said body.

Abstract: A blank for a box made from an expandable material, which is initially molded to be substantially flat and in which folds forming hinges are to be made to enable the formation of the box. The tooling defines the shape of the blank is such as to provide a thickness of the expanded material that is less than the thickness of a major portion of the blank, in which folds are to be made having defined edges, generally in the direction of each fold; the fold and subsequently applying pressure along an area where folds are to be permitted to reduce the blank are made without removing material therefrom for providing hinges to permit formation of the box. A related method for making the blank and a box that is made from the blank are further provided.

Abstract: There is described a method of creating a hinge in a body of expandable material, said body being substantially flat and having at least two planar regions connected by said hinge to facilitate folding of the planar regions about said hinge, comprising: expanding said expandable material to form said body; creating a region of excess expandable material in said body adjacent said hinge; and compressing said region of excess expandable material into the hinge of said body after the expandable material has fused to create a hinge having a concentrated volume of expanded material when compared to said at least two planar regions of said body.

Abstract: A container (10) consists of a substantially planar blank having a plurality of regions, the regions including a base (18), side walls (14), end walls (16) and a lid (12). Each of the regions is connectable to at least one of the other regions by a hinge (20) formed within the blank. The blank is able to be converted into a first unassembled configuration in which regions of the blank are pivoted around the hinges (20) connecting the regions in relation to other regions, to form a rectangular slab in which compact mode blanks are able to be stacked, and a second configuration in which the blank is erected to form the container (10), which has a cuboidal structure of substantially uniform cross-section, for the storage of articles.

Abstract: There is described a method of creating a hinge in a body of expandable material, said body being substantially flat and having at least two planar regions connected by said hinge to facilitate folding of the planar regions about said hinge, comprising: expanding said expandable material to form said body; creating a region of excess expandable material in said body adjacent said hinge; and compressing said region of excess expandable material into the hinge of said body after the expandable material has fused to create a hinge having a concentrated volume of expanded material when compared to said at least two planar regions of said body.

Abstract: A container (10) consists of a substantially planar blank having a plurality of regions, the regions including a base (18), side walls (14), end walls (16) and a lid (12). Each of the regions is connectable to at least one of the other regions by a hinge (20) formed within the blank. The blank is able to be converted into a first unassembled configuration in which regions of the blank are pivoted around the hinges (20) connecting the regions in relation to other regions, to form a rectangular slab in which compact mode blanks are able to be stacked, and a second configuration in which the blank is erected to form the container (10), which has a cuboidal structure of substantially uniform cross-section, for the storage of articles.

Abstract: A blank for a box made from an expandable material which is initially moulded generally flat in which, where folds forming hinges are to be made to enable the formation of the box, the tooling which defines the shape of the blank is such as to provide a thickness of the expanded material less than the thickness of the major part of the blank where the folds are to be made having defined edges generally in the direction of each fold the fold and subsequently applying pressure along the area where folds are to be permitted to reduce the thickness of the this blank without removing material therefrom thereby providing hinges to permit formation of the box. The invention also provides a method of making the blank and a box made from the blank.