METHODS AND APPARATUS FOR FORMING A REINFORCED TRAY
An apparatus for forming a container is provided. The apparatus includes a hopper station including a hopper assembly configured to store a plurality of blanks and retrieve a single blank from the plurality of blanks, and a blank feeder assembly including a plurality of tab bullets each configured to fold a respective stacking tab of the blank. The apparatus further includes a laminating station downstream from the hopper station and configured to laminate at least a portion of the container, and a compression station downstream from the laminating station, the compression station configured to form at least one corner wall of the container.
1 . An apparatus for forming a container, said apparatus comprising:
a hopper station comprising:
a hopper assembly configured to store a plurality of blanks and retrieve a single blank from the plurality of blanks; and
a blank feeder assembly comprising a plurality of tab bullets each configured to fold a respective stacking tab of the blank;
a laminating station downstream from said hopper station and configured to laminate at least a portion of the container; and
a compression station downstream from said laminating station, said compression station configured to form at least one corner wall of the container.
2 . An apparatus in accordance with claim 1 , wherein said blank feeder assembly further comprises at least one rollover arm configured to at least partially fold a side panel of the blank.
3 . An apparatus in accordance with claim 1 , wherein said blank feeder assembly further comprises two opposing C-shaped funnel portions configured to capture and guide the blank to said laminating station.
4 . An apparatus in accordance with claim 1 , wherein said laminating station comprises:
a ledge squaring assembly including at least one squaring arm configured to square a ledge panel of said blank;
a squaring plate assembly including at least one squaring plate configured to square the ledge panel; and
a laminating assembly including at least one laminating plate and at least one laminating arm configured to seal at least a portion of the blank.
5 . An apparatus in accordance with claim 1 , wherein said compression station comprises a mandrel assembly comprising a plurality of end compression plates, wherein each end compression plate includes a miter corner face configured to form a corner wall of the container.
6 . An apparatus in accordance with claim 5 , wherein said mandrel assembly further comprises a spring-loaded side face.
7 . An apparatus in accordance with claim 1 , wherein said compression station comprises a compression assembly comprising a plurality of corner forming bars, wherein each corner forming bar is configured to form a corner wall of the container.
8 . An apparatus in accordance with claim 7 , wherein said compression assembly further comprises a plurality of tapering fingers configured to taper two opposing side walls of the container.
9 . An apparatus in accordance with claim 1 , further comprising a pusher lug configured to transport the blank through said apparatus.
10 . An apparatus in accordance with claim 1 , wherein said hopper assembly comprises at least one vacuum cup configured to retrieve the single blank.
11 . A method for forming a container, said method comprising:
transporting a blank through a container forming apparatus using a pusher lug;
folding at least one stacking tab in a blank feeder assembly using at least one tab bullet;
laminating at least a portion of the blank in a laminating assembly; and
compressing the blank using a mandrel assembly.
12 . A method in accordance with claim 11 , further comprising retrieving the blank from a hopper assembly.
13 . A method in accordance with claim 12 , wherein retrieving the blank comprises retrieving the blank using at least one vacuum cup.
14 . A method in accordance with claim 11 , further comprising at least partially folding a side panel of the blank in the blank feeder assembly using a rollover arm.
15 . A method in accordance with claim 14 , further comprising guiding the blank downstream using the rollover arm.
16 . A method in accordance with claim 11 , further comprising forming a ledge panel in a ledge squaring assembly using a ledge squaring arm and a squaring plate.
17 . A method in accordance with claim 11 , wherein laminating at least a portion of the blank comprises laminating at least a portion of the bank using a laminating plate and a laminating arm in the laminating assembly.
18 . A method in accordance with claim 11 , wherein compressing the blank comprises driving the blank through a compression assembly using the mandrel assembly, the compression assembly having a plurality of forming plates to form the container.
19 . A method in accordance with claim 11 , further comprising using two opposing C-shaped funnel portions to guide the blank from the blank feeder assembly into the laminating assembly.
20 . A method in accordance with claim 11 , further comprising manipulating a hand wheel to adjust a position of the blank feeder assembly.