Methods and apparatus for forming a reinforced container

1. An apparatus for forming a container, said apparatus comprising:

a hopper assembly storing a plurality of blanks, wherein each blank includes a bottom panel, a pair of opposing end panels, at least one stacking tab, at least one inner side panel, and at least one outer side panel;

a transport mechanism positioned below said hopper assembly, said transport mechanism configured to transport a blank of the plurality of blanks from a first position to a second position;

a pair of opposing folding plows positioned below said hopper assembly, said folding plows configured to rotate the inner side panels and the stacking tabs of the blank as the blank is transported from the first position to the second position; and

at least one stacking tab bullet configured to move a respective stacking tab relative to a corresponding inner side panel while said corresponding inner side panel is in contact with at least one of said folding plows.

2. The apparatus according to claim 1 , wherein each stacking tab bullet is configured to extend at least partially through a corresponding folding plow.

3. The apparatus according to claim 2 , wherein said opposing folding plows are configured to maintain the plurality of stacking tabs in a partially folded position.

4. The apparatus according to claim 1 , further comprising an adhesive application assembly including at least one adhesive application device configured to apply adhesive to selected portions of the blank.

5. The apparatus according to claim 1 , further comprising a roller assembly including at least one set of rollers configured to transport the blank downstream through said apparatus.

6. The apparatus according to claim 1 , further comprising a laminating assembly positioned downstream of said hopper assembly, said laminating assembly comprising:

a pair of opposing squaring arms each including a first squaring edge;

a pair of opposing laminating plates; and

a pair of opposing squaring plates including a second squaring edge, wherein said squaring arms, said laminating plates, and said squaring plates are configured to square and laminate selected adjacent portions of the blank when the blank is positioned between each of said pair of opposing squaring arms, said pair of laminating plates, and said pair of squaring plates.

7. The apparatus according to claim 6 , further comprising a cam assembly positioned proximate said laminating assembly, said cam assembly comprising:

a cam follower coupled to each opposing squaring arm; and

a cam coupled to each cam follower, said cam including a circumference that when traced by said cam follower facilitates operation of said laminating assembly.

8. The apparatus according to claim 1 , further comprising a mandrel assembly positioned downstream of said hopper assembly, said mandrel assembly comprising:

a mandrel body; and

a mandrel drive coupled to said mandrel body, said mandrel drive configured to facilitate transition of said mandrel body between a first position proximate to the blank and a second position in which said mandrel body is biased against the bottom panel of the blank.

9. The apparatus according to claim 8 , said mandrel body comprising:

opposing spring-loaded side faces;

opposing end compression plates; and

a plurality of corner faces, wherein said opposing end compression plates and said plurality of corner faces are operated by an actuator to form at least a portion of the container.

10. The apparatus according to claim 1 , further comprising a compression assembly comprising:

a plurality of corner forming plates configured to form a corner wall of the container;

a plurality of side forming plates configured to form opposing side walls of the container; and

a plurality of end forming plates configured to form opposing end walls of the container.

11. The apparatus according to claim 10 , further comprising a conveyor assembly configured to receive the container from said compression assembly and transport the container out of said apparatus.

12. A method for forming a container, said method comprising:

transporting a blank from a first position to a second position within a hopper assembly using a transport mechanism positioned below the hopper assembly, wherein the blank includes a bottom panel, a pair of opposing end panels, at least one stacking tab, at least one inner side panel, and at least one outer side panel;

rotating the inner side panels and the stacking tabs using a pair of opposing folding plows as the blank is transported from the first position to the second position, wherein the pair of opposing folding plows are positioned below the hopper assembly; and

moving each stacking tab relative to a corresponding inner side panel using a respective stacking tab bullet while said corresponding inner side panel is in contact with at least one of said folding plows.

13. The method according to claim 12 , wherein moving each stacking tab relative to a corresponding inner side panel using a respective stacking tab bullet further comprises extending each stacking tab bullet at least partially through a corresponding folding plow.

14. The method according to claim 12 further comprising applying an adhesive to selected portions of the blank using an adhesive application assembly.

15. The method according to claim 12 further comprising transporting the blank downstream from the second position using a roller assembly.

16. The method according to claim 12 further comprising laminating at least a portion of the blank in a laminating assembly using at least one laminating plate, at least one squaring plate, and at least one squaring arm.

17. The method according to claim 16 further comprising controlling operation of the laminating assembly using a cam assembly, wherein the cam assembly includes at least one cam and at least one cam follower.

18. The method according to claim 17 wherein each cam follower is coupled to a respective squaring arm and wherein each cam follower traces a circumference of the cam to control operation of each squaring arm.

19. The method according to claim 12 further comprising biasing a mandrel assembly against the bottom panel of the blank such that the mandrel assembly drives the blank through a compression assembly having a plurality of forming plates that form the container.

20. The method according to claim 19 further comprising biasing a pair of opposing end compression plates against at least one of the plurality of forming plates to form at least one wall of the container therebetween.