CN117916078A

CN117916078A - Method and machine for forming a container having a top flange with glued corners

Info

Publication number: CN117916078A
Application number: CN202280061183.0A
Authority: CN
Inventors: T·J·威特林; A·J·谢勒; J·瓦伦西亚
Original assignee: WestRock Packaging Systems LLC
Current assignee: WestRock Packaging Systems LLC
Priority date: 2021-07-09
Filing date: 2022-07-11
Publication date: 2024-04-19
Also published as: CN117916161A

Abstract

A method of forming a container from a blank is provided. The blank includes at least one denesting assembly. The method comprises the following steps: applying a hot melt adhesive to the inner surface of the side flange tab; rotating the end panel inwardly toward the bottom panel; rotating the side panels inwardly toward the bottom panel; rotating the side flange panels outwardly to an orientation parallel to the bottom panel; after the rotating the side flange panels, rotating the end flange panels to an orientation parallel to the bottom panel; and coupling the end flange tab to the side flange tab to form a container having a fully formed top flange. Once the top flange is fully formed, the denesting tab extends outwardly from the side panel beyond the end panel and does not extend beyond the peripheral outer edge of the flange.

Description

Method and machine for forming a container having a top flange with glued corners

Cross Reference to Related Applications

The present application requires priority for each of: U.S. provisional patent application No. 63/220,311, titled "METHOD OF FORMING CONTAINERS HAVING TOP FLANGE WITH GLUED CORNERS,SAME CONTAINERS,AND BLANKS FOR FORMING SAME", filed on 7/9 at 2021; U.S. provisional patent application No. 63/248,039 entitled "METHODS AND MACHINE FOR FORMING CONTAINERS HAVING TOP FLANGE WITH GLUED CORNERS" filed at 24, 9, 2021; U.S. provisional patent application No. 63/309,805, titled "METHOD OF FORMING CONTAINERS HAVING TOP FLANGE WITH GLUED CORNERS,SAME CONTAINERS,AND BLANKS FOR FORMING SAME", filed on day 14, 2, 2022; and U.S. provisional patent application No. 63/320,428, filed on 3/16 of 2022, entitled "METHOD OF FORMING CONTAINERS HAVING TOP FLANGE WITH GLUED CORNERS,SAME CONTAINERS,AND BLANKS FORFORMING SAME", each of which is incorporated herein by reference in its entirety.

Background

The field of the present disclosure relates generally to machines and methods of forming containers, and more particularly, to machines for forming containers having top flanges with corners thereof that are glued during the formation of the containers by the machine.

Containers take various forms. Some conventional containers (such as boxes, baskets, trays, etc.) typically have a closed bottom portion with four sides. Some containers include a top portion or lid to close the container, while others have an open top. In some cases, the container is formed and later filled with product, and then sealed with a film adhered across its top to close the container.

In some such cases, the containers are initially formed with an open top portion so that they can be filled later. Often, such containers are formed and stacked or nested on one another and transported to another location for filling and/or sealing. In some cases, the container includes a flanged portion around its top rim to which the sealing film ultimately adheres. In some known containers that include these flanged portions, the flanges are not formed at the same time that the container was originally formed. Instead, the formed containers with flat (flangeless) sidewalls are stacked and transported for filling; once filled, the flange of the container is folded outwardly to form a sealing surface during the sealing process.

Other conventional containers may have flanges formed during initial formation of the container, but the flanges are formed by simply folding the flanges into place. I.e. the flange is not fixed or glued in place.

These known containers may be weak and tend to disengage the various portions of the flange from one another. Further, such containers may experience poor sealing because the flanges tend to disengage, or more robust sealing is required, which can be complex, time consuming, and/or expensive to produce.

Disclosure of Invention

In one aspect, a container forming apparatus for forming a container from a blank is disclosed. The blank comprises: a bottom panel; two opposite side panels; two opposite end plates; a respective end flange panel extending from a top edge of each end panel; a respective end flange tab extending from each side edge of each end flange panel; a respective side flange panel extending from a top end of each side panel; and a respective side flange tab extending from each end edge of each side flange panel. The device comprises: a blank transfer station comprising an adhesive assembly having a plurality of adhesive applicators; and a compression station downstream of the blank transfer station. The blank is transferred in a blank transfer direction through an adhesive assembly where at least one of the adhesive applicators applies a hot melt adhesive to the inner surface of the side flange tab. The compression station comprises a vertically movable mandrel and a forming tool below the mandrel, wherein the forming tool defines a cavity therein and has an inner profile complementary in shape to the outer profile of the mandrel. The blank is positioned under the mandrel and the mandrel drives the blank downwardly into the cavity of the forming tool, which drives the end panel inwardly into engagement with the mandrel and the side panel inwardly into engagement with the mandrel and the end panel. The compression station further includes an end compression plate and a side compression plate coupled to the mandrel. The side compression plate rotates the side flange panel outwardly into engagement with the top edge of the forming tool and then the end compression plate rotates the end flange panel outwardly into engagement with the top edge of the forming tool, the end compression panel further compressing the end flange tab against the side flange tab to form a container having a fully formed top flange.

In another aspect, a method of forming a container from a blank using a container forming apparatus is provided. The blank comprises: a bottom panel; two opposite side panels; two opposite end plates; a respective end flange panel extending from a top edge of each end panel; a respective end flange tab extending from each side edge of each end flange panel; a respective side flange panel extending from a top end of each side panel; and a respective side flange tab extending from each end edge of each side flange panel. The device comprises: (i) A blank transfer station comprising an adhesive assembly having a plurality of adhesive applicators; and (ii) a compression station downstream of the blank transfer station, the compression station comprising a vertically movable mandrel and a forming tool below the mandrel, wherein the forming tool defines a cavity therein and has an inner profile complementary in shape to the outer profile of the mandrel. The method comprises the following steps: transferring the blank through an adhesive assembly; applying a hot melt adhesive to the inner surface of the side flange tab using the plurality of adhesive applicators; and positioning the blank under the mandrel. The method further comprises the steps of: using a mandrel to drive the blank down into the cavity of the forming tool, the driving causing the forming tool to: (a) Rotating the end panel inwardly into engagement with the spindle, and (b) rotating the side panel inwardly into engagement with the spindle and into engagement with the end panel. The method further comprises the steps of: rotating the side flange panels outwardly to an orientation parallel to the bottom panel using a side compression plate coupled to the mandrel; after rotating the side flange panels, rotating the end flange panels to an orientation parallel to the bottom panel using an end compression plate coupled to the mandrel; and compressing the end flange tabs against the side flange tabs using an end compression plate to form a container having a fully formed top flange.

In other aspects, containers formed using such methods and blanks for forming such containers are also provided.

Drawings

Fig. 1 is a top plan view of an example blank of sheet material for forming a container according to the present disclosure.

Fig. 2 is a perspective view of an example container formed from the blank shown in fig. 1.

Fig. 3 is a side perspective view of a stack of a plurality of containers shown in fig. 2.

Fig. 4 is a top plan view of another embodiment of a blank of sheet material for forming a container according to the present disclosure.

Fig. 5 is a perspective view of an example container formed from the blank shown in fig. 4.

Fig. 6 is a top plan view of another embodiment of a blank of sheet material for forming a container according to the present disclosure.

Fig. 7 is a top plan view of another embodiment of a blank of sheet material for forming a container according to the present disclosure.

Fig. 8 is a perspective view of an example container formed from the blank shown in fig. 7.

Fig. 9 is a flow chart of a method of forming a container from a blank according to the present disclosure.

Fig. 10 is a perspective view of a container forming apparatus according to the present disclosure.

Fig. 11-15 depict various views of the blank feed station of the container forming apparatus shown in fig. 10.

Fig. 16 depicts a blank transfer station of the container forming apparatus shown in fig. 10.

Fig. 17, 18A and 18B depict a compression station of the container forming apparatus shown in fig. 10.

Fig. 19 and 20 depict a stacking station of the container forming apparatus shown in fig. 10.

Fig. 21 is a schematic block diagram of a control system of the container forming apparatus shown in fig. 10.

Detailed Description

The following detailed description illustrates the disclosure by way of example, and not by way of limitation. This description clearly enables one skilled in the art to make and use the disclosure, describes several embodiments, adaptations, variations, alternatives, and uses of the disclosure, including what is presently believed to be the best mode of carrying out the disclosure.

Embodiments of the present disclosure provide a stackable container including a top flange. The container is constructed from a blank of sheet material using a machine and/or by hand. For example, the blank can be folded about a mandrel to form the container, or the container can be formed by hand and/or by another style of tray forming machine. Alternatively, a folder/gluer can be used to form the container. In one embodiment, the container is made of paperboard material. However, the container may be manufactured using any suitable material and is thus not limited to a particular type of material. In alternative embodiments, the container is manufactured using cardboard, plastic, fiberboard, foam board, corrugated paper, and/or any suitable material known to those skilled in the art and guided by the teachings herein provided.

In an example embodiment, the container includes at least one indicia thereon, including, but not limited to, indicia conveying the product, the manufacturer of the product, and/or the vendor of the product. For example, the indicia may include printed text indicating the name of the product and briefly describing the product, a logo and/or trademark indicating the manufacturer and/or seller of the product, and/or a design and/or decoration that draws attention. As used herein, "printing," "printed," and/or any other form of "printing" may include, but are not limited to, including inkjet printing, laser printing, screen printing, art micro-jets, pens and inks, painting, offset printing, flexographic printing, letterpress printing, rotogravure printing, dye transfer, and/or any suitable printing technique known to those skilled in the art and guided by the teachings herein provided. In another embodiment, the container is not marked, such as, but not limited to, an indicium conveying the product, the manufacturer of the product, and/or the vendor of the product.

In some embodiments, the interior and/or exterior surfaces of the blank and the resulting container are coated or sealed. Such coatings or seals may render the container waterproof or antimicrobial. In other embodiments, the seal or coating may facilitate maintaining the freshness of the product (e.g., agricultural product) retained in the container. In any embodiment, such a coating or seal may be applied to any section(s) of any surface(s) of the container.

Referring now to the drawings, and more particularly to FIG. 1, a top plan view of an example embodiment of a blank 100 of sheet material is depicted. A container 200 (see fig. 2) is formed from the blank 100. The blank 100 has a first or inner surface 101 and an opposing second or outer surface 103. Further, the blank 100 defines a leading edge 102 and an opposite trailing edge 104. In one embodiment, the blank 100 comprises a first end panel 106, a bottom panel 108, and a second end panel 110 coupled together one after the other along preformed, generally parallel fold lines 112 and 114, respectively.

More specifically, the first end panel 106 extends from the free edge 105 to the fold line 112, the bottom panel 108 extends from the fold line 112 to the fold line 114, and the second end panel 110 extends from the fold line 114 to the free edge 107. When the container 200 is formed from the blank 100, as further described herein, the fold line 112 defines a bottom edge of the first end panel 106 and a first end edge of the bottom panel 108, and the fold line 114 defines a second end edge of the bottom panel 108 and a bottom edge of the second end panel 110.

The first side panel 116 extends from a fold line at a first side edge 118 of the bottom panel 108 to a fold line 120, and the opposing second side panel 122 extends from a fold line at a second side edge 124 of the bottom panel 108 to a fold line 126. When the container 200 is formed from the blank 100, as further described herein, the fold line at the first side edge 118 defines a bottom edge of the first side panel 116 and a first side edge of the bottom panel 108, and the fold line at the second side edge 124 defines a second side edge of the bottom panel 108 and a bottom edge of the second side panel 122.

In the exemplary embodiment, first end panel 106, second end panel 110, first side panel 116, and second side panel 122 include a plurality of cut-outs 128 defined therein. In the exemplary embodiment, cutout 128 is leaf-shaped and each of first end panel 106, second end panel 110, first side panel 116, and second side panel 122 has six cutouts. Alternatively, blank 100 may include any suitable number of cut-outs 128 having any suitable shape and/or in any suitable location that enables blank 100 and/or container 200 to function as described herein. In still other embodiments, one or more of the panels 106, 110, 116, and 122 of the blank 100 may not have a cut-out 128.

The first end panel 106 has a height H ₁, the second end panel 110 has a height H ₂, the first side panel 116 has a height H ₃, and the second side panel 122 has a height H ₄. In the example embodiment, the height H ₁ of the first end panel 106, the height H ₂ of the second end panel 110, the height H ₃ of the first side panel 116, and the height H ₄ of the second side panel 122 are substantially the same. Further, the bottom panel 108 has a length L ₁ and a width W ₁. In an example embodiment, the length L ₁ is greater than the width W ₁ such that the bottom panel 108 is rectangular. In an alternative embodiment, width W ₁ is substantially equal to or greater than length L ₁.

In an example embodiment, the side edges 170 of the end panels 106, 110 and the end edges 172 of the side panels 116, 122 are generally linear and extend at respective angles relative to the bottom panel 108. In other words, in the example embodiment, the side edges 170 of the end panels 106, 110 are not parallel to the side edges 118, 124 of the bottom panel 108, and the end edges 172 of the side panels 116, 122 are not parallel to the end edges (at fold lines 112 and 114) of the bottom panel 108.

Thus, the first end panel 106, the second end panel 110, the first side panel 116, and the second side panel 122 each have a generally trapezoidal shape, wherein the panels 106, 110, 116, 122 taper outwardly as they extend away from the bottom panel 108. That is, the respective width (not specifically shown) of the end panels 106, 110 adjacent the bottom panel 108 is less than the respective width (not specifically shown) of the end panels 106, 110 opposite the bottom panel 108. Likewise, the respective lengths (not specifically shown) of the side panels 116, 122 adjacent the bottom panel 108 are less than the respective lengths (not specifically shown) of the side panels 116, 122 opposite the bottom panel 108.

Alternatively, the first end panel 106, the second end panel 110, the first side panel 116, the second side panel 122, and/or the bottom panel 108 may have any suitable shape and/or any suitable size that enables the blank 100 and/or the container 200 to function as described herein.

An interior side panel 130 (also referred to as a glue panel) extends from each side edge of each end panel 106, 110 at a respective fold line 132. Thus, the blank 100 includes four interior side panels 130. Each of the side-interior panels 130 has a respective free edge 178 opposite the respective fold line 132 from which the side-interior panel 130 extends. In an example embodiment, the free edge 178 includes a plurality of linear portions, such as four contiguous linear portions. In alternative embodiments, the free edge 178 may be partially or fully arcuate, or may have any suitable shape that enables the blank 100 and/or container 200 to function as described herein.

Additionally, a first end flange panel 134 extends from the first end panel 106 and a second end flange panel 138 extends from the second end panel 110. More particularly, the first end flange panel 134 extends from the free edge 105 to a fold line 136 at the top edge of the first end panel 106, and the second end flange panel 138 extends from a fold line 140 at the top edge of the second end panel 110 to the free edge 107.

The first and second end flange panels 134, 138 include first and second end flange tabs 142, 144, respectively. The first end flange tab 142 extends from a respective fold line 166 at each side edge of the first end flange panel 134 and the second end flange tab 144 extends from a respective fold line 168 at each side edge of the second end flange panel 138. In the exemplary embodiment, each of first end flange tab 142 and second end flange tab 144 has a substantially arcuate shaped free outer edge 146 and a substantially linear free inner edge 148, respectively. As further described herein with respect to the container 200, when the container 200 (see fig. 2) is formed from the blank 100, the shape of the free outside edge 146 generally defines the shape of the corner 218 of the formed top flange 214 of the container 200. Thus, in various alternative embodiments, the first end flange tab 142 and the second end flange tab 144 may have any suitable shape that enables the blank 100 and/or the container 200 to function as described herein.

A first side flange panel 150 extends from the first side panel 116 and a second side flange panel 152 extends from the second side panel 122. More particularly, the first side flange panel 150 extends from the fold line 120 to a free edge 154 (also referred to as the front edge 102 or first side edge of the blank 100), and the second side flange panel 152 extends from the fold line 126 to a free edge 156 (also referred to as the rear edge 104 or second side edge of the blank 100).

The first and second side flange panels 150, 152 include first and second side flange tabs 158, 160, respectively. A first side flange tab 158 extends from each end edge of the first side flange panel 150 and a second side flange tab 160 extends from each end edge of the second side flange panel 152. In the exemplary embodiment, each of first and second side flange tabs 158, 160 has a substantially arcuate shaped free outer side edge 162 and a substantially linear free inner side edge 164, respectively. As further described herein with respect to container 200, when container 200 (see fig. 2) is formed from blank 100, the shape of free outside edge 162 generally defines the shape of corner 218 of formed top flange 214 of container 200. Thus, in various alternative embodiments, the first side flange tab 158 and the second side flange tab 160 may have any suitable shape that enables the blank 100 and/or the container 200 to function as described herein.

In the exemplary embodiment, first end flange tab 142 and second end flange tab 144 also each include a respective notch 184 defined between an inboard edge 148 thereof and a side edge from which end flange tab 142/144 of respective end flange panel 134/138 extends. Likewise, the first and second side flange tabs 158, 160 also each include a respective notch 186 defined between an inboard edge 164 thereof and an end edge from which the side flange tab 158/160 of the respective side flange panel 150/152 extends. These notches 184, 186 improve the formation of the container 200 formed from the blank 100 by reducing interference between adjacent end flange tabs 142/144 and side flange tabs 158/160 when the blank 100 is folded into the container 200, as further described herein. Additionally, the notches 184, 186 may facilitate folding and/or coupling or mating of the respective flange panels and/or flange tabs.

In the exemplary embodiment, the side flange tabs 158, 160 are "deeper" than the end flange tabs 142, 144 or extend farther inward toward the bottom panel 108. That is, the extension of the side flange tabs 158, 160 in the horizontal direction (relative to the view of fig. 1) is greater than the extension of the end flange tabs 142, 144 in the vertical direction (relative to the view of fig. 1).

In the exemplary embodiment, the fold lines 166, 168 adjacent the end flange tabs 142, 144 are generally aligned with the side edges 170 of the end panels 106, 110. That is, each end flange tab 142, 144 may be folded obliquely relative to the end flange panel 134/138 from which it extends. Additionally, fold lines 180, 182 adjacent side flange tabs 158, 160 are generally perpendicular to fold lines 120, 126. That is, each side flange tab 158, 160 may be folded substantially perpendicularly with respect to the side flange panel 150/152 from which it extends. In other embodiments, each fold line 166, 168, 180, 182 of each flange tab 142, 144, 158, 160 may have any orientation that enables the blank 100 and/or container 200 to function as described herein.

In some embodiments, portions of the flange tabs 142, 144, 158, 160 have a reduced thickness such that the corners 218 of the flange 214 (see fig. 2) formed by the coupled flange tabs have improved denesting characteristics when the container 200 is formed from the blank 100. The thickness of the flange tabs 142, 144, 158, 160 may be reduced by scoring, compressing, collapsing, etc. one or more portions of the flange tabs 142, 144, 158, 160.

Fig. 2 is a perspective view of an example container 200 formed from blank 100 (shown in fig. 1). The container 200 includes a bottom wall 202, opposing first and second end walls 204, 206, and opposing first and second side walls 208, 210. Generally, the bottom wall 202 comprises the bottom panel 108 of the blank 100, the first end wall 204 comprises the first end panel 106, the second end wall 206 comprises the second end panel 110, the first side wall 208 comprises the first side panel 116 and two interior side panels 130 (one extending from each of the first and second end panels 106, 110), and the second side wall 210 comprises the second side panel 122 and two interior side panels 130 (one extending from each of the first and second end panels 106, 110). The end walls 204, 206, side walls 208, 210, and bottom wall 202 define a cavity 212 of the container 200 for receiving and retaining a product (not shown) therein.

In the example embodiment, the first and second end walls 204, 206 and the first and second side walls 208, 210 extend obliquely away from the bottom wall 202 due to the trapezoidal shape of the panels 106, 110, 116, and 122. Specifically, in one embodiment, each end wall 204, 206 and each side wall 208, 210 form an interior angle greater than about 90 degrees, respectively, with respect to bottom wall 202. That is, in the example embodiment, the walls 204, 206, 208, 210 of the formed container 200 are generally angled outwardly (i.e., away from) the bottom wall 202 of the container 200. Thus, the resulting container 200 generally has a trapezoidal prism or truncated pyramid shape. However, in alternative embodiments, the end walls 204, 206 and side walls 208, 210 may form any angle with the bottom wall 202 that enables the blank 100 and/or container 200 to function as described herein.

The container 200 also includes a flange 214 extending from the top of each of the first and second end walls 204, 206 and the first and second side walls 208, 210. In the exemplary embodiment, flange 214 extends outwardly or away from cavity 212 and is defined by a free edge 216 that includes both straight and arcuate segments; specifically, the corners 218 of the flange 214 are generally arcuate. In the exemplary embodiment, flange 214 is oriented parallel to bottom wall 202. Due to the orientation of the walls of the container 200, the flange 214 is oriented oblique to the first and second end walls 204, 206 and the first and second side walls 208, 210. Alternatively, flange 214 may extend in any direction and have any suitable shape that enables blank 100 and/or container 200 to function as described herein.

The container 200 is formed by folding the various panels and tabs of the blank 100 along respective fold lines. Specifically, each interior side panel 130 is rotated about fold line 132 toward the interior surface 101 of each end panel 106, 110 such that each interior side panel 130 is substantially perpendicular to the respective end panel 106, 110. The first and second end panels 106 and 110 are rotated about fold lines 112 and 114, respectively, toward the inner surface 101 of the bottom panel 108 to form first and second end walls 204 and 206, respectively. In one embodiment, the first end panel 106 and the second end panel 110 rotate to form an angle greater than 90 degrees with respect to the bottom panel 108. However, in alternative embodiments, the first and second end panels 106, 110 may form any angle with the bottom panel 108 that enables the blank 100 and/or container 200 to function as described herein.

The first side panel 116 rotates about the fold line 118 toward the inner surface 101 of the bottom panel 108 and is in face-to-face relation with the outer surfaces 103 of the two interior side panels 130. Likewise, the second side panel 122 rotates about the fold line 124 toward the inner surface 101 of the bottom panel 108 and is in face-to-face relation with the outer surfaces 103 of the other two interior side panels 130. In one embodiment, the first side panel 116 and the second side panel 122 rotate to form an angle greater than 90 degrees with respect to the bottom panel 108. However, in alternative embodiments, the first side panel 116 and the second side panel 122 rotate and may form any angle with the bottom panel 108 that enables the blank 100 and/or container 200 to function as described herein.

In an example embodiment, an adhesive, particularly a hot melt adhesive, is applied to end portions of the inner surfaces 101 of the first side panel 116 and the second side panel 122. Thus, when these panels 116, 122 are rotated into face-to-face contact with the interior side panels 130, the end portions of the interior surfaces 101 of the panels 116, 122 are respectively coupled and adhered to the exterior surfaces 103 of the interior side panels 130. Thereby, end walls 204, 206 and side walls 208, 210 are formed.

In alternative embodiments, adhesive may be applied to the inner surface 101 of the side-interior panel 130. In such a case, the side panels 116, 122 may first be rotated into position, and then the end panels 106, 110 may be rotated such that the interior side panels 130 are coupled and adhered to the exterior surfaces 103 of the side panels 116, 122. In still alternative embodiments, the interior side panels may instead extend from the side panels 116, 122; in such a case, the adhesive may be applied and the panels 106, 110, 116, 122 rotated in any suitable order to form the container 200.

Additionally, substantially simultaneously (e.g., within the same forming step) with the formation of the walls of the container 200, the side flange panels 150, 152 are rotated outwardly (e.g., away from the bottom wall 202) about the fold lines 120, 126, respectively, until the side flange panels 150, 152 are parallel to the bottom wall 202. The side flange tabs 158, 160 move with the side flange panels 150, 152. That is, rotation of the side flange panels 150, 152 causes the side flange tabs 158, 160 to simultaneously rotate to a parallel orientation relative to the bottom wall 202.

In one example embodiment, the walls of the container 200 are formed substantially simultaneously with the rotation of the side flange panels 150, 152. It is noted, however, that rotation of the side flange panels 150, 152 may occur before or during folding of the end panels 106, 110 to form the side walls 204, 206. In particular, the side flange panels 150, 152 are folded such that the end flange tabs 142, 144 and the side flange tabs 158, 160 do not interfere with each other at the corners of the partially formed container. Even more specifically, because the end flange tabs 142, 144 are "shorter" or "shallower" than the side flange tabs 158, 160 (e.g., the inner edges thereof extend less than the inner edges of the side flange tabs 158, 160), the inner edges of the end flange tabs 142, 144 do not "catch" on the folded side flange tabs 158, 160 as the end panels 106, 110 are folded inwardly to form the side walls 204, 206.

In a separate step (which may be several milliseconds to several seconds, for example, after a predetermined amount of time has elapsed), the end flange panels 134, 138 are rotated outwardly (e.g., away from the bottom wall 202) about fold lines 136, 140, respectively, until the end flange panels 134, 138 are parallel to the bottom wall 202. The end flange tabs 142, 144 move with the end flange panels 134, 138. That is, rotation of the end flange panels 134, 138 causes the end flange tabs 142, 144 to simultaneously rotate to a parallel orientation relative to the bottom wall 202. Further, such rotation of the end flange panels 134, 138 couples the outer surfaces 103 of the end flange tabs 142, 144 in face-to-face relation against the inner surfaces 101 of the side flange tabs 158, 160 (which have been in their final position, previously rotated).

Notably, in the example embodiment, an adhesive (such as a hot melt adhesive) is applied to the inner surfaces 101 of the side flange tabs 158, 160 prior to forming the container 200 (e.g., simultaneously with the application of the adhesive to the side panels 116, 122). Thus, when the end flange panels 134, 138 are rotated after the side flange panels 150, 152 are rotated, the outer surfaces 103 of the end flange tabs 142, 144 are coupled against and adhered to the inner surfaces 101 of the side flange tabs 158, 160.

Thereafter, the end flange panels 134, 138, side flange panels 150, 152, end flange tabs 142, 144, and side flange tabs 158, 160 are properly oriented and secured to form flange 214. Flange corners 218 are formed at the overlap of the corresponding end flange tabs 142, 144 and side flange tabs 158, 160. In an example embodiment, flange 214 (also referred to as a "top flange") is substantially flat or planar and is stronger than conventional flanges that are not glued or glued until the container is sealed. In at least some instances, where the end flange tabs 142, 144 and/or the side flange tabs 158, 160 feature a reduced thickness, the entire flange 214 may be even more desirably planar, which in turn may improve the sealing characteristics and/or rigidity of the container 200.

Once formed, the containers 200 are nested or stacked (see stack 300 of containers 200 shown in fig. 3) for storage and/or transport thereof. In some cases, these containers 200 are ultimately used to retain various objects. In some embodiments, the stack 300 of containers 200 is delivered to a filling location where individual containers 200 are removed from the stack 300. As described herein, the flange corners 218 of the container 200 (including the end flange tabs 142, 144 and/or the side flange tabs 158, 160 with embossments and/or featuring reduced thickness) may improve the de-nesting characteristics of the container 200.

The open, empty and denested container 200 is then filled with a product (e.g., produce). The membrane 220 is placed across the top of the container 200 and sealed against the flange 214 to form a seal. The film 220 may be coupled and adhered to the flange 214 using any suitable method or material (e.g., adhesive, heat seal, etc.).

As described elsewhere herein, flange 214 of container 200 provides structural advantages over flanges of similar containers. That is, adhesive is applied to the side flange tabs 158, 160 during initial formation of the container 200 to couple the end flange tabs 142, 144 to the side flange tabs 158, 160, which improves both the structural integrity and the sealing capability of the container 200. Conventional containers may have a top flange, but as described above, such conventional containers are not formed in the same manner as container 200 (i.e., do not include a formed flange or do not apply adhesive to join flange tabs during initial container formation), and thus container 200 provides an improvement over known conventional containers.

The application of adhesive when coupling the end flange tabs 142, 144 to the side flange tabs 158, 160 reinforces and reinforces the corners 218 of the flange 214, thus enhancing the structural rigidity of the container 200. For example, the container 200 may be able to hold a greater weight of product and/or more effectively prevent leakage of liquid. Such enhancements may also reduce the risk of structural failure of the container 200 once filled and sealed. Additionally, such reinforcement promotes improved sealing of the container 200. Furthermore, flange 214 may be substantially flatter than the flange of a conventional container. Such a flange 214 enables easier, faster, simpler, and/or more cost-effective (e.g., using less sealing material) application of a sealing film to seal the container 200. These enhancements enable the container 200 to function more efficiently than other conventional containers.

Fig. 4 is a top plan view of an alternative blank 400 of sheet material for forming a container 500 (see fig. 5). The blank 400 is substantially similar to the blank 100 (shown in fig. 1), except as noted below. Thus, components common to the blank 100 and the blank 400 are labeled with the same reference numerals.

In one embodiment, the blank 400 includes cut-outs 402 extending from the fold lines 112, 114, 118, 120, 124, 126, 136, 140 into each of the first end panel 106, the second end panel 110, the first side panel 116, and the second side panel 122. In this embodiment, the cut-out 402 has a generally rectangular shape adjacent to the fold lines 112, 114, 118, 120, 124, 126, 136, 140 and a generally semi-circular shape at opposite ends. In the exemplary embodiment, each end panel 106, 110 contains four cutouts 402 and each side panel contains five cutouts 402. In alternative embodiments, the blank 400 may include any suitable number of cut-outs 402 in any suitable location having any suitable shape that enables the blank 400 and/or container 500 to function as described herein.

In one embodiment, the blank 400 further comprises interior side panels 430 having a different overall shape than the interior side panels 130 of the blank 100. The interior side panel 430 of the blank 400 has a free edge 178 opposite the fold line 132, wherein the free edge 178 includes a plurality of linear portions and curved portions. In particular, each free edge 178 includes a curved notch 404 such that when the container 500 is formed from a blank, the inside edge 430 does not cover or otherwise interfere with the cut-out 402 on the side panels 116, 122. That is, the curved notch 404 of the interior side panel 430 prevents the interior side panel 430 from overlapping the cut-out 402 in the side panels 116, 122. In alternative embodiments, one or more of the free edges 178 may have any suitable shape that enables the blank 400 and/or container 500 to function as described herein.

Additionally, the bottom panel 108 of the blank 400 is smaller and more square than the bottom panel 108 of the blank 100. In an example embodiment, the blank 400 includes end flange tabs 142, 144 and side flange tabs 158, 160 similar to the blank 100. However, in the blank 400, the fold lines 166, 168, 180, 182 defining the flange tabs are angled such that each flange tab 142, 144, 158, 160 is foldable perpendicular to its respective flange panel 134, 138, 150, 152. In other embodiments, fold lines 166, 168, 180, 182 may have any orientation that enables blank 400 and/or container 500 to function as described herein.

Fig. 5 is a perspective view of an example container 500 formed from blank 400 (shown in fig. 4). The container 500 is substantially similar to the container 200 (shown in fig. 2) and is formed from the blank 400 using a method similar to the method of forming the container 200 from the blank 100. The container 500 may have a different size than the container 200.

Fig. 6 is a top plan view of an alternative blank 600 of sheet material for forming a container. The blank 600 is substantially similar to the blank 100 (shown in fig. 1), except as noted below. Thus, components common to the blank 100 and the blank 600 are labeled with the same reference numerals.

In one embodiment, the blank 600 includes a cut-out 602 extending along fold lines 112, 114, 118, 124, 120, 126, 136, and 140. Additionally, a fold line 604 between the side panels 116, 122 and an inner end panel 606 (described further herein) also has a cut out 602 extending therethrough. In an example embodiment, the resection port 602 has a general "stadium" shape. In alternative embodiments, the blank 600 may include any suitable number of cut-outs 602 having any suitable shape that enables the blank 600 and/or any container formed therefrom to function as described herein.

In one embodiment, the blank 600 further comprises an interior end panel 606 extending along the fold line 604 from the end edges of the first side panel 116 and the second side panel 122, instead of the interior side panel 130 as in the blank 100. Thus, in the exemplary embodiment, blank 600 includes four interior end panels 606. In the exemplary embodiment, the interior end panel 606 has a different overall shape than the interior side panel 130 of the blank 100. In the exemplary embodiment, inner end panel 606 has a free edge 608 opposite fold line 604, wherein free edge 608 includes a plurality of linear portions and/or curved portions. In alternative embodiments, one or more of the free edges 608 may have any suitable shape that enables the blank 600 and/or any container formed therefrom to function as described herein.

In the exemplary embodiment, each end panel 106, 110 has a recess 610 formed in a side edge thereof. In the exemplary embodiment, once container 700 is formed from blank 600, recess 610 receives cut-out 602 in inner end panel 606 of blank 600. That is, when formed, the notch 610 prevents the end panels 106, 110 from overlapping the cut-out 602 in the inner end panel 606.

Additionally, the blank 600 includes a notch 612 formed in the side panels 116, 122 between the bottom edge of the inner end panel 606 and the fold line 118/124. The notches 612 may facilitate folding and/or coupling or mating of the corresponding flange panels and/or flange tabs.

In this example embodiment, the end flange tabs 142, 144 and side flange tabs 158, 160 of the blank 600 do not include the notches 182/184 and have a different general shape than the flange tabs in the blank 100. In the blank 600, each flange tab 142, 144, 158, 160 has a respective free edge 146 that includes a curved portion and a straight portion. Additionally, the fold lines 166, 168, 180, 182 defining each flange tab 142, 144, 158, 160 are angled such that each flange tab 142, 144, 158, 160 is foldable obliquely to its respective flange panel 134, 138, 150, 152.

The container formed from the blank 600 is formed in a similar manner to the container 200, with the interior end panel 606 of the blank 600 folded in a similar manner to the interior side panel 130 of the blank 100, but coupled to the end panels 106, 110 instead of the side panels 116, 122.

Fig. 7 is a top plan view of an alternative blank 800 of sheet material for forming a container.

In an example embodiment, similar to blank 100, blank 800 includes a first end panel 802, a second end panel 804, a first side panel 806, a second side panel 808, and a bottom panel 810. The first end panel 802, the second end panel 804, the first side panel 806, and the second side panel 808 each have a generally trapezoidal shape, and the bottom panel 810 has a generally rectangular shape with chamfered corners. Thus, in the example embodiment, the bottom panel 810 has eight edges. Similar to the blank 100, the blank 800 further comprises a first end flange panel 812, a second end flange panel 814, first and second side flange panels 816, 818, and first and second end flange tabs 820, 822, 824, 826.

In an example embodiment, the flange tabs 820, 822, 824, 826 of the blank 800 have different sizes and overall shapes than the flange tabs of the blank 100. In particular, the flange tabs 820, 822, 824, 826 each have a respective free end edge 828 that includes a plurality of straight and/or curved lines. In the example embodiment, the flange tabs 820, 822, 824, 826 also each include a respective notch 830 on their respective inner side edges 832. The flange tabs 820, 822, 824, 826 can have any suitable shape that enables the blank 800 and/or container 900 to function as described herein.

In an example embodiment, the blank 800 further comprises a corner panel 834 extending from the fold line 836 at a chamfered or angled corner of the bottom panel 810. An interior corner panel 838 (also referred to as a glue panel) extends from each side edge of each corner panel 834. Thus, in the exemplary embodiment, blank 800 includes eight interior corner panels 838. Each interior corner panel 838 extends from a side edge of the corresponding corner panel 834 at fold lines 840 (only one fold line 840 is labeled on fig. 7 for clarity).

Corner panels 834 of the blank 800 also each comprise a corner flange panel 842. Each corner flange panel 842 extends from a respective fold line 844 to a free edge 845 at the top of the respective corner panel 834. Corner flange tabs 846 extend from each end edge of each corner flange panel 842. In the example embodiment, the corner flange tabs 846 are defined by fold lines 848 and free edges 849, respectively. In the exemplary embodiment, corner flange tab 846 also includes a notch 850 defined in an inboard edge thereof. The fold lines 848 defining each corner flange tab 846 are angled such that each corner flange tab 846 can be folded obliquely to its respective corner flange panel 842. In other embodiments, the fold line 848 may have any orientation that enables the blank 800 and/or container 900 to function as described herein.

In an example embodiment, similar to the blank 100, the first end panel 802, the second end panel 804, the first side panel 806, and the second side panel 808 include a plurality of cut-out openings 852 defined therein. Specifically, first end panel 802 and second end panel 804 each include three cutouts 852 located adjacent fold lines 854, 856, and first side panel 806 and second side panel 808 each include four cutouts 852 located adjacent fold lines 858, 860. Alternatively, blank 800 may include any suitable number of cutouts 852 having any suitable shape and/or in any suitable position that enables blank 800 and/or container 900 to function as described herein.

In some embodiments, portions of the flange tabs 820, 822, 824, 826, 846 have reduced thickness such that the corners 918 of the flange 914 (see fig. 8) formed by the coupled flange tabs have improved denesting characteristics when the container 900 is formed from the blank 800. The thickness of the flange tabs 820, 822, 824, 826, 846 may be reduced by scoring, compressing, collapsing, etc. one or more portions of the flange tabs.

Fig. 8 is a perspective view of an example faujased container 900 formed from a blank 800 (shown in fig. 7). The container 900 includes a bottom wall 902, opposing first and second end walls 904, 906, opposing first and second side walls 908, 910, and four angled corner walls 920. Generally, the bottom wall 902 includes the bottom panel 810 of the blank 800, the first end wall 904 includes the first end panel 802 and two interior corner panels 838, the second end wall 906 includes the second end panel 804 and two interior corner panels 838, the first side wall 908 includes the first side panel 806 and two interior corner panels 838, the second side wall 910 includes the second side panel 808 and two interior corner panels 838, and each corner wall 920 includes one of the corner panels 834. End walls 904, 906, side walls 908, 910, corner wall 920, and bottom wall 902 define a cavity 912 of container 900 for receiving and retaining a product (not shown) therein. Similar to container 200, the walls of container 900 are oriented obliquely at an angle greater than 90 degrees relative to bottom wall 902. In the example embodiment, the bottom wall 902 of the container 900 has a generally rectangular shape with straight chamfered corners. Thus, the bottom wall 902 of the container includes eight sides. Alternatively, container 900 may have any suitable shape and/or size that enables blank 800 and/or container 900 to function as described herein.

The container 900 also includes a flange 914 extending from the top of the walls 904, 906, 908, 910, 920. In the exemplary embodiment, flange 914 extends outwardly or away from cavity 912 and is defined by a free edge 916 that includes both straight and arcuate segments; specifically, the corners 918 of flange 914 formed by corner flange panels 842 are generally arcuate. In the exemplary embodiment, flange 914 is oriented parallel to bottom wall 902. Due to the orientation of the walls of the container 900, the flange 914 is oriented obliquely to the walls 904, 906, 908, 910, 920. Alternatively, flange 914 may extend in any direction and have any suitable shape that enables container 900 to function as described herein.

The container 900 is formed by folding the various panels and tabs of the blank 800 along respective fold lines. Specifically, corner panel 834 rotates inwardly (toward bottom panel 810) about fold line 836, and inner corner panel 838 rotates inwardly (toward the corresponding corner panel 834) about fold line 840. The first side panel 806 rotates about fold line 858 toward the interior surface of the bottom panel 810 and the second side panel 808 rotates about fold line 860 toward the interior surface of the bottom panel 810. Each of the first side panel 806 and the second side panel 808 are coupled to two respective interior corner panels 834 using an adhesive (such as a hot melt adhesive) to form side walls 908, 910. First end panel 802 rotates about fold line 854 toward the inner surface of bottom panel 810 and second end panel 804 rotates about fold line 856 toward the inner surface of bottom panel 810. Each of the first end panel 802 and the second end panel 804 are coupled to two respective interior corner panels 838 using an adhesive (such as a hot melt adhesive) to form end walls 904, 906. The first side panel 806, the second side panel 808, the first end panel 802, and the second end panel 804 can be rotated about fold lines 858, 860, 854, 856, respectively, and attached to the interior corner panel 838 in any order that enables the blank 800 and/or container 900 to function as described herein.

Additionally, substantially simultaneously (e.g., within the same forming step) with the formation of the walls of the container 900, the end flange panels 812, 814 and side flange panels 816, 818 are rotated outwardly (e.g., away from the bottom wall 902) until the flange panels 812, 814, 816, 818 are parallel to the bottom wall 902. Such rotation of the flange panels 812, 814, 816, 818 causes the flange tabs 820, 822, 824, 826 to simultaneously rotate to a parallel orientation relative to the bottom wall 902.

In a separate step (which may be several milliseconds to several seconds, for example, after a predetermined amount of time has elapsed), corner flange panel 842 is rotated outwardly about fold line 844 until corner flange panel 842 is substantially parallel to bottom panel 810. Rotation of corner flange panel 842 causes corner flange tab 846 to simultaneously rotate to a parallel orientation relative to bottom wall 902. In addition, such rotation of the corner flange panel 842 also couples the corner flange tab 846 in overlapping relation with the end flange tabs 820, 822 and the side flange tabs 824, 826 (which have been previously rotated in their final positions).

Notably, in the example embodiment, an adhesive (such as a hot melt adhesive) is applied to the inner surfaces of the end flange tabs 820, 822 and the side flange tabs 824, 826 prior to forming the container 900. Thus, when corner flange panel 842 rotates after end flange panels 812, 814 and side flange panels 816, 818 are rotated, the outer surfaces of corner flange tabs 846 couple against and adhere to the inner surfaces of corresponding end flange tabs 820, 822 and side flange tabs 824, 826.

When formed using the methods described herein, container 900 includes the same advantages as container 200. In particular, flange 914 (also referred to as a "top flange") is substantially flat or planar and is stronger than conventional flanges that are not glued or glued until the container is sealed. In at least some instances, where any of the flange tabs 820, 822, 824, 826, and/or 846 feature a reduced thickness, the entire flange 914 may be even more desirably planar, which in turn may improve the sealing characteristics and/or rigidity of the container 900.

Once formed, the containers 900 are nested or stacked for storage and/or shipping. In some cases, these containers 900 are ultimately used to retain various objects. In some embodiments, the stack of containers 900 is delivered to a filling location where individual containers 900 are removed from the stack. As described herein, the flange corners 918 of the container 900 (including the flange tabs 820, 822, 824, 826, and/or 846 with embossments and/or featuring reduced thickness) may improve the denesting characteristics of the container 900.

The open, empty and denested container 900 is then filled with the product (e.g., produce). A membrane (not shown) is placed across the top of the container 900 and sealed against the flange 914 to form a seal. The membrane may be coupled and adhered to flange 914 using any suitable method or material (e.g., adhesive, heat seal, etc.). As described elsewhere herein, flange 914 of container 900 provides structural advantages over similar flanges of conventional containers. That is, adhesive is applied to the end flange tabs 820, 822 and the side flange tabs 824, 826 during initial formation of the container 900 to couple the corner flange tabs 846 to the end flange tabs 820, 822 and the side flange tabs 824, 826, which improves both the structural integrity and the sealing capability of the container 900. Conventional containers may have a top flange, but as described above, such conventional containers are not formed in the same manner as container 900 (i.e., do not include a formed flange or do not apply adhesive to join flange tabs during initial container formation), and thus container 900 provides an improvement over known conventional containers.

The application of adhesive when coupling the end flange tabs 820, 822 and the side flange tabs 824, 826 to the corner flange tabs 846 reinforces and reinforces the corners 918 of the flange 914, thus enhancing the structural rigidity of the container 900. For example, the container 900 may be able to hold a greater weight of product and/or more effectively prevent leakage of liquid. Such enhancements may also reduce the risk of structural failure of the container 900 once filled and sealed. Additionally, such reinforcement promotes improved sealing of the container 900. Furthermore, flange 914 may be substantially flatter than the flange of a conventional container. Such a flange 914 enables easier, faster, simpler, and/or more cost-effective (e.g., using less sealing material) application of a sealing film to seal the container 900. These enhancements enable the container 900 to function more efficiently than other conventional containers.

Fig. 9 is a flow chart of a method 1000 of forming a container from a blank. In some embodiments, the blank comprises: a bottom panel; two opposite side panels; two opposite end plates; a respective end flange panel extending from a top edge of each end panel; a respective end flange tab extending from each side edge of each end flange panel; a respective side flange panel extending from a top end of each side panel; and a respective side flange tab extending from each end edge of each side flange panel. The method 1000 includes: applying 1002 a hot melt adhesive to the inner surface of the side flange tab; rotating 1004 the end panel inwardly toward the bottom panel; and rotating 1006 the side panels inwardly toward the bottom panel. The method 1000 further comprises: rotating 1008 the side flange panels outwardly to an orientation parallel to the bottom panel; and after rotating 1008, rotating 1010 the end flange panel to an orientation parallel to the bottom panel. The method 1000 further comprises: the end flange tabs are coupled 1012 to the side flange tabs to form a container with a fully formed top flange.

In some embodiments, the blank further comprises a respective interior side panel extending from each side edge of each end panel. In some such cases, the method 1000 further comprises: applying a hot melt adhesive to a portion of the interior surface of the side panels; rotating the interior side panels inwardly; after the rotation of the interior side panels, performing a rotation 1008; and coupling the side panels to the interior side panels.

Method 1000 may include additional, fewer, and/or alternative steps, including those disclosed elsewhere herein.

Fig. 10 illustrates an exemplary container forming apparatus 1100 for forming a blank into a fully formed container or tray. For clarity, when describing a blank or features thereof, reference will be made to blank 100 (shown in fig. 1) and features thereof. Also, for clarity, when describing a container or features thereof, reference will be made to container 200 (shown in fig. 2) and features thereof. This discussion is not limiting of the disclosed apparatus 1100, as the apparatus 1100 may be applicable to any of the blanks or containers described herein, as well as additional or alternative blanks and containers.

The container forming apparatus 1100 generally includes a frame 1102, a blank feeder station 1104, a transfer station 1106, a compression station 1108, a stacking station 1110, and a control system 1112. Direction X is generally referred to herein as the blank transfer direction X and indicates the overall path taken by the blank 100 through the apparatus 1100. The direction Y is perpendicular to the blank transfer direction X and is referred to herein as the lateral direction Y or transverse direction Y. The direction Z is perpendicular to both the blank transfer direction X and the lateral direction Y, and is referred to herein as the vertical direction Z.

Fig. 11-15 illustrate the blank feeder station 1104 in more detail. The blank feeder station 1104 generally includes a conveyor belt 1120, a guide rail 1122, a pick and place assembly 1124, and a platform (deck) 1126.

As generally shown in fig. 12, the blanks 100 are stacked such that each blank 100 extends in a vertical direction Z, with one face facing the blank transfer direction X and the other face opposite the blank transfer direction X. In other words, the blanks 100 are stacked on the conveyor belt 1120 to "stand" on their side or end edges.

The conveyor 1120 is driven at a parameterized rate (e.g., by a motor (not shown) operated by the control system 1112) in the blank transfer direction X to drive individual blanks 100 one at a time toward the pick window 1128. It should be readily appreciated that the rate may be adjusted substantially infinitely between the predefined minimum and maximum rates based on various parameters of the device 1100 and the subject blank (e.g., the size of the blank may affect how quickly the device 1100 can operate). As the blanks 100 are driven by the conveyor belt 1120, they are held in their upright position by the guide rail 1122.

In an example embodiment, the blank feeder station 1104 further includes any suitable number and location of sensors to ensure that the blank feeder station 1104 operates according to instructions from the control system 1112. For example, the sensor 1130 monitors the number of blanks 100 in the stack of blanks and may transmit an alarm when the number of blanks 100 is below a threshold. In this manner, uninterrupted operation may be facilitated (e.g., by facilitating refilling of blank 100 before the stack becomes empty, which would interrupt operation of apparatus 1100). For operational and/or safety purposes, other sensors may be used, for example, to ensure that the blank 100 does not fall out of its "standing" position, move in the correct direction, move at the correct speed, etc.

The blank 100 is transferred from its vertical orientation by the pick and place assembly 1124 and is disposed in a horizontal orientation onto the platform 1126. Pick and place assembly 1124 includes: a stationary arm 1132 coupled to frame 1102 at a first end 1134 thereof; and a pivot arm 1136 pivotably coupled to frame 1102 at a first end 1138 thereof. In particular, a first end 1138 of pivot arm 1136 is coupled to frame 1102 via a first pivot rod 1140 that rotates about a first pivot axis 1142 defined in lateral direction Y. A servomotor 1144 controls the pivotal movement of the pivot arm 1136 about the first pivot axis 1142.

The second pivot rod 1146 is coupled between the second ends 1148 of the fixed arms 1132 and rotates in the lateral direction Y about a second pivot axis 1150 defined parallel to the first pivot axis 1142. Vacuum assembly 1152 is coupled to a second pivot rod 1146. Vacuum assembly 1152 is also pivotably coupled to a second end 1154 of pivot arm 1136 via a cylinder 1156. The cylinder 1156 pivots about a third pivot axis 1157. A rod 1158 couples the cylinder 1156 to the second pivot rod 1146. The vacuum assembly 1152 includes a plurality of vacuum cups 1160 that are activated when picking up the blank 100 to initiate a suction operation and are deactivated when lowering or placing the blank 100. The vacuum chuck 1160 is operatively coupled to internal conduits (not shown) whose internal pressures are monitored and controlled, for example, by the control system 1112.

Referring to fig. 14, for example, pick and place assembly 1124 is shown in a first "pick" configuration. The pivot arm 1136 is in a first position, and the vacuum assembly 1152 is in a first position, with the vacuum cup 1160 facing the vertically oriented blank 100. The vacuum cups 1160 are placed in engagement with the face of the individual blanks 100 and activated such that the blanks 100 are sucked up and held against the vacuum cups 1160.

Referring now to fig. 15, once a blank 100 has been picked from the stack of blanks, the pivot arm 1136 pivots about the first pivot axis 1142 into a second position, and the vacuum assembly 1152 rotates into the second position. In particular, vacuum assembly 1152 is both lowered by pivot arm 1136 and pivoted about second pivot axis 1150 and third pivot axis 1157 (due to the connection between cylinder 1156, rod 1158 and second pivot rod 1146) such that vacuum cup 1160 is facing downward and blank 100 is positioned horizontally.

The vacuum cup 1160 is deactivated and the blank 100 is released onto the platform 1126. Although not specifically shown, when the blank 100 is seated on the platform 1126, the leading edge 102 (see fig. 1) faces the blank transfer direction X, and the inner surface 101 (see fig. 1) faces upward in the vertical direction Z (such that the outer surface 103 (see fig. 1) faces downward, against the platform 1126).

Turning to fig. 16, a platform 1126 extends from the blank feeder station 1104 through the blank transfer station 1106 in the blank transfer direction X. In the illustrated embodiment, the platform 1126 includes two parallel legs 1162 extending in the blank transfer direction X and defining a transfer surface 1164 thereon. The blank transfer station 1106 may comprise a transfer belt, chain, lug, or any other suitable mechanism coupled to the legs 1162 as part of the platform 1126 to advance the blank 100 along the platform 1126 on the transfer surface 1164. Additionally or alternatively, the blank transfer station 1106 may include a pusher mechanism (not shown) that engages the trailing edge 104 (see fig. 1) of the blank 100 to push the blank 100 in the blank transfer direction X.

The blank 100 is advanced through the blank transfer station 1106 in the blank transfer direction X toward the compression station 1108. As the blank 100 is advanced, the blank 100 is transferred through the adhesive assembly 1170 within the blank transfer station 1106. The adhesive assembly 1170 includes a plurality of adhesive applicators 1172 configured to apply adhesive to specific locations of the blank 100, specifically to the interior surface 101 of the blank 100, as described elsewhere herein. In an example embodiment, the adhesive is a hot melt adhesive, although other adhesive types are contemplated within the scope of the present disclosure. The adhesive assembly 1170 also includes one or more sensors (e.g., optical sensors, not shown) to detect the position of the blank 100 within or relative to the adhesive assembly 1170. The adhesive applicator 1172 is activated (e.g., by the control system 1112) based on signals from the sensors and/or servo motor encoder positions to ensure accurate and precise placement of the adhesive on the blank 100.

Although various adhesives may be used, the adhesive may be a hot melt adhesive and may preferably have a viscosity of greater than or equal to 2000cps, a non-limiting commercially available example of which is "Technomelt Supra 100Plus-22" manufactured by the hangao company. The control system 1112 may use the planned high speed output and high speed glue solenoids driven by the motion cycle within the processor to achieve the level of accuracy required to place the adhesive onto the blank 100 at the predetermined flange target.

Once the adhesive is applied to the blank 100, the blank 100 is advanced from the blank transfer station 1106 to the compression station 1108. The timing of the application of adhesive to the blank and the movement to the compression station 1108 is set to ensure that the adhesive is in a molten state until compression is applied, and the compression timing is set to allow curing to occur rapidly. Referring now to fig. 17, compression station 1108 includes a plunger mechanism 1180 configured to drive spindle 1182 upward and downward in a vertical direction Z. In the example embodiment, plunger mechanism 1180 includes a subframe 1184 and a post 1186. Subframe 1184 is raised and lowered along two vertical rails 1188, and posts 1186 are coupled to subframe 1184 and maintain the position of spindle 1182 relative thereto. Mandrel 1182 includes an outer contour that is complementary in shape to the inner contour of the shape of the container to be formed. Spindle 1182 is replaceable based on the particular container to be formed thereby. Spindle 1182 includes a plurality of side plates 1190 (see fig. 18A) and a bottom plate (not shown) that collectively define an outer surface of spindle 1182. Although not shown, the bottom plate has holes therein; suction is applied to the blank 100 through these apertures to maintain the position of the blank 100 relative to the spindle 1182 during formation of the container 200. Alternatively, the mandrel 1182 does not include a bottom plate, and has one or more vacuum cups (not shown) at its bottom that are oriented downward to receive the blank 100 and hold the blank relative to the mandrel 1182. In some embodiments, one or more of the side panels 1190 may include apertures to apply suction to the walls of the formed container, as further described herein.

A plurality of compression plates 1192 are coupled to column 1186 and are operable independently of the vertical movement of plunger mechanism 1180 to raise and lower spindle 1182, as further described herein. In particular, the compression station 1108 includes a side compression plate 1194 and an end compression plate 1196 (see fig. 18A). Each compression plate 1192 defines a respective compression surface on a bottom or lower surface thereof. Each compression plate 1192 is raised and lowered by a respective actuator (e.g., pneumatic, spring-based, etc.). The operation of the side compression plates 1194 is independent of the operation of the end compression plates 1196.

As shown in fig. 18A, the compression station 1108 further includes a forming tool 1198 positioned directly below the mandrel 1182. The forming tool 1198 includes a plurality of side walls and a bottom wall defining a cavity 1202 therebetween. The forming tool 1198 comprises an inner contour, the shape of which complements the outer contour of the shape of the container to be formed; thus, the inner profile of forming tool 1198 is also complementary to the outer profile of mandrel 1182. The forming tool 1198 is also replaceable based on the particular container to be formed in the apparatus 1100.

In operation, container 200 is formed from blank 100 by driving mandrel 1182 (with blank 100 coupled thereto) downward into forming tool 1198. More particularly, the blank 100 is advanced into the compression station 1108 in a position below the mandrel 1182. Even more particularly, the blank 100 is positioned such that the bottom panel 108 of the blank 100 is located below the bottom surface of the mandrel 1182 (e.g., the bottom panel of the mandrel 1182, or the bottom edge of the side panel 1190 forming the mandrel 1182). The suction function of spindle 1182 is enabled to hold blank 100 in place relative to spindle 1182. The mandrel 1182 is then driven downward by actuation of the plunger mechanism 1180, which forces the blank 100 into the cavity 1202 of the forming tool 1198.

The forming tool 1198 is specifically shaped to cause the side panels 116, 122 and end panels 106, 110 of the blank 100 to fold such that an outer perimeter of the container 200 is formed. For example, the end walls of the forming tool 1198 may extend slightly higher than the side walls of the forming tool 1198 to ensure that the end panels 106, 110 are folded inwardly before the side panels 116, 122. The complementary shapes of forming tool 1198 and mandrel 1182 facilitate predictable and accurate folding of side panels 116, 122, glue panel 130, and end panels 106, 110 about mandrel 1182 in their respective fully folded configurations. Further, as blank 100 is driven into forming tool 1198 and folded against mandrel 1182, the complementary relationship of forming tool 1198 and mandrel 1182 causes glue panels 130 to compress against inner surfaces 101 of side panels 116, 122, thereby securing the panels in stacked face-to-face relationship.

Once the mandrel 1182 is fully lowered, the side compression plate 1194 is lowered to rotate the side flange panels 150, 152 outwardly and fold the side flange panels 150, 152 against the top edge of the forming tool 1198. Thus, the side flange panels 150, 152 are folded into their fully folded configuration parallel to the bottom panel 108 of the blank 100. Thereafter, the end compression plate 1196 is lowered to rotate the end flange panels 134, 138 outwardly and fold the end flange panels 134, 138 against the top edge of the forming tool 1198. This rotation causes the end flange tabs 142, 144 to fold atop the side flange tabs 158, 160 into overlying face-to-face relationship therewith. In addition, the end compression plate 1196 applies sufficient force to compress the end flange tabs 142, 144 against the side flange tabs 158, 160 to ensure that these flange tabs adhere to one another. Thereby, the top flange 214 of the container 200 is fully formed and secured.

Referring to fig. 18B, in some example embodiments, spindle 1182 is lowered to engage tray 200 and remain in place by vacuum cups located in the bottom of spindle 1182. Tray flaps (or glue panels) 130 may first be engaged by shaped ears 1191 to force them into the interior cavity of tray 200. As the mandrel 1182 descends into the cavity 1202, the walls 106, 110, 116, 122 fold upward. With the shaped lugs 1191 inside the perimeter of the flange of the tray 200, a cam 1193 mounted on the mandrel 1182 engages with a cam follower bearing 1195 using a bushing bearing to force the tab fold lug mounting plates 1197 and 1199 to unfold over the perimeter of the tray 200 on plane 1189. When the tray 200 is disposed between the mandrel 1182 and the female cavity 1202, the tab 130 is compressed to the side walls 116, 122 and adheres thereto. The side flanges 150, 156 are folded into position against a folding anvil 1194 mounted to the mandrel 1182. The end flanges 134, 138 will now remain vertical. When the mandrel 1182 reaches the bottom of the cavity 1202, the folding anvil 1196 moves downward as the axis continues to descend, as the folding anvil 1196 is connected to a spring-loaded separate floating shaft, thereby folding the end flanges 134, 138 located on top of the side flanges 150, 156 into their forming positions. The axis then moves downward a small amount to engage the primary compliant spring, thereby applying pressure to the flange and curing the adhesive.

As described elsewhere herein, the container formed using apparatus 1100 includes a planar top flange, wherein the flange tabs are secured using a hot melt adhesive. These containers exhibit improved stacking and de-stacking (or de-nesting) characteristics, are stronger than conventional trays without adhered or fixed flanges, and further exhibit improved functionality when sealed with a top film.

Once the container is formed, spindle 1182 is raised by actuating plunger mechanism 1180. The pumping function of spindle 1182 remains active and container 200 is raised with spindle 1182 and remains coupled thereto. Tray collection assembly 1210 is actuated to retrieve the formed containers 200 from spindle 1182. The tab fold mechanisms 1197, 1199 will return to the original position when the cam 1193 leaves the cam follower bearing 1195 and be pulled into place by the spring 1187.

More specifically, referring to fig. 19 and 20, the stacking station 1110 includes a tray collection assembly 1210 that itself includes a horizontal linear rail 1212 (e.g., a belt drive) extending along the blank transfer direction X. The clamping tool 1214 is driven along a track 1212, which is parallel to the blank transfer direction X. The clamping tool 1214 includes a sub-frame 1216 and an articulating clamping mechanism 1218 coupled to an upstream end of the sub-frame 1216. In operation, clamp tool 1214 is driven toward compression station 1108 until articulating clamp mechanism 1218 is engaged with container 200, while mandrel 1182 is lifted from its lowered position (not specifically shown) within forming tool 1198 to its raised position (shown in fig. 17). Clamping tool 1214, plunger mechanism 1180, and mandrel 1182 operate in conjunction with one another such that hinged clamping mechanism 1218 clamps formed container 200 as mandrel 1182 is raised by plunger mechanism 1180, and at the same time, the pumping function of mandrel 1182 is disabled. Accordingly, container 200 is released from spindle 1182 as spindle 1182 rises, and clamping tool 1214 is driven back in blank transfer direction X to retract container 200 from the vertical path of spindle 1182, out of compression station 1108, and into stacking station 1110.

The clamping tool 1214 may take the form of a fixed metal finger with a corresponding cut-out in the spindle 1182 to allow the finger to be positioned inside the perimeter of the spindle 1182 and thus on the inside of the tray 200 when the spindle 1182 is lifted vertically upwards (in the z-direction). Based on the position of the spindle 1182 (which may be determined from the servo motor encoder position), a pneumatic cylinder with a clamping surface is operable to hold the tray 200 in place until the spindle 1182 is retracted from the cavity of the tray 200, at which point the clamping tool can be driven horizontally (in the x-direction) to a stacked position at which the tray 200 is released.

Slots or channels 1220 are disposed in stacking station 1110. The channel 1220 is formed from a plurality of vertically extending plates 1222 and is configured to receive a plurality of containers 200 therein. In particular, channels 1220 receive containers 200 and arrange them therein in stacks 300 (as shown in fig. 3).

In operation, the clamping tool 1214 is driven in the blank transfer direction X until the container 200 is positioned over the channel 1220. Hinged gripping mechanism 1218 is actuated to release container 200 into channel 1220. In some embodiments, the container 200 is actively diverted into the channel 1220, for example, by a controlled flow of air (not shown). This arrangement may facilitate improved stacking of containers within the channel 1220. In other embodiments, the container 200 passively transfers or falls into the channel 1220.

The stacking station 1110 further includes one or more sensors (e.g., weight sensors, optical sensors, etc., not shown) that detect when a complete stack of containers is formed. For example, the sensor may sense the weight of the stack, the height of the stack, or the number of containers in the stack. The stack is considered "complete" and can be easily adjusted by an operator based on parameters input to and/or stored in the control system 1112. Once a complete stack is detected, the side plates 1224 of the channels 1220 are opened and an ejector plate (not shown) is actuated to push the stack out of the channels 1220 and to a subsequent station.

In an example embodiment, the apparatus 1100 is designed to achieve high throughput and is configured to form up to 30 containers per minute according to the operations described above. It should be appreciated that the device 1100 is highly customizable. For example, the blank feed station 1104 includes an adjustment mechanism (not shown) to accommodate blanks of different lengths and widths. The adjustment mechanism may be manually operated. Additionally or alternatively, the adjustment mechanism may be operated via a user interface of the control system 1112. For example, an operator may use the user interface to input the length and width of the blank, and the control system 1112 may automatically control the adjustment mechanism accordingly. In some cases, one or more of the adjustment mechanisms (whether manually controlled or computer controlled) may cause an adjustment to be made to one or more components of the device 1100. For example, one adjustment mechanism that is manipulated to accommodate the width of the blank may control components throughout the apparatus 1100 (e.g., components in the blank feeder station 1104, transfer station 1106, compression station 1108, and/or stacking station 1110).

Additionally, with respect to the blank feeder station 1104, the control system 1112 can be configured to adjust the position of the vacuum chuck 1160 and/or the vacuum pressure generated in the vacuum assembly 1152 to accommodate blanks of different sizes and weights. With respect to the blank transfer station 1106, the control system 1112 can be used to adjust the position of the adhesive applicator 1172 and enable control to accommodate blanks of different sizes, shapes, and configurations. The amount and temperature of the applied adhesive can also be precisely controlled.

With respect to compression station 1108, mandrel 1182 and forming tool 1198 are interchangeable to accommodate blanks/containers of various sizes and configurations (e.g., four sided, eight sided, etc.). In addition, the control system 1112 may be used to adjust the vacuum pressure generated in the mandrel 1182 to accommodate various blanks. In the stacking station 1110, the positions of the various components (e.g., the hinged clamping mechanism 1218, the plates 1222 of the channel 1220) can be adjusted manually or via the control system 1112 to accommodate containers of varying sizes and shapes. Additionally or alternatively, the apparatus 1100 may not include a stacking station (e.g., the formed containers may be ejected from the apparatus 1100 for stacking elsewhere or for filling product without stacking), or the apparatus 1100 may include additional stations such as a product filling station, a container sealing station, a container packaging station, and the like.

Additionally, the operation of the components of the device 1100 (such as its timing, speed, and position) is virtually infinitely customizable via the control system 1112. That is, any of the components may be independently operable via a corresponding servo motor (or other servo mechanism) controlled by control system 1112 in accordance with instructions provided thereto by an operator through a user interface.

In one example embodiment, the apparatus 1100 includes a blank transfer station that includes an adhesive assembly having a plurality of adhesive applicators. The blank is transferred in a blank transfer direction through an adhesive assembly where at least one of the adhesive applicators applies a hot melt adhesive to the inner surface of the side flange tab. The apparatus 1100 also includes a compression station downstream of the blank transfer station that includes a vertically movable mandrel and a forming tool below the mandrel. The forming tool defines a cavity therein and has an inner profile complementary in shape to the outer profile of the mandrel. The blank is positioned under the mandrel and the mandrel drives the blank downwardly into the cavity of the forming tool, which drives the end panel inwardly into engagement with the mandrel and the side panel inwardly into engagement with the mandrel and the end panel. The compression station also includes an end compression plate and a side compression plate coupled to the mandrel. The side compression plate rotates the side flange panel outwardly into engagement with the top edge of the forming tool and then the end compression plate rotates the end flange panel outwardly into engagement with the top edge of the forming tool, the end compression panel further compressing the end flange tab against the side flange tab to form a container having a fully formed top flange.

Additionally or alternatively, the device 1100 may include any of the following features or components in any combination:

(A) When the blank further includes a respective interior side panel extending from each side edge of each end panel, at least one of the plurality of adhesive applicators is further configured to apply a hot melt adhesive to a portion of the interior surface of the side panel as the blank is transferred through the adhesive assembly, and wherein, as the mandrel drives the blank into the cavity of the forming tool, the forming tool rotates the interior side panel inwardly into engagement with the mandrel prior to rotating the side panel into engagement with the mandrel, and the forming tool compresses the side panels against the interior side panel in stacked face-to-face relationship;

(B) The compression station further includes a plurality of shaped ears positioned about the perimeter of the folding tool, each shaped ear extending partially inwardly into the cavity to engage the interior side panels as the blank is lowered toward the folding tool;

(C) The compression station further includes a cam mounted on the mandrel and engaged with the cam follower bearing to rotate the forming lugs away from the cavity as the mandrel lowers the blank further toward the folding tool;

(D) The blank transfer station is configured to advance a blank comprising a hot melt adhesive applied thereto from the adhesive assembly to the compression station while the hot melt adhesive remains in a molten state;

(E) Using a control system to control the timing of the compression stations such that the hot melt adhesive cures during compression of the blank to form a container;

(F) The adhesive applicator is configured to apply a hot melt adhesive having a viscosity of at least 2000 centipoise (cps);

(G) The mandrel includes a vacuum assembly configured to hold the blank against the mandrel;

(H) Further comprising a gripping tool configured to transfer the formed containers from the compression station to the stacking station; and

(I) The movement of the side compression plates and the end compression plates is controlled independently of the movement of the mandrel using a control system.

Fig. 21 depicts a schematic block diagram of the control system 1112. In an example embodiment, control system 1112 includes a control panel 1302, a processor 1304, a memory 1306, and a communication interface 1308. In certain embodiments, a reprogramming scheme (recipe) or protocol embodied on a non-transitory computer readable storage medium (e.g., stored in memory 1306) is programmed in and/or uploaded to processor 1304, and such schemes include, but are not limited to, predetermined speed and timing profiles, wherein each profile is associated with forming a container from a blank having a predetermined size and shape.

In certain embodiments, control system 1112 is configured to facilitate the speed and/or timing of movement and/or enablement of any of the disclosed components of selection device 1100. These components may be controlled independently or as part of one or more linked mechanisms.

The control panel 1302 includes one or more input devices 1310 or components (e.g., touch screen, keyboard, mouse, microphone, and/or other input controls), and one or more output devices 1312 or components (e.g., touch screen, non-touch screen) (e.g., LCD monitor), speakers, lights, and/or other output devices). In certain embodiments, the control panel 1302 allows an operator to select a solution appropriate for a particular blank and/or container. Each of which is a set of computer instructions that form a container to instruct the device 1100. In embodiments in which one or more actuators within the apparatus 1100 are servomechanisms, the control system 1112 can independently control movement of each such actuator relative to any other component of the apparatus 1100. This enables an operator to maximize the number of containers that can be formed by the apparatus 1100, easily change the size of the blank and/or the containers formed on the apparatus 1100, and automatically change the type of blank and/or the containers formed on the apparatus 1100 while reducing or eliminating manual adjustments to the apparatus 1100.

In an example embodiment, control system 1112 is shown as being centralized within device 1100, however, control system 1112 may be a distributed system throughout device 1100, within building premises equipment 1100, and/or at a remote control center. The control system 1112 includes a processor 1304 configured to control the device 1100 to perform the methods and/or steps described herein (e.g., the steps of the method 1000 shown in fig. 9). As used herein, the term "processor" is not limited to integrated circuits referred to in the art as a computer, but broadly refers to a controller, a microcontroller, a microcomputer, a Programmable Logic Controller (PLC), an application specific integrated circuit, and other programmable circuits, and these terms are used interchangeably herein. It should be appreciated that the processor and/or control system can also include memory, input channels, and/or output channels.

In the embodiments described herein, memory 1306 may include, but is not limited to, computer-readable media, such as Random Access Memory (RAM), and computer-readable non-volatile media, such as flash memory. Alternatively, a floppy disk, compact disc read only memory (CD-ROM), magneto-optical disk (MOD), and/or Digital Versatile Disc (DVD) may also be used.

Communication interface 1308 is used to transmit instructions from control system 1112 to various components of apparatus 1100 (e.g., actuators) and to receive information from various components of apparatus 1100 (e.g., actuators, sensors, etc.) and/or from remote devices. The communication interface 1308 may be any suitable wired or wireless communication interface to facilitate the control system 1112 and any suitable communication format within the device 1100 (e.g., wi-Fi, bluetooth, cellular data connection, etc.).

The processor described herein processes information transmitted from a plurality of electrical and electronic devices that may include, but are not limited to, sensors, actuators, compressors, control systems, and/or monitoring devices. Such processors may be physically located in, for example, a control system, sensors, monitoring devices, desktop computers, laptop computers, PLC cabinets, and/or Distributed Control System (DCS) cabinets. The RAM and storage devices store and transfer information and instructions to be executed by the processor(s). RAM and storage devices can also be used to store and provide temporary variables, static (i.e., non-changing) information and instructions or other intermediate information to the processors during execution of instructions by the processor(s). The executed instructions may include, but are not limited to, flow control system control commands. Execution of sequences of instructions is not limited to any specific combination of hardware circuitry and software instructions.

In an example embodiment, method 1000 (shown in fig. 9) is performed by control system 1112 sending commands and/or instructions to components of device 1100. The processor 1304 is programmed with code segments that are configured to perform the method 1000. Alternatively, method 1000 is encoded on a computer readable medium stored in memory 1306 and readable by control system 1112.

The steps of the container forming method performed by apparatus 1100 under the operation of control system 1112 may include, for example: (i) transferring the blank through an adhesive assembly; (ii) Applying a hot melt adhesive to the inner surface of the side flange tab using the plurality of adhesive applicators; (iii) positioning the blank under the mandrel; (iv) Using a spindle, the blank is driven down into the cavity of the forming tool, the driving causing the forming tool to: (a) rotating the end plate inwardly into engagement with the mandrel; and (b) rotating the side panels inwardly into engagement with the mandrel and into engagement with the end panels; (v) Rotating the side flange panels outwardly to an orientation parallel to the bottom panel using a side compression plate coupled to the mandrel; (vi) After the rotating the side flange panels, rotating the end flange panels to an orientation parallel to the bottom panel using an end compression plate coupled to a mandrel; and (vii) compressing the end flange tabs against the side flange tabs using an end compression plate to form a container having a fully formed top flange.

Additionally or alternatively, the method may include any of the following steps in any combination thereof:

(A) Where the blank further comprises a respective interior side panel extending from each side edge of each end panel, the method further comprises: applying a hot melt adhesive to a portion of the interior surface of the side panel using the plurality of adhesive applicators; rotating the side inner panels inwardly using a forming tool; after the rotating the side inner panels, performing the inwardly rotating side panels; and compressing the side panels against the interior side panels between the mandrel and the forming tool.

(B) Where the compression station further includes a plurality of shaped ears positioned about the perimeter of the folding tool, each shaped ear extends partially inwardly into the cavity, the method further comprising: engaging the side inner panels with the shaped ears as the blank is lowered toward the folding tool;

(C) In the case where the compression station further includes a cam mounted on the spindle, the method further includes: engaging the cam with a cam follower bearing; and rotating the forming ears away from the cavity as the mandrel lowers the blank further toward the folding tool;

(D) Advancing a blank comprising a hot melt adhesive applied thereto from an adhesive assembly to a compression station while the hot melt adhesive remains in a molten state;

(F) Applying a hot melt adhesive having a viscosity of at least 2000 centipoise (cps);

(G) Holding the blank against the mandrel using a vacuum assembly;

(H) Transferring the formed containers from the compression station to the stacking station using a gripping tool;

Exemplary embodiments of containers and blanks for making the containers are described above in detail. The container and blank are not limited to the specific embodiments described herein, but rather, components of the blank and/or container may be utilized independently and separately from other components described herein. Further, embodiments of an apparatus for forming a container from a blank are described in detail above. The apparatus is not limited to the specific embodiments described herein nor is the apparatus limited to forming containers from the specific blanks described herein. Rather, the apparatus may be used to form additional or alternative containers to those described herein.

Although specific features of various embodiments of the disclosure may be shown in some drawings and not in others, this is for convenience only. Any feature of the drawings may be referenced and/or claimed in combination with any feature of any other drawings in accordance with the principles of the present disclosure.

This written description uses examples to disclose the various embodiments, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

1. A container forming apparatus for forming a container from a blank, the blank comprising: a bottom panel; two opposite side panels; two opposite end plates; a respective end flange panel extending from a top edge of each end panel; a respective end flange tab extending from each side edge of each end flange panel; a respective side flange panel extending from a top end of each side panel; and a respective side flange tab extending from each end edge of each side flange panel, the apparatus comprising:

A blank transfer station comprising an adhesive assembly comprising a plurality of adhesive applicators,

Wherein the blank is transferred through the adhesive assembly in a blank transfer direction, at least one of the adhesive applicators applying a hot melt adhesive to an inner surface of the side flange tab at the adhesive assembly; and

A compression station downstream of the blank transfer station, the compression station comprising a vertically movable mandrel and a forming tool below the mandrel, wherein the forming tool defines a cavity therein and has an inner profile complementary in shape to the outer profile of the mandrel,

Wherein the blank is positioned below the mandrel and the mandrel drives the blank downwardly into the cavity of the forming tool, the drive rotating the end panel inwardly into engagement with the mandrel and rotating the side panel inwardly into engagement with the mandrel and the end panel,

The compression station further includes an end compression plate and a side compression plate coupled to the mandrel,

Wherein the side compression plate rotates the side flange panel outwardly into engagement with a top edge of the forming tool and then the end compression plate rotates the end flange panel outwardly into engagement with the top edge of the forming tool, the end compression panel further compressing the end flange tab against the side flange tab to form the container with a fully formed top flange.

2. The container forming apparatus of claim 1, wherein the blank further comprises a respective interior side panel extending from each side edge of each end panel,

Wherein at least one of the plurality of adhesive applicators is further configured to apply the hot melt adhesive to a portion of the interior surface of the side panel as the blank is transferred through the adhesive assembly,

Wherein, as the mandrel drives the blank into the cavity of the forming tool, the forming tool rotates the interior side panels inwardly into engagement with the mandrel prior to rotating the side panels into engagement with the mandrel, and the forming tool compresses the side panels against the interior side panels in stacked face-to-face relationship.

3. The container forming apparatus of claim 2, wherein the compression station further comprises a plurality of forming ears positioned about a perimeter of the folding tool, each forming ear extending partially inwardly into the cavity to engage the interior side panel as the blank is lowered toward the folding tool.

4. A container forming apparatus as claimed in claim 3, wherein the compression station further comprises a cam mounted on the mandrel, wherein the cam engages with a cam follower bearing to rotate the forming lugs away from the cavity as the mandrel lowers the blank further towards the folding tool.

5. The container forming apparatus of claim 1, wherein the blank transfer station is configured to advance the blank including the hot melt adhesive applied thereto from the adhesive assembly to the compression station while the hot melt adhesive remains in a molten state.

6. The container forming apparatus of claim 5, wherein a control system is used to control the timing of the compression stations such that the hot melt adhesive cures during compression of the blank to form the container.

7. The container forming apparatus of claim 1, wherein the adhesive applicator is configured to apply the hot melt adhesive having a viscosity of at least 2000 centipoise (cps).

8. The container forming apparatus of claim 1, wherein the mandrel includes a vacuum assembly configured to hold the blank against the mandrel.

9. The container forming apparatus of claim 1, further comprising a gripping tool configured to transfer the formed containers from the compression station to a stacking station.

10. The container forming apparatus of claim 1, wherein movement of the side compression plates and the end compression plates is controlled independently of movement of the mandrel using a control system.

11. A method of forming a container from a blank using a container forming apparatus, the blank comprising: a bottom panel; two opposite side panels; two opposite end plates; a respective end flange panel extending from a top edge of each end panel; a respective end flange tab extending from each side edge of each end flange panel; a respective side flange panel extending from a top end of each side panel; and a respective side flange tab extending from each end edge of each side flange panel, the apparatus comprising: (i) A blank transfer station comprising an adhesive assembly having a plurality of adhesive applicators, and (ii) a compression station downstream of the blank transfer station, the compression station comprising a vertically movable mandrel and a forming tool below the mandrel, wherein the forming tool defines a cavity therein and has an inner profile complementary in shape to the outer profile of the mandrel,

The method comprises the following steps:

transferring the blank through the adhesive assembly;

applying a hot melt adhesive to an inner surface of the side flange tab using the plurality of adhesive applicators;

Positioning the blank below the mandrel;

using the mandrel to drive the blank downwardly into the cavity of the forming tool, the driving causing the forming tool to:

rotating the end plate inwardly into engagement with the mandrel;

rotating the side panels inwardly into engagement with the mandrel and with the end panels;

Rotating the side flange panels outwardly to an orientation parallel to the bottom panel using a side compression plate coupled to the mandrel;

After the rotating the side flange panels, rotating the end flange panels to an orientation parallel to the bottom panel using an end compression plate coupled to the mandrel; and

The end flange tabs are compressed against the side flange tabs using the end compression plate to form the container with a fully formed top flange.

12. The method of claim 11, wherein the blank further comprises a respective interior side panel extending from each side edge of each end panel, the method further comprising:

applying a hot melt adhesive to a portion of the interior surface of the side panel using the plurality of adhesive applicators;

Rotating the interior side panels inwardly using the forming tool;

performing the inward rotation of the side panels after the rotation of the side panels; and

The side panels are compressed against the interior side panels between the mandrel and the forming tool.

13. The method of claim 12, wherein the compression station further comprises a plurality of shaped ears positioned around a perimeter of the folding tool, each shaped ear extending partially inward into the cavity, the method further comprising:

The shaped ears are used to engage the side interior panels as the blank is lowered toward the folding tool.

14. The method of claim 13, wherein the compression station further comprises a cam mounted on the spindle, the method further comprising:

engaging the cam with a cam follower bearing; and

The forming ears are rotated away from the cavity as the mandrel lowers the blank further toward the folding tool.

15. The method as recited in claim 11, further comprising:

Advancing the blank comprising the hot melt adhesive applied thereto from the adhesive assembly to the compression station while the hot melt adhesive remains in a molten state.

16. The method as recited in claim 15, further comprising: a control system is used to control the timing of the compression stations such that the hot melt adhesive cures during compression of the blank to form the container.

17. The method of claim 11, applying the hot melt adhesive comprising: the hot melt adhesive is applied with a viscosity of at least 2000 centipoise (cps).

18. The method as recited in claim 11, further comprising: a vacuum assembly is used to hold the blank against the mandrel.

19. The method as recited in claim 11, further comprising: the formed containers are transferred from the compression station to a stacking station using a gripping tool.

20. The method as recited in claim 11, further comprising: a control system is used to control movement of the side compression plates and the end compression plates independently of movement of the mandrel.