Blow molded article having an integrally molded living hinge and method of making the same

1. A method of forming a blow molded article having a coextruded living hinge, the method comprising:

providing a blow mold machine comprising a blow mold;

coextruding a parison comprising a first material and a second, more flexible, longitudinal strip of material;

closing the mold about the parison;

blow molding the parison into the article;

cooling the article in the mold;

opening the mold; and

removing the article from the mold;

wherein the article comprises a body made out of a first material having a first body portion and a spaced apart second body portion, and an integrally molded, coextruded living hinge made out of a second material, the hinge being disposed between the body portions, such that the first and second portions are disposed on and contact laterally spaced sides of the living hinge, wherein the first material is a first polymeric material and the second material is a second polymeric material which is more flexible than the first polymeric material.

2. The method of claim 1 wherein the body has portion disposed on three side of the living hinge.

3. The method of claim 1 wherein the body has a first side and spaced apart second side, the living hinge being disposed between the first and second sides.

4. The method of claim 3 wherein the body has portions disposed on three sides of the living hinge.

5. The method of claim 4 wherein the first portions include extension portions extending between and connecting the first side and the living hinge, the extension portions extending from the first side towards the second side.

6. The method of claim 1 wherein the first material is a glass-filled polypropylene material.

7. The method of claim 1 wherein the second material is a non-filled polypropylene material.

8. The method of claim 1 wherein the blow mold has at least one cavity, the method further comprising the step of applying a carpet to the at least one cavity of the mold before closing the mold on the parison to bond the carpet to the parison.

9. The method of claim 1 wherein the blow mold has at least one cavity, the method further comprising the step of applying a decorative layer to the at least one cavity of the mold before closing the mold on the parison to bond the decorative layer to the parison.

10. The method of claim 1 wherein the blow mold machine further comprises a multiple extrusion head.

11. A method of forming a blow molded article having a coextruded living hinge, the method comprising:

coextruding a parison comprising a first material and a second, more flexible, longitudinal strip of material; and

blow molding the parison into the article;

wherein the article comprises a body made out of the first material and an integrally molded, coextruded living hinge made out of the second material, wherein the body has portions contacting opposing sides of the living hinge, and the body has portions disposed on three sides of the living hinge, wherein the first material is a first polymeric material and the second material is a second polymeric material which is more flexible than the first polymeric material.

12. The method of claim 11 wherein the first material is a glass-filled polypropylene material.

13. The method of claim 11 wherein the second material is a non-filled polypropylene material.

14. The method of claim 11 wherein the blow mold has at least one cavity, the method further comprising the step of applying a carpet to the at least one cavity of the mold before closing the mold on the parison to bond the carpet to the parison.

15. The method of claim 11 wherein the blow mold has at least one cavity, the method further comprising the step of applying a decorative layer to the at least one cavity of the mold before closing the mold on the parison to bond the decorative layer to the parison.

16. A method of forming a blow molded article having a coextruded living hinge, the method comprising:

coextruding a parison comprising a first material and a second, more flexible, longitudinal strip of material; and

blow molding the parison into the article;

wherein the article comprises a body made out of the first material, the body having a first side and a spaced apart second side, and an integrally molded, coextruded living hinge made out of the second material, the living hinge being disposed between the first and second sides, wherein the body has first and second portions disposed on and contacting laterally spaced sides of the living hinge, wherein the first material is a first polymeric material and the second material is a second polymeric material which is more flexible than the first polymeric material.

17. The method of claim 16 wherein the first material is a glass-filled polypropylene material.

18. The method of claim 16 wherein the second material is a non-filled polypropylene material.

19. The method of claim 16 wherein the blow mold has at least one cavity, the method further comprising the step of applying a carpet to the at least one cavity of the mold before closing the mold on the parison to bond the carpet to the parison.

20. The method of claim 16 wherein the blow mold has at least one cavity, the method further comprising the step of applying a decorative layer to the at least one cavity of the mold before closing the mold on the parison to bond the decorative layer to the parison.