Method for forming a double glued corner tray structure

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

providing a paperboard blank having a plurality of fold lines therein, the blank having a bottom panel, first and second opposing end panels attached to opposing peripheral end portions of the bottom panel at first fold lines, first and second opposing side panels attached to opposing peripheral side portions of the bottom panel at second fold lines, wherein each of the opposing end panels has an inside corner support member attached to opposing edges of each of the opposing end panels at a third fold line, each of the opposing side panels having a top wall portion attached thereto at a fifth fold line, and wherein an outside corner support member is attached to the top wall portion at a sixth fold line, the outside corner support member having a seventh fold line therein for forming an outside corner support having an end fold portion and a side fold portion thereof;

applying an adhesive to a surface of the blank along each of the outside corner support members and portions of the side panels proximate thereto;

biasing a platen against the bottom panel so as to move the blank to a first forming position;

advancing the platen through a forming rail positioned downstream the first forming position for folding the end panels about the first fold lines and the side panels about the second fold lines, wherein each inside corner support member is folded about the third fold line inwardly of the opposing side panels, and wherein the inside corner support member is further folded about the fourth fold line through a biasing of the platen against the corner portion and the forming rail for forming a corner of a partially formed tray;

further advancing the platen downstream and thus the partially formed tray to a second forming position, wherein a distal portion of the forming rail secures the blank into a partially formed tray, and wherein the partially formed tray is configured with the end and side panels positioned generally orthogonal to the bottom panel and each of the inside corner support members folded about the third fold line and in juxtaposition with the side panel portions having the adhesive thereon, and wherein each of the top wall portions and outside corner support members are generally parallel to respective side panels thereof;

retracting the platen from the partially formed tray;

positioning a compression plate in spaced relation and generally parallel to a fixed plate for forming a passage therebetween;

biasing a first folding arm against the top wall portion and folding the top wall portion about the fifth fold line to a position generally parallel to the bottom panel;

biasing a second folding arm against the end fold portion of the outside corner support member and folding the end fold portion about the sixth fold line into the passage and against the end panel, wherein the side fold portion is partially folded about the seventh fold line by contacting the fixed plate providing a guiding surface therefor;

biasing the compression plate against each of the side fold portions for compressing the side fold portions against the side panels thus forming a fully formed;

retracting the compression plate for releasing the biasing on the fully formed tray; and

advancing the fully formed tray further downstream.

2. A method according to claim 1 , further comprising controlling a space between the fixed plate and the compression plate to be less than a width dimension of the outside corner support member, wherein a partially folded corner support member when folded along the sixth folding line folds to a position against the fixed plate due to the space between the fixed plate and the compression plate.

3. A method according to claim 1 , further comprising forming a bevel within the inside corner support member through a folding thereof, wherein the platen includes bevelled corners, and wherein the inside corner support member includes a fourth fold line therein.

4. A method according to claim 1 , further comprising locking the partially formed tray in place prior to the platen retracting.

5. A method according to claim 4 , further comprising unlocking the fully formed tray for advancing the fully formed tray downstream.

6. A method according to claim 1 , further comprising advancing the fully formed tray downstream into a frame for setting the adhesive.

7. A method according to claim 1 , wherein the adhesive applying is completed prior to the platen biasing.

8. A method according to claim 7 , wherein the adhesive applying provides double glued corner portions formed from a sandwiching of each of the side panels between each of the side fold portions of the outside corner support members and the inside corner support members.

9. A method according to claim 1 , wherein the compression plate biasing step follows the first folding arm biasing step.

10. A method according to claim 1 , wherein the compression plate biasing step follows the second folding arm biasing step.

11. A method according to claim 1 , wherein the compression plate biasing step follows the platen retracting step.

12. A method according to claim 1 , further comprising a step of locking the partially formed tray prior to the first folding arm biasing step and maintaining the locking through the compression plate retracting step.

13. A method according to claim 12 , further comprising unlocking the partially formed tray following the second folding arm biasing step.

14. A method according to claim 1 , wherein the platen further advancing downstream step advancing the partially formed tray to the second forming position, thus causing each inside corner support member to be adhesively attached to the side panels, is completed prior to the platen retracting step.

15. A method according to claim 1 , wherein the compression plate biasing step is completed after the platen retracting step.

16. A method according to claim 1 , wherein the fixed plate is fixed relative to the end fold portion of the partially formed tray, and wherein the step of the second folding arm biasing against the end fold portion folds the end fold portion along the guiding surface provided by the fixed plate.