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

1. An apparatus for forming a tray from a blank of sheet material, the apparatus comprising:

a platen configured to move along a path between a first position and a second position to bias the platen against the blank and drive the blank downstream from the first position, wherein in the first position the platen is proximate and in spaced relation to the blank;

a first folding arm configured to rotate into and out of the path of the platen to bias against and fold an extended portion of the blank to form the blank into a partially formed tray, the partially formed tray including a side panel and an end panel that are substantially perpendicular to a bottom panel and at least a portion of the extended portion being substantially parallel to the bottom panel; and

a fixed plate and a movable plate spaced from and movable with respect to the fixed plate, the fixed plate and the movable plate defining a passage therebetween, wherein the fixed plate guides the extended portion of the partially formed tray through the passage to a position adjacent at least one of the side panel and the end panel to form a tray wall of the tray.

2. An apparatus according to claim 1 , further comprising a second folding arm configured to rotate against the extended portion of the partially formed tray to fold the extended portion through the passage, wherein an axis of rotation of the first folding arm is generally orthogonal to an axis of rotation of the second folding arm.

3. An apparatus according to claim 1 , further comprising a forming rail positioned downstream from the first position for receiving the blank and folding portions of the blank as the blank moves past the forming rail.

4. An apparatus according to claim 3 , wherein the forming rail comprises:

a proximal portion configured to partially fold peripheral portions of the blank; and

a distal portion configured to secure the blank as the partially formed tray.

5. An apparatus according to claim 1 further comprising a forming rail positioned downstream from the first position for receiving the blank and folding portions of the blank as the blank moves through the forming rail to the second position, the forming rail comprising:

opposing end folding rails configured to fold end panels of the blank upwardly with respect to a bottom panel of the blank;

opposing edge rails each associated with an end rail of the opposing end folding rails, the edge rails configured to inwardly fold inside corner support members connected to the end panels; and

opposing side folding rails configured to fold side panels of the blank upwardly with respect to the bottom panel while capturing the inside corner support members between the side panels.

6. An apparatus according to claim 5 , wherein the forming rail includes proximal ends configured to receive the blank, and a distal portion configured to secure the blank as the partially formed tray.

7. An apparatus in accordance with claim 1 , wherein the platen further comprises a guide plate coupled to a periphery of the platen, the guide plate including a compression surface adjacent a side wall of the tray for coupling the side panel to an inside corner support member to form the side wall.

8. An apparatus according to claim 7 , wherein the compression surface comprises depressions configured to reduce friction between the compression surface an adjacent portion of the tray.

9. An apparatus according to claim 7 , wherein the guide plate comprises a plurality of guide plates configured to adjustably a platen peripheral define the compression surface about the periphery of the platen.

10. An apparatus according to claim 2 , wherein the fixed plate contacts the extended portion of the partially formed tray to guide the extended portion through the passage as the second folding arm rotates against the extended portion to fold the extended portion through the passage.