Method and mold for molding a foamed plastic foldable container, and container manufactured thereby

A mold for molding a foamed plastic foldable container comprising a first wall, a pair of mutually facing second walls hingedly coupled to the first wall, a pair of mutually facing third walls hingedly coupled to the first wall, and a closing wall comprising at least one panel hingedly coupled to one of said second walls, said second side walls, third walls, and the closing wall are movable between an upright configuration, wherein the second walls are parallel to one another and perpendicular to the first wall, the third walls are parallel to one another and perpendicular to the first wall and to the second walls, and the closing wall is parallel to the first wall;

• and a folded configuration, wherein said first wall, second walls, third walls, and closing wall are mutually parallel and overlapping;
• each panel of the closing wall is movable between an opening position and a closing position of the container in its upright configuration;
• the mold comprising a first half-mold and a second half-mold defining a molding chamber therebetween;
• the molding chamber is so shaped as to form said first wall, second walls and third walls in the upright configuration;
• and a first forming assembly to form, for each said second and third walls, a respective first connection hinge integral with each said second and third walls to connect the second walls and the third walls to the first wall;
• wherein the first half-mold and the second half-mold are configured to further form, in the molding chamber, each panel of the closing wall in the opening position;
• a second forming assembly is provided to form, for each panel of the closing wall, a respective second connection hinge to connect the panel to the corresponding second wall, wherein the respective second connection hinge is integral with the corresponding second wall, and wherein in the folded configuration, the mutually facing third walls are folded atop the first wall and are coplanar and the pair of second walls are folded atop the third walls and are coplanar.

A method for molding a foamed plastic foldable container comprising a first wall, a pair of mutually facing second walls hingedly coupled to the first wall, a pair of mutually facing third walls hingedly coupled to the first wall, and a closing wall comprising at least a panel hingedly coupled to one of said second walls;

• said second walls, third walls, and closing wall are movable between an upright configuration, in which the second walls are mutually parallel and perpendicular to the first wall, the third walls are mutually parallel and perpendicular to the first wall and to the second walls, and the closing wall is parallel to the first wall, and a folded configuration, in which said first wall, second walls, third walls, and closing wall are mutually parallel and overlapping;
• each panel of the closing wall is movable between an opening position and a closing position of the container in its upright configuration;
• the method comprising the steps of:
• feeding a plastic material into a molding chamber to form said first wall, second walls, and third walls in the upright configuration;
• and
• forming, for each of said second and third walls, a respective first connection hinge to connect the second walls and, respectively, the third walls to the first wall wherein the first connection hinge is integral with a respective one of the second and third walls;
• feeding the plastic material into a molding chamber to mold each panel of the closing wall in the opening position;
• and
• forming, for each panel of the closing wall, a respective second connection hinge to connect the panel to the corresponding second wall, wherein each panel is integral with the respective second connection hinge;
• and
• wherein in the folded configuration, the mutually facing third walls are folded atop the first wall and are coplanar and the pair of second walls are folded atop the third walls and are coplanar.