Apparatus and method for forming a container having an enhanced corner support structure

1. A method of forming a container from a paperboard blank, the method comprising:

providing a generally flat paperboard blank having a plurality of fold lines therein for defining a bottom panel, opposing end panels attached to the bottom panel via first fold lines, opposing side panels attached to the bottom panel via second fold lines, wherein each of the opposing end panels includes opposing outside edge portions for forming an inside corner support member, wherein each of the opposing outside edge portions are attached to opposing edges of the end panels via a third fold line;

positioning the blank at a first forming position;

supporting a platen proximate the first folding position in spaced relation to the blank, the platen dimensioned and aligned to fit proximate the first and second fold lines when contacting the bottom panel;

providing first and second opposing edge rail pairs mechanically operable and positioned for folding the outside edge portions of the end panels;

mechanically operating the first and second opposing edge rail pairs for folding the outside edge portions of the end panels along the third folding lines of the blank;

providing opposing first and second mechanically operable end folding rails positioned for receiving the end panels of the blank;

mechanically operating the opposing first and second end folding rails for folding the end panels upwardly from the bottom panel along the first folding lines, the outside edge portions of the end panel already being inwardly folded;

providing opposing first and second side folding rails carried in a fixed position relative to and operable with the platen for receiving the opposing side panels through an action of moving the platen downstream from the first forming position; and

biasing the platen against the bottom panel of the blank for advancing the blank downstream the first forming position for folding the opposing side panels upwardly from the bottom panel along the second folding lines, wherein an initial movement of the platen is sufficient for securing the outside edge portions of the end panels in a folded position through a biasing of the opposing side panels thereagainst, thus initially securing the outside edge portions of the end panels in the folded position prior to a further advancing of the platen further downstream.

2. A method according to claim 1 , further comprising advancing the platen downstream and thus the blank along the path to the second forming position, wherein a forming rail secures the blank into a partially formed container, wherein the partially formed container is configured with the end and side panels positioned generally orthogonal to the bottom panel and each of the inside corner support members is folded about the third fold line and in juxtaposition with the side panel portions having adhesive thereon, and wherein each of the top wall portions and outside corner support members are generally parallel to respective side panels thereof.

3. A method according to claim 2 , further comprising retracting the platen from the second forming position upstream along the forming path to the first position.

4. A method according to claim 3 , further comprising biasing a first folding arm against the top wall portion for folding the top wall portion about a fifth fold line, the fifth fold line attaching the top wall portion to an edge of the side panel, the top wall portion being folded to a position generally parallel to the bottom panel, wherein the outside corner support member is partially folded about a seventh fold line within the outside corner support member, the seventh fold line forming an end fold portion foldable about a side fold portion, and wherein the side fold portion is partially folded about the seventh fold line by contacting a plate.

5. A method according to claim 4 , further comprising:

biasing a second folding arm against each of the end fold portions for a folding thereof about a sixth fold line, the sixth fold line folding end fold portions of the outside corner support member about a fold line attaching outside corner support member to the top wall portion, the second folding arm folding the end fold portion into contact with the end wall; and

compressing each of the side fold portions against the side walls for forming a fully formed container having double glued corner portions formed from the sandwiching of the side panel between the side fold portion of the outside corner support member and the inside corner support member.

6. A method according to claim 1 , wherein the steps from providing first and second opposing edge rail pairs through mechanically operating the opposing first and second end folding rails takes place prior to the platen biasing step.

7. A method according to claim 1 , wherein the steps from providing first and second opposing edge rail pairs through mechanically operating the opposing first and second end folding rails takes place with the platen biasing step.

8. A method according to claim 4 , wherein the platen retracting step takes place prior to the first folding arm biasing step.

9. A method according to claim 5 , wherein the platen retracting step takes place prior to the second folding arm biasing step.