Machine and method for forming reinforced polygonal containers from blanks

1. A method of forming a container from a blank of sheet material using a machine, the blank including a reinforcing panel assembly including a plurality of reinforcing panels separated by a plurality of fold lines, the plurality of reinforcing panels including a first reinforcing side panel, a second reinforcing side panel, and an inner end panel, the reinforcing panel assembly extending from a side edge of an end panel of the blank, the machine including a forming station, said method comprising:

forming a reinforcing corner assembly from the reinforcing panel assembly by folding the plurality of reinforcing panels about the plurality of fold lines by compressing the plurality of reinforcing panels into face-to-face relationship using a male forming member and a female forming member within the forming station;

compressing the first reinforcing side panel against the second reinforcing side panel, and the end panel against the inner end panel using the male forming member and the female forming member; and

rotating a first portion of the reinforcing panel assembly with respect to a second portion of the reinforcing panel assembly by forcing the first portion towards a miter plate using a guide bar to form the container, wherein the miter plate and the guide bar are positioned downstream from the male and female forming members.

2. The method in accordance with claim 1 , further comprising applying adhesive to predetermined panels of the reinforcing corner assembly as the reinforcing side panels are further rotated by the guide bar.

3. The method in accordance with claim 1 further comprising coupling the first and second reinforcing side panels of the reinforcing panel assembly to a side panel of the blank to further form the container.

4. The method in accordance with claim 1 , wherein the blank further includes a bottom panel having opposing side edges and opposing end edges, two opposing side panels each extending from one of the side edges of the bottom panel, two opposing end panels including the end panel, each end panel extending from one of the end edges of the bottom panel, said method further comprising rotating the side panels and the end panels to be substantially perpendicular to the bottom panel by directing the blank through a compression station within the forming station.

5. The method in accordance with claim 4 , further comprising maintaining an alignment of the reinforcing corner assembly as the end panel is rotated using support bars within the compression station.

6. The method in accordance with claim 4 , wherein the blank further includes an outer reinforcing corner panel extending from an end edge of one of the side panels, said method further comprising attaching the outer reinforcing corner panel to an exterior surface of the reinforcing corner assembly using a corner pusher within the compression station.

7. The method in accordance with claim 1 , wherein the machine includes a folder arm positioned adjacent to the male and female forming members, and wherein the reinforcing panel assembly further includes corner panels, said method further comprising:

rotating the inner end panel of the reinforcing panel assembly into face-to-face relationship with the end panel, the reinforcing side panels into face-to-face relationship, and the corner panels of the reinforcing panel assembly into face-to-face relationship by rotating the folder arm from a starting position to a folding position.

8. The method in accordance with claim 7 , further comprising:

contacting at least one of the inner end panel and reinforcing side panels with the male forming member as the inner end panel and reinforcing side panels are rotated by the folder arm; and

folding the inner end panel and reinforcing side panel about an interconnecting fold line with the male forming member.

9. The method in accordance with claim 1 , wherein said forming the reinforcing corner assembly further comprises rotating corner panels of the reinforcing panel assembly with respect to the end panel and the inner end panel of the reinforcing panel assembly and with respect to the reinforcing side panels to form the reinforcing corner assembly by compressing the male and female forming members together.

10. The method in accordance with claim 1 , wherein forcing the first portion of the reinforcing panel assembly towards the miter plate using the guide bar includes positioning the first portion between the miter plate and the guide bar as the blank is moved within the machine.

11. A method of forming a container from a blank of sheet material using a machine, the blank including a reinforcing panel assembly including a plurality of reinforcing panels separated by a plurality of fold lines, the plurality of reinforcing panels including at least one reinforcing side panel, the reinforcing panel assembly extending from a side edge of an end panel of the blank, the machine including an initial forming station and a secondary forming station, said method comprising:

rotating a first portion of the at least one reinforcing panel assembly with respect to a second portion of the at least one reinforcing panel assembly within the initial forming station;

transporting the blank from the initial forming station through the secondary forming station;

forming a reinforcing corner assembly from the reinforcing panel assembly by folding the plurality of reinforcing panels about the plurality of fold lines by compressing the plurality of reinforcing panels into face-to-face relationship using a male forming member and a female forming member within the secondary forming station; and

rotating a third portion of the reinforcing panel assembly with respect to a fourth portion of the reinforcing panel assembly by forcing the third portion towards a miter plate using a guide bar, wherein the miter plate and the guide bar are positioned downstream from the male and female forming members.

12. The method in accordance with claim 11 , wherein the blank further includes an end panel, wherein the plurality of reinforcing panels further include an inner end panel, and wherein the at least one reinforcing side panel includes a first reinforcing side panel and a second reinforcing side panel, said method further comprising compressing the first reinforcing side panel against the second reinforcing side panel, and the end panel against the inner end panel using the male forming member and the female forming member to form the container.

13. The method in accordance with claim 11 , further comprising applying adhesive to predetermined panels of the reinforcing corner assembly as the third portion is rotated by the guide bar.

14. The method in accordance with claim 11 further comprising coupling at least one of the first and second reinforcing side panels of the reinforcing panel assembly to a side panel of the blank to form the container.

15. The method in accordance with claim 11 , wherein the blank further includes a bottom panel having opposing side edges and opposing end edges, two opposing side panels each extending from one of the side edges of the bottom panel, two opposing end panels including the end panel, each end panel extending from one of the end edges of the bottom panel, said method further comprising rotating the side panels and the end panels to be substantially perpendicular to the bottom panel by directing the blank through a compression station within the secondary forming station.

16. The method in accordance with claim 15 , further comprising maintaining an alignment of the reinforcing corner assembly as the end panel is rotated using support bars within the compression station.

17. The method in accordance with claim 15 , wherein the blank further includes an outer reinforcing corner panel extending from an end edge of one of the side panels, said method further comprising attaching the outer reinforcing corner panel to an exterior surface of the reinforcing corner assembly using a corner pusher within the compression station.

18. The method in accordance with claim 11 , wherein the blank further includes an end panel, wherein the plurality of reinforcing panels further includes an inner end panel and corner panels, and wherein the machine includes a folder arm positioned adjacent to the male and female forming members, said method further comprising:

rotating the inner end panel of the reinforcing panel assembly into face-to-face relationship with the end panel, the reinforcing side panels into face-to-face relationship, and the corner panels of the reinforcing panel assembly into face-to-face relationship by rotating the folder arm from a starting position to a folding position.

19. The method in accordance with claim 18 , further comprising:

contacting at least one of the inner end panel and reinforcing side panels with the male forming member as the inner end panel and reinforcing side panels are rotated by the folder arm; and

folding the inner end panel and reinforcing side panel about an interconnecting fold line with the male forming member.

20. The method in accordance with claim 11 , wherein forcing the third portion of the reinforcing panel assembly towards the miter plate using the guide bar includes positioning the first portion between the miter plate and the guide bar as the blank is moved within the machine.