Method and machine for forming containers having top flanges with glued corners

Abstract

A container forming apparatus for forming containers from blanks includes a blank transfer station including an adhesive assembly with multiple adhesive applicators, and a compression station downstream of the blank transfer station, the compression station including a vertically movable mandrel and a forming tool below the mandrel. The forming tool defines a cavity therein and has an inner profile complementary in shape to the outer profile of the mandrel. Hot melt adhesive is applied to the surface of the blank as it is transferred through the adhesive assembly. The blank is positioned below the mandrel, which feeds the blank downward into the cavity of the forming tool. A compression plate folds the panels of the blank, and the formed container includes a fully formed upper flange.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application is a continuation-in-part of International Patent Application No. PCT / US2022 / 036722, filed July 11, 2022, which claims priority to U.S. Provisional Patent Application No. 63 / 220,311, filed July 9, 2021, U.S. Provisional Patent Application No. 63 / 309,805, filed February 14, 2022, U.S. Provisional Patent Application No. 63 / 320,428, filed March 16, 2022, and U.S. Provisional Patent Application No. 63 / 248,039, filed September 24, 2021, each of which is incorporated by reference in its entirety.

[0002] The field of the disclosure relates generally to machines and methods for forming containers, and more particularly to machines for forming containers having a top flange with corners that are glued during the machine's formation of the container. [Background technology]

[0003] Containers come in a variety of forms. Certain conventional containers (e.g., boxes, punnets, trays, etc.) typically have an enclosed bottom portion with four sides. Some containers include a top portion or lid to close the container, while other containers are open at the top. In some cases, the container is formed, later filled with product, and then sealed with a film adhered across the top to close the container.

[0004] In some such cases, the containers are initially formed with open top portions so that they can be filled later. Often, such containers are formed, stacked or nested on top of one another, and shipped to another location for filling and / or sealing. In some cases, the containers include flanges around their upper edges, to which a sealing film is ultimately adhered. In some known containers that contain these flanges, the flanges are not formed at the same time the containers are initially formed. Rather, formed containers with flat (flangeless) sidewalls are stacked and shipped for filling. Once filled, the flanges of the containers are folded outward to form a sealing surface during the sealing process.

[0005] Other conventional containers may have flanges formed during the initial formation of the container, but the flanges are formed by simply bending the flanges into place, i.e., the flanges are not fastened or glued in place.

[0006] These known containers may be weak and prone to various portions of the flange disengaging from one another. Furthermore, such containers may have poor seals due to the proneness of the flanges to disengage, or may require stronger, longer-lasting seals that may be complex, time-consuming, and / or expensive to produce. Summary of the Invention [Means for solving the problem]

[0007] In one embodiment, a container-forming apparatus is provided for forming a container from a blank. The blank includes a bottom panel, two opposing side panels, two opposing end panels, four corner panels, and respective flange panels extending from upper edges of the end panels, side panels, and corner panels. The apparatus includes a blank-transfer station including an adhesive assembly including multiple adhesive applicators. The blank is transported through the adhesive assembly in a blank-transfer direction, with at least one of the adhesive applicators applying hot melt adhesive to an outer surface of the flange panel extending from the upper edge of the corner panel. The apparatus also includes a compression station downstream of the blank-transfer station, the compression station including a vertically movable mandrel and a forming tool below the mandrel, the forming tool defining a cavity therein and having an inner profile complementary in shape to the outer profile of the mandrel. The blank is positioned below a mandrel, which feeds the blank downward into a cavity of a forming tool, which rotates the corner panels inward to engage the mandrel and rotates the side and end panels inward to engage the mandrel. The compression station further includes a compression plate coupled to the mandrel. The compression plate rotates the flange panels outward to engage a top edge of the forming tool, which further compresses the flange panels extending from the top edges of the corner panels against the flange panels extending from the top edges of the side and end panels to form a container having a fully formed top flange.

[0008] In a further aspect, a method is provided for forming a container from a blank using a container-forming apparatus. The blank includes a bottom panel, two opposing side panels, two opposing end panels, four corner panels, and respective flange panels extending from upper edges of each of the end panel, side panel, and corner panel. The apparatus includes: (i) a blank transfer station including an adhesive assembly having a plurality of adhesive applicators; and (ii) a compression station downstream of the blank transfer station, the compression station including a vertically movable mandrel and a forming tool below the mandrel, the forming tool having an inner profile defining a cavity therein and complementary in shape to the outer profile of the mandrel. The method includes the steps of transferring the blank through the adhesive assembly, applying hot melt adhesive to the outer surfaces of the flange panels extending from the upper edges of the corner panels using the plurality of adhesive applicators, and positioning the blank below the mandrel. The method further includes using a mandrel to feed the blank downwardly into a cavity of a forming tool, the feeding causing the forming tool to (a) rotate the corner panels inwardly into engagement with the mandrel and (b) rotate the side and end panels inwardly into engagement with the mandrel. The method also includes using a compression plate coupled to the mandrel to rotate the flange panels outwardly into engagement with a top edge of the forming tool, and using the compression plate to compress the flange panels extending from the top edges of the corner panels against the flange panels extending from the top edges of the side and end panels to form a container having a fully formed top flange.

[0009] In another aspect, a container forming apparatus is disclosed for forming a container from a blank. The blank includes a bottom panel, two opposing side panels, two opposing end panels, respective end flange panels extending from the top edges of the respective end panels, respective end flange tabs extending from the respective side edges of the respective end flange panels, respective side flange panels extending from the top edges of the respective side panels, and respective side flange tabs extending from the respective end edges of the respective side flange panels. The apparatus includes a blank transfer station including an adhesive assembly having multiple adhesive applicators, and a compression station downstream of the blank transfer station. The blank is transported in the blank transfer direction through the adhesive assembly, where at least one of the adhesive applicators applies hot melt adhesive to the inner surfaces of the side flange tabs. The compression station includes a vertically movable mandrel and a forming tool below the mandrel, the forming tool defining a cavity therein and having an inner profile complementary in shape to the outer profile of the mandrel. The blank is positioned below a mandrel, which feeds the blank downward into a cavity of a forming tool, which rotates the end panels inward to engage the mandrel and rotates the side panels inward to engage the mandrel and the end panels. The compression station further includes end compression plates and side compression plates coupled to the mandrel. The side compression plates rotate the side flange panels outward to engage with the top edge of the forming tool, after which the end compression plates rotate the end flange panels outward to engage with the top edge of the forming tool, which further compresses the end flange tabs against the side flange tabs to form a container having a fully formed top flange.

[0010] In another aspect, a method is provided for forming a container from a blank using a container-forming apparatus. The blank includes a bottom panel, two opposing side panels, two opposing end panels, respective end flange panels extending from a top edge of each end panel, respective end flange tabs extending from a respective side edge of each end flange panel, respective side flange panels extending from a top edge of each side panel, and respective side flange tabs extending from a respective end edge of each side flange panel. The apparatus includes: (i) a blank transfer station including an adhesive assembly having a plurality of adhesive applicators; and (ii) a compression station downstream from the blank transfer station, the compression station including a vertically movable mandrel and a forming tool below the mandrel, the forming tool having an inner profile defining a cavity therein and complementary in shape to the outer profile of the mandrel. The method includes transporting a blank through an adhesive assembly, applying hot melt adhesive to the interior surfaces of the side flange tabs using a plurality of adhesive applicators, and positioning the blank below a mandrel. The method also includes using the mandrel to feed the blank downward into a cavity of a forming tool, the feeding step causing the forming tool to (a) rotate the end panels inwardly into engagement with the mandrel, and (b) rotate the side panels inwardly into engagement with the mandrel and with the end panels. The method further includes using side compression plates coupled to the mandrel to rotate the side flange panels outwardly to a parallel orientation relative to the bottom panel, and after the side flange panel rotating step, using end compression plates coupled to the mandrel to rotate the end flange panels to a parallel orientation relative to the bottom panel, and using the end compression plates to compress the end flange tabs against the side flange tabs to form a container having a fully formed top flange.

[0011] In other aspects, containers formed using such methods, and blanks for forming such containers, are also provided. [Brief explanation of the drawings]

[0012] [Figure 1] 1 is a top view of an exemplary blank of sheet material for forming a container according to the present disclosure. FIG. [Figure 2] 2 is a perspective view of an exemplary container formed from the blank shown in FIG. 1. [Figure 3] FIG. 3 is a side perspective view of a stack of multiple containers shown in FIG. 2. [Figure 4] FIG. 10 is a top view of another embodiment of a blank of sheet material for forming a container according to the present disclosure. [Figure 5] FIG. 5 is a perspective view of an exemplary container formed from the blank shown in FIG. 4. [Figure 6] FIG. 10 is a top view of another embodiment of a blank of sheet material for forming a container according to the present disclosure. [Figure 7] FIG. 10 is a top view of another embodiment of a blank of sheet material for forming a container according to the present disclosure. [Figure 8] FIG. 8 is a perspective view of an exemplary container formed from the blank shown in FIG. 7. [Figure 9] 1 is a flow diagram of a method of forming a container from a blank according to the present disclosure. [Figure 10] 1 is a perspective view of a container forming apparatus according to the present disclosure; [Figure 11] 11A-11C are various views of the blank feed station of the container forming apparatus shown in FIG. 10. [Figure 12] 11A-11C are various views of the blank feed station of the container forming apparatus shown in FIG. 10. [Figure 13] 11A-11C are various views of the blank feed station of the container forming apparatus shown in FIG. 10. [Figure 14]11A-11C are various views of the blank feed station of the container forming apparatus shown in FIG. 10. [Figure 15] 11A-11C are various views of the blank feed station of the container forming apparatus shown in FIG. 10. [Figure 16] 11 is a diagram depicting a blank transfer station of the container forming apparatus shown in FIG. 10. [Figure 17] 11 is a diagram illustrating a compression station of the container forming apparatus shown in FIG. 10. [Figure 18A] 11 is a diagram illustrating a compression station of the container forming apparatus shown in FIG. 10. [Figure 18B] 11 is a diagram illustrating a compression station of the container forming apparatus shown in FIG. 10. [Figure 19] 11 depicts a stacking station of the container forming apparatus shown in FIG. 10. [Figure 20] 11 depicts a stacking station of the container forming apparatus shown in FIG. 10. [Figure 21] 11 is a schematic block diagram of a control system of the container forming apparatus shown in FIG. 10. [Figure 22] FIG. 10 is a top view of another embodiment of a blank of sheet material for forming a container according to the present disclosure. [Figure 23] FIG. 23 is a perspective view of an exemplary container formed from the blank shown in FIG. 22. [Figure 24] FIG. 24 is a side perspective view of a stack of multiple containers shown in FIG. 23. [Figure 25] FIG. 10 is a top view of another embodiment of a blank of sheet material for forming a container according to the present disclosure. [Figure 26] FIG. 26 is a side view of an exemplary container formed from the blank shown in FIG. 25. [Figure 27] 11 is a perspective view of an alternative embodiment of the compression station of the container forming apparatus shown in FIG. 10. [Figure 28] FIG. 28 is an enlarged view of the compression station shown in FIG. 27. DETAILED DESCRIPTION OF THE INVENTION

[0013] The following detailed description illustrates the present disclosure by way of example, and not by way of limitation. This specification clearly enables one skilled in the art to make and use the present disclosure, describing several embodiments, adaptations, variations, and alternatives and utilizing the present disclosure, including what is currently contemplated to be the best mode of carrying out the disclosure.

[0014] Embodiments of the present disclosure provide stackable containers that include a top flange. The containers are constructed from blanks of sheet material using a machine and / or by hand. For example, the blanks can be folded around a mandrel to form the container, or the containers can be formed by hand and / or by another style tray forming machine. Alternatively, a folding / gluing machine can be used to form the container. In one embodiment, the containers are made from paperboard material. However, the containers can be made using any suitable material and are therefore not limited to a particular type of material. In alternative embodiments, the containers are made using cardboard, plastic, fiberboard, foam board, corrugated paper, and / or any suitable material known to those skilled in the art and guided by the teachings provided herein.

[0015] In an exemplary embodiment, the container includes at least one marking thereon, including, but not limited to, indicia identifying the product, its manufacturer, and / or its distributor. For example, the marking can include printed text identifying the product's name and briefly describing it, a logo and / or trademark identifying the manufacturer and / or distributor, and / or an attention-grabbing design and / or decoration. Any other forms of "printing," "printed," and / or "printing" as used herein can include, but are not limited to, inkjet printing, laser printing, screen printing, giclee, pen and ink, painting, offset lithography, flexography, relief printing, rotogravure printing, dye transfer, and / or any suitable printing technique known to those skilled in the art and guided by the teachings provided herein. In another embodiment, the container lacks marking (such as, but not limited to, indicia identifying the product, its manufacturer, and / or its distributor).

[0016] In some embodiments, the interior and / or exterior surfaces of the blank and the resulting container are coated or sealed. Such coating or sealing can make the container water-resistant or bacteria-resistant. In other embodiments, the seal or coating can help preserve the freshness of a product (e.g., a produce product) held within the container. In any embodiment, such coating or sealing can be applied to any section of any surface of the container.

[0017] Referring now to the drawings, and more particularly to FIG. 1, a top view of an exemplary embodiment of a blank 100 of sheet material is depicted. A container 200 (see FIG. 2) is formed from blank 100. Blank 100 has a first, or interior, surface 101 and an opposing second, or exterior, surface 103. Additionally, blank 100 defines a leading edge 102 and an opposing trailing edge 104. In one embodiment, blank 100 includes, in series, a first end panel 106, a bottom panel 108, and a second end panel 110, which are joined together along preformed, generally parallel fold lines 112 and 114, respectively.

[0018] More specifically, first end panel 106 extends from free edge 105 to fold line 112, bottom panel 108 extends from fold line 112 to fold line 114, and second end panel 110 extends from fold line 114 to free edge 107. As further described herein, when container 200 is formed from blank 100, fold line 112 defines a bottom edge of first end panel 106 and a first end edge of bottom panel 108, and fold line 114 defines a second end edge of bottom panel 108 and a bottom edge of second end panel 110.

[0019] The first side panel 116 extends from a fold line at a first side edge 118 of the bottom panel 108 to a fold line 120, and the opposing second side panel 122 extends from a fold line at a second side edge 124 of the bottom panel 108 to a fold line 126. As described further herein, when the container 200 is formed from the blank 100, the fold line at the first side edge 118 defines the bottom edge of the first side panel 116 and the first side edge of the bottom panel 108, and the fold line at the second side edge 124 defines the second side edge of the bottom panel 108 and the bottom edge of the second side panel 122.

[0020] In the exemplary embodiment, the first end panel 106, the second end panel 110, the first side panel 116, and the second side panel 122 include a plurality of cutouts 128 defined therein. In the exemplary embodiment, the cutouts 128 are leaf-shaped, with the first end panel 106, the second end panel 110, the first side panel 116, and the second side panel 122 each having six cutouts. Alternatively, the blank 100 can include any suitable number of cutouts 128 in any suitable shape and / or in any suitable location that enables the blank 100 and / or the container 200 to function as described herein. In still other embodiments, one or more of the panels 106, 110, 116, and 122 of the blank 100 may not have a cutout 128.

[0021] The first end panel 106 has a height H1, the second end panel 110 has a height H2, the first side panel 116 has a height H3, and the second side panel 122 has a height H4. In the exemplary embodiment, the height H1 of the first end panel 106, the height H2 of the second end panel 110, the height H3 of the first side panel 116, and the height H4 of the second side panel 122 are substantially the same. Additionally, the bottom panel 108 has a length L1 and a width W1. In the exemplary embodiment, the length L1 is greater than the width W1, such that the bottom panel 108 is rectangular. In alternative embodiments, the width W1 is substantially equal to or greater than the length L1.

[0022] In the exemplary embodiment, the side edges 170 of the end panels 106, 110 and the end edges 172 of the side panels 116, 122 are generally linear and extend at respective angles relative to the bottom panel 108. In other words, in the exemplary embodiment, the side edges 170 of the end panels 106, 110 are not parallel to the side edges 118, 124 of the bottom panel 108, and the end edges 172 of the side panels 116, 122 are not parallel to the end edges (at fold lines 112 and 114) of the bottom panel 108.

[0023] Thus, the first end panel 106, the second end panel 110, the first side panel 116, and the second side panel 122 each have a generally trapezoidal shape, with the panels 106, 110, 116, 122 tapering outward as they extend away from the bottom panel 108. That is, the width (not specifically shown) of each of the end panels 106, 110 adjacent the bottom panel 108 is less than the width (not specifically shown) of each of the end panels 106, 110 opposite the bottom panel 108. Similarly, the length (not specifically shown) of each of the side panels 116, 122 adjacent the bottom panel 108 is less than the length (not specifically shown) of each of the side panels 116, 122 opposite the bottom panel 108.

[0024] Alternatively, the first end panel 106, the second end panel 110, the first side panel 116, the second side panel 122, and / or the bottom panel 108 can have any suitable shape and / or any suitable dimensions that enable the blank 100 and / or the container 200 to function as described herein.

[0025] An interior side panel 130 (also referred to as a glue panel) extends from each side edge of each end panel 106, 110 at a respective fold line 132. As such, the blank 100 includes four interior side panels 130. Each interior side panel 130 has a respective free edge 178 opposite the respective fold line 132 from which the interior side panel 130 extends. In the exemplary embodiment, the free edge 178 includes multiple linear portions (e.g., four adjacent linear portions, etc.). In alternative embodiments, the free edge 178 can be partially or completely arcuate, or can have any suitable shape that enables the blank 100 and / or container 200 to function as described herein.

[0026] Additionally, a first end flange panel 134 extends from first end panel 106, and a second end flange panel 138 extends from second end panel 110. More specifically, first end flange panel 134 extends from free edge 105 to fold line 136 at the top edge of first end panel 106, and second end flange panel 138 extends from fold line 140 at the top edge of second end panel 110 to free edge 107.

[0027] The first and second flange panels 134, 138 include first and second end flange tabs 142, 144, respectively. The first and second end flange tabs 142 extend from respective fold lines 166 at respective side edges of the first end flange panel 134, and the second end flange tabs 144 extend from respective fold lines 168 at respective side edges of the second end flange panel 138. In the exemplary embodiment, the first and second end flange tabs 142, 144 each have a generally arcuate free outer edge 146 and a generally linear free inner edge 148. As described further herein with respect to the container 200, the shape of the free outer edge 146 generally defines the shape of the corners 218 (see FIG. 2 ) of the formed top flange 214 of the container 200 when the container 200 is formed from the blank 100. Thus, in various alternative embodiments, the first end flange tab 142 and the second end flange tab 144 can have any suitable shape that enables the blank 100 and / or container 200 to function as described herein.

[0028] First side flange panel 150 extends from first side panel 116, and second side flange panel 152 extends from second side panel 122. More specifically, first side flange panel 150 extends from fold line 120 to a free edge 154 (also referred to as the leading edge 102 or first side edge of blank 100), and second side flange panel 152 extends from fold line 126 to a free edge 156 (also referred to as the trailing edge 104 or second side edge of blank 100).

[0029] The first and second side flange panels 150, 152 include a first and second side flange tab 158, 160, respectively. The first side flange tab 158 extends from an end edge of each of the first side flange panels 150, and the second side flange tab 160 extends from an end edge of each of the second side flange panels 152. In the exemplary embodiment, each of the first and second side flange tabs 158, 160 has a generally arcuate free outer edge 162 and a generally linear free inner edge 164, respectively. As described further herein with respect to the container 200, the shape of the free outer edge 162 generally defines the shape of the corner 218 (see FIG. 2 ) of the formed top flange 214 of the container 200 when the container 200 is formed from the blank 100. Thus, in various alternative embodiments, the first side flange tab 158 and the second side flange tab 160 can have any suitable shape that enables the blank 100 and / or container 200 to function as described herein.

[0030] Also in the exemplary embodiment, first end flange tab 142 and second end flange tab 144 each include a respective notch 184 defined between its inner edge 148 and the side edge of the respective end flange panel 134 / 138 from which end flange tab 142 / 144 extends. Similarly, first side flange tab 158 and second side flange tab 160 each include a respective notch 186 defined between its inner edge 164 and the end edge of the respective side flange panel 150 / 152 from which side flange tab 158 / 160 extends. These notches 184, 186 improve the formation of the container 200 formed from the blank 100 by reducing interference between adjacent end flange tabs 142 / 144 and side flange tabs 158 / 160 when the blank 100 is folded into the container 200, as described further herein. Additionally, the notches 184, 186 can facilitate the folding and / or joining or mating of the respective flange panels and / or flange tabs.

[0031] In the exemplary embodiment, the side flange tabs 158, 160 are "deeper" or extend further inward toward the bottom panel 108 than the end flange tabs 142, 144. That is, the side flange tabs 158, 160 may have more extension horizontally (with respect to the view of FIG. 1) than the end flange tabs 142, 144 extend vertically (with respect to the view of FIG. 1).

[0032] In the exemplary embodiment, the fold lines 166, 168 adjacent the end flange tabs 142, 144 are generally aligned with the side edges 170 of the end panels 106, 110. That is, each end flange tab 142, 144 can be folded diagonally relative to the end flange panel 134 / 138 from which it extends. Additionally, the fold lines 180, 182 adjacent the side flange tabs 158, 160 are generally perpendicular to the fold lines 120, 126. That is, each side flange tab 158, 160 can be folded substantially perpendicular to the side flange panel 150 / 152 from which it extends. In other embodiments, the respective fold lines 166, 168, 180, 182 of the respective flange tabs 142, 144, 158, 160 can have any orientation that enables the blank 100 and / or container 200 to function as described herein.

[0033] In some embodiments, portions of the flange tabs 142, 144, 158, 160 have a reduced thickness so that corners 218 of the flange 214 (see FIG. 2) formed from the connected flange tabs have improved de-nesting characteristics when the container 200 is formed from the blank 100. The thickness of the flange tabs 142, 144, 158, 160 can be reduced by scoring, compressing, crushing, or the like, of one or more portions of the flange tabs 142, 144, 158, 160.

[0034] 2 is a perspective view of an exemplary container 200 formed from blank 100 (shown in FIG. 1). Container 200 includes a bottom wall 202, first and second opposing end walls 204, 206, and first and second opposing side walls 208, 210. Generally, the bottom wall 202 comprises the bottom panel 108 of the blank 100, the first end wall 204 comprises the first end panel 106, the second end wall 206 comprises the second end panel 110, the first side wall 208 comprises the first side panel 116 and two interior side panels 130 (one extending from each of the first and second end panels 106, 110), and the second end wall 210 comprises the second side panel 122 and two interior side panels 130 (one extending from each of the first and second end panels 106, 110). The end walls 204, 206, side walls 208, 210, and bottom wall 202 define a cavity 212 of the container 200 for receiving and holding a product (not shown) therein.

[0035] In the exemplary embodiment, due to the trapezoidal shape of panels 106, 110, 116, and 122, first and second end walls 204, 206 and first and second side walls 208, 210 extend obliquely away from bottom wall 202. Specifically, in one embodiment, each end wall 204, 206 and each side wall 208, 210 each form an internal angle with bottom wall 202 that is greater than about 90 degrees. That is, in the exemplary embodiment, walls 204, 206, 208, 210 of the formed container 200 are generally angled outward (i.e., away from) bottom wall 202 of container 200. Thus, the resulting container 200 is generally in the shape of a trapezoidal prism or a truncated pyramid. However, in alternative embodiments, the end walls 204, 206 and side walls 208, 210 may form any angle with the bottom wall 202 that enables the blank 100 and / or container 200 to function as described herein.

[0036] The container 200 also includes a flange 214 extending from the top of each of the first and second end walls 204, 206 and the first and second side walls 208, 210. In the exemplary embodiment, the flange 214 extends outward (or away from the cavity 212) and is bounded by a free edge 216, which includes both straight and arcuate segments; specifically, the corners 218 of the flange 214 are generally arcuate. In the exemplary embodiment, the flange 214 is oriented parallel to the bottom wall 202. Due to the orientation of the walls of the container 200, the flange 214 is oriented obliquely relative to the first and second end walls 204, 206 and the first and second side walls 208, 210. Alternatively, the flange 214 may extend in any direction and may have any suitable shape that enables the blank 100 and / or container 200 to function as described herein.

[0037] The container 200 is formed by folding the various panels and tabs of the blank 100 along respective fold lines. Specifically, each interior side panel 130 is rotated about fold line 132 toward the interior surface 101 of the respective end panel 106, 110 so that each interior side panel 130 is substantially perpendicular to the respective end panel 106, 110. The first and second end panels 106, 110 are rotated about fold lines 112 and 114, respectively, toward the interior surface 101 of the bottom panel 108 to form first and second end walls 204, 206, respectively. In one embodiment, the first and second end panels 106, 110 are rotated to form an angle greater than 90 degrees with respect to the bottom panel 108. However, in alternative embodiments, the first and second end panels 106, 110 may form any angle with the bottom panel 108 that enables the blank 100 and / or container 200 to function as described herein.

[0038] The first side panel 116 is rotated about fold line 118 toward the interior surface 101 of the bottom panel 108 so as to face the exterior surfaces 103 of the two interior side panels 130. Similarly, the second side panel 122 is rotated about fold line 124 toward the interior surface 101 of the bottom panel 108 so as to face the exterior surfaces 103 of the other two interior side panels 130. In one embodiment, the first and second side panels 116, 122 are rotated to form an angle greater than 90 degrees with the bottom panel 108. However, in alternative embodiments, the first and second side panels 116, 122 can be rotated to form any angle with the bottom panel 108 that enables the blank 100 and / or container 200 to function as described herein.

[0039] In the exemplary embodiment, adhesive (specifically, a hot melt adhesive) is applied to the end portions of the interior surfaces 101 of the first and second side panels 116, 122. Thus, when these panels 116, 122 are rotated into face-to-face contact with the interior side panel 130, the end portions of the interior surfaces 101 of the panels 116, 122 are respectively coupled and adhered to the exterior surface 103 of the interior side panel 130, thereby forming the end walls 204, 206 and the side walls 208, 210.

[0040] In alternative embodiments, adhesive can be applied to the interior surface 101 of the interior side panel 130. In such cases, the side panels 116, 122 can be rotated into position first, and the end panels 106, 110 can be rotated thereafter, such that the interior side panel 130 is coupled and adhered to the exterior surface 103 of the side panels 116, 122. In further alternative embodiments, the interior side panels can instead extend from the side panels 116, 122; in such cases, adhesive can be applied, and the panels 106, 110, 116, 122 can be rotated in any suitable order to form the container 200.

[0041] Additionally, substantially simultaneously with the formation of the walls of the container 200 (e.g., during the same forming step), the side flange panels 150, 152 are rotated outward (e.g., away from the bottom wall 202) about the fold lines 120, 126, respectively, until the side flange panels 150, 152 are parallel to the bottom wall 202. The side flange tabs 158, 160 are moved along with the side flange panels 150, 152. That is, the rotation of the side flange panels 150, 152 results in the simultaneous rotation of the side flange tabs 158, 160 to a parallel orientation relative to the bottom wall 202.

[0042] In one exemplary embodiment, the walls of the container 200 are formed substantially simultaneously with the rotation of the side flange panels 150, 152. However, the rotation of the side flange panels 150, 152 can occur prior to or during the folding of the end panels 106, 110 to form the side walls 204, 206. In particular, the side flange panels 150, 152 are folded to avoid interference between the end flange tabs 142, 144 and the side flange tabs 158, 160 at the corners of the partially formed container. Even more specifically, because the end flange tabs 142, 144 are "shorter" or "shallower" than the side flange tabs 158, 160 (e.g., their inner edges extend less than the inner edges of the side flange tabs 158, 160), the inner edges of the end flange tabs 142, 144 do not "catch" on the folded side flange tabs 158, 160 when the end panels 106, 110 are folded inward to form the side wall portions 204, 206.

[0043] In a separate step (e.g., after a predetermined amount of time, which may be from a few milliseconds to a few seconds), end flange panels 134, 138 are rotated outward (e.g., away from bottom wall 202) about fold lines 136, 140, respectively, until end flange panels 134, 138 are parallel to bottom wall 202. End flange tabs 142, 144 are moved along with end flange panels 134, 138. That is, the rotation of end flange panels 134, 138 results in the simultaneous rotation of end flange tabs 142, 144 to a parallel orientation relative to bottom wall 202. Moreover, this rotation of end flange panels 134, 138 couples outer surfaces 103 of end flange tabs 142, 144 into a face-to-face relationship with inner surfaces 101 of side flange tabs 158, 160 (which are already in their final positions because they were previously rotated).

[0044] In particular, in the exemplary embodiment, an adhesive (e.g., a hot melt adhesive, etc.) is applied to the interior surfaces 101 of the side flange tabs 158, 160 prior to the formation of the container 200 (e.g., simultaneously with the application of adhesive to the side panels 116, 122). Thus, when the side flange panels 150, 152 are rotated followed by the rotation of the end flange panels 134, 138, the exterior surfaces 103 of the end flange tabs 142, 144 are coupled and adhered to the interior surfaces 101 of the side flange tabs 158, 160.

[0045] Thereafter, the end flange panels 134, 138, side flange panels 150, 152, end flange tabs 142, 144, and side flange tabs 158, 160 are appropriately oriented and secured to form the flange 214. A flange corner 218 is formed at the overlap of the corresponding end flange tabs 142, 144 and side flange tabs 158, 160. In exemplary embodiments, the flange 214 (also referred to as the "top flange") is substantially flat or planar and is stronger than conventional flanges that are not glued (or are not glued until the container is sealed). In at least some cases, if the end flange tabs 142, 144 and / or the side flange tabs 158, 160 are characterized by a reduced thickness, the overall flange 214 can be even more desirably planar, which can improve the sealing characteristics and / or rigidity of the container 200.

[0046] Once formed, the containers 200 are nested or stacked for storage and / or transportation (see stack 300 of containers 200 shown in FIG. 3). In some cases, these containers 200 are ultimately used to hold various objects. In some embodiments, the stack 300 of containers 200 is delivered to a filling location, where individual containers 200 are removed from the stack 300. As described herein, flange corners 218 of the containers 200 (including end flange tabs 142, 144 and / or side flange tabs 158, 160 that are embossed and / or feature a reduced thickness) can improve the de-nesting characteristics of the containers 200.

[0047] The open, empty, de-nested container 200 is then filled with product (e.g., produce). A film 220 is placed across the top of the container 200 and sealed against the flange 214 to form a seal. The film 220 can be coupled and adhered to the flange 214 using any suitable method or material (e.g., adhesive, heat sealing, etc.).

[0048] As explained elsewhere herein, the flange 214 of the container 200 provides a structural advantage over the flanges of similar containers. That is, applying an adhesive to the side flange tabs 158, 160 to connect the end flange tabs 142, 144 to the side flange tabs 158, 160 during the initial formation of the container 200 improves both the structural integrity and sealing capabilities of the container 200. While conventional containers may have top flanges, as explained above, such conventional containers are not formed in the same manner as the container 200 (i.e., do not include a formed flange or do not have adhesive applied to join the flange tabs during the initial container formation), and therefore, the container 200 provides an improvement over known conventional containers.

[0049] Applying adhesive when connecting the end flange tabs 142, 144 to the side flange tabs 158, 160 reinforces and strengthens the corners 218 of the flange 214, thus improving the structural rigidity of the container 200. For example, the container 200 may be able to hold a heavier weight of product and / or more effectively prevent liquid leakage. Such improvements may also reduce the risk of structural failure of the container 200 when filled and sealed. Additionally, such reinforcement promotes improved sealing of the container 200. Moreover, the flange 214 may be substantially flatter than flanges of conventional containers. Such a flange 214 allows for easier, faster, simpler, and / or more cost-effective (e.g., using less sealing material) application of a sealing film to the sealed container 200. These improvements allow the container 200 to function more effectively than other conventional containers.

[0050] Figure 4 is a top view of an alternative blank 400 of sheet material for forming a container 500 (see Figure 5). Blank 400 is substantially similar to blank 100 (shown in Figure 1), except as described below. As such, components common to blank 100 and blank 400 are labeled with the same reference numerals.

[0051] In one embodiment, the blank 400 includes cutouts 402 extending from the fold lines 112, 114, 118, 120, 124, 126, 136, 140 into each of the first end panel 106, second end panel 110, first side panel 116, and second side panel 122. In this embodiment, the cutouts 402 have a generally rectangular shape adjacent the fold lines 112, 114, 118, 120, 124, 126, 136, 140 and a generally semicircular shape at the opposite ends. In the exemplary embodiment, each end panel 106, 110 contains four cutouts 402 and each side panel contains five cutouts 402. In alternative embodiments, blank 400 can include any suitable number of cutouts 402 in any suitable location having any suitable shape that enables blank 400 and / or container 500 to function as described herein.

[0052] In one embodiment, the blank 400 also includes interior side panels 430 having a different overall shape than the interior side panels 130 of the blank 100. The interior side panels 430 of the blank 400 have free edges 178 opposite the fold lines 132, the free edges 178 including a plurality of linear and curved portions. Among other things, each free edge 178 includes a curved notch 404 to prevent the interior side edges 430 from covering or otherwise interfering with the cutouts 402 in the side panels 116, 122 when the container 500 is formed from the blank. That is, the curved notches 404 in the interior side panels 430 keep the interior side panels 430 from overlapping with the cutouts 402 in the side panels 116, 122. In alternative embodiments, one or more of the free edges 178 can have any suitable shape that enables the blank 400 and / or container 500 to function as described herein.

[0053] Additionally, the bottom panel 108 of blank 400 is smaller and more square-shaped than the bottom panel 108 of blank 100. In the exemplary embodiment, like blank 100, blank 400 includes end flange tabs 142, 144 and side flange tabs 158, 160. However, in blank 400, the fold lines 166, 168, 180, 182 that demarcate the flange tabs are angled so that each flange tab 142, 144, 158, 160 can be folded perpendicular to its respective flange panel 134, 138, 150, 152. In other embodiments, the fold lines 166, 168, 180, 182 can have any orientation that enables blank 400 and / or container 500 to function as described herein.

[0054] 5 is a perspective view of an exemplary container 500 formed from blank 400 (shown in FIG. 4). Container 500 is substantially similar to container 200 (shown in FIG. 2) and is formed from blank 400 using methods similar to forming container 200 from blank 100. Container 500 can have different dimensions than container 200.

[0055] 6 is a top view of an alternative blank 600 of sheet material for forming a container. Blank 600 is substantially similar to blank 100 (shown in FIG. 1), except as described below. As such, components common to blank 100 and blank 600 are labeled with the same reference numerals.

[0056] In one embodiment, blank 600 includes cutouts 602 extending along fold lines 112, 114, 118, 124, 120, 126, 136, and 140. Additionally, fold line 604 between side panels 116, 122 and interior end panel 606 (described further herein) also has cutouts 602 extending therethrough. In the exemplary embodiment, cutouts 602 have a general "stadium" shape. In alternative embodiments, blank 600 can include any suitable number of cutouts 602 having any suitable shape that enables blank 600 and / or any container formed therefrom to function as described herein.

[0057] In one embodiment, the blank 600 also includes interior end panels 606 that extend along fold lines 604 from the end edges of the first and second side panels 116, 122, rather than from the interior side panels 130 of the blank 100. As such, in the exemplary embodiment, the blank 600 includes four interior end panels 606. In the exemplary embodiment, the interior end panels 606 have a different overall shape than the interior side panels 130 of the blank 100. In the exemplary embodiment, the interior end panels 606 have free edges 608 opposite the fold lines 604, the free edges 608 including a plurality of linear and / or curved portions. In alternative embodiments, one or more of the free edges 608 can have any suitable shape that enables the blank 600 and / or any container formed therefrom to function as described herein.

[0058] In the exemplary embodiment, each end panel 106, 110 has a notch 610 formed in its side edge. In the exemplary embodiment, when the container 700 is formed from the blank 600, the notch 610 accommodates the cutout 602 in the interior end panel 606 of the blank 600. That is, when formed, the notch 610 prevents the end panels 106, 110 from overlapping the cutout 602 in the interior end panel 606.

[0059] Additionally, the blank 600 includes notches 612 formed in the side panels 116, 122 between the bottom edge of the inner end panel 606 and the fold lines 118 / 124. The notches 612 can facilitate folding and / or joining or mating of the respective flange panels and / or flange tabs.

[0060] In this exemplary embodiment, the end flange tabs 142, 144 and side flange tabs 158, 160 of the blank 600 do not include notches 182 / 184 and are of a different general shape than the flange tabs in the blank 100. In the blank 600, each flange tab 142, 144, 158, 160 has a respective free edge 146, which includes a curved portion and a straight portion. Additionally, the fold lines 166, 168, 180, 182 that define each flange tab 142, 144, 158, 160 are angled to allow each flange tab 142, 144, 158, 160 to be folded diagonally relative to its respective flange panel 134, 138, 150, 152.

[0061] A container formed from blank 600 is formed in a manner similar to container 200, with inner end panel 606 of blank 600 folded in a manner similar to inner side panel 130 of blank 100, but connected to end panels 106, 110 instead of side panels 116, 122.

[0062] FIG. 7 is a top view of an alternative blank 800 of sheet material for forming a container.

[0063] In the exemplary embodiment, similar to blank 100, blank 800 includes a first end panel 802, a second end panel 804, a first side panel 806, a second side panel 808, and a bottom panel 810. First end panel 802, second end panel 804, first side panel 806, and second side panel 808 each have a generally trapezoidal shape, and bottom panel 810 has a generally rectangular shape with chamfered corners. Thus, in the exemplary embodiment, bottom panel 810 has eight edges. Also, like blank 100, blank 800 includes a first end flange panel 812, a second end flange panel 814, a first side flange panel 816, and a second side flange panel 818, as well as a first end flange tab 820, a second end flange tab 822, a first side flange tab 824, and a second side flange tab 826.

[0064] In the exemplary embodiment, flange tabs 820, 822, 824, 826 of blank 800 have a different size and overall shape than the flange tabs of blank 100. Notably, flange tabs 820, 822, 824, 826 each have a respective free end edge 828 that includes a plurality of straight and / or curved lines. In the exemplary embodiment, flange tabs 820, 822, 824, 826 also each include a respective notch 830 positioned on its respective inner edge 832. Flange tabs 820, 822, 824, 826 can have any suitable shape that enables blank 800 and / or container 900 to function as described herein.

[0065] Also, in the exemplary embodiment, blank 800 includes corner panels 834 extending from fold lines 836 at the chamfered or angled corners of bottom panel 810. Interior corner panels 838 (also referred to as glue panels) extend from each side edge of each corner panel 834. As such, in the exemplary embodiment, blank 800 includes eight interior corner panels 838. Each interior corner panel 838 extends from the side edge of its respective corner panel 834 at fold lines 840 (for clarity, only one fold line 840 is labeled in FIG. 7 ).

[0066] Additionally, the corner panels 834 of the blank 800 each include a corner flange panel 842. Each corner flange panel 842 extends from a respective fold line 844 to a free edge 845 at the top of the respective corner panel 834. A corner flange tab 846 extends from a respective end edge of each corner flange panel 842. In the exemplary embodiment, the corner flange tabs 846 are each bounded by a fold line 848 as well as a free edge 849. In the exemplary embodiment, the corner flange tabs 846 also include a notch 850 defined in their inner edges. The fold line 848 bounding each corner flange tab 846 is angled to allow each corner flange tab 846 to be folded diagonally relative to its respective corner flange panel 842. In other embodiments, the fold line 848 can have any orientation that enables the blank 800 and / or container 900 to function as described herein.

[0067] In the exemplary embodiment, similar to blank 100, first end panel 802, second end panel 804, first side panel 806, and second side panel 808 include a plurality of cutouts 852 defined therein. Specifically, first and second end panels 806, 808 each include three cutouts 852 positioned near fold lines 854, 856, and first and second side panels 806, 808 each include four cutouts 852 positioned near fold lines 858, 860. Alternatively, blank 800 can include any suitable number of cutouts 852 of any suitable shape and / or in any suitable location that enables blank 800 and / or container 900 to function as described herein.

[0068] In some embodiments, portions of the flange tabs 820, 822, 824, 826, 846 have a reduced thickness so that corners 918 (see FIG. 8) of the flange 914 formed from the coupled flange tabs have improved de-nesting characteristics when the container 900 is formed from the blank 800. The thickness of the flange tabs 820, 822, 824, 826, 846 can be reduced by scoring, compressing, crushing, and the like, of one or more portions of the flange tabs.

[0069] 8 is a perspective view of an exemplary octagonal container 900 formed from blank 800 (shown in FIG. 7). Container 900 includes a bottom wall 902, first and second opposing end walls 904, 906, first and second opposing side walls 908, 910, and four angled corner walls 920. Generally, the bottom wall 902 comprises the bottom panel 810 of the blank 800, the first end wall 904 comprises the first end panel 802 and two interior corner panels 838, the second end wall 906 comprises the second end panel 804 and two interior corner panels 838, the first side wall 908 comprises the first side panel 806 and two interior corner panels 838, and the second end wall 910 comprises the second side panel 808 and two interior corner panels 838, and each corner wall 920 comprises one of the corner panels 834. The end walls 904, 906, side walls 908, 910, corner walls 920, and bottom wall 902 define a cavity 912 of the container 900 for receiving and holding a product (not shown) therein. Like container 200, the walls of container 900 are oriented obliquely at an angle greater than 90 degrees relative to bottom wall 902. In the exemplary embodiment, bottom wall 902 of container 900 has a generally rectangular shape with straight, chamfered corners. Thus, bottom wall 902 of container 900 includes eight sides. Alternatively, container 900 can have any suitable shape and / or dimensions that enable blank 800 and / or container 900 to function as described herein.

[0070] The container 900 also includes a flange 914 extending from the top of the walls 904, 906, 908, 910, and 920. In the exemplary embodiment, the flange 914 extends outward (or away from the cavity 912) and is bounded by a free edge 916, which includes both straight and arcuate segments; specifically, the corners 918 of the flange 914 formed by the corner flange panels 842 are generally arcuate. In the exemplary embodiment, the flange 914 is oriented parallel to the bottom wall 902. Due to the orientation of the walls of the container 900, the flange 914 is oriented at an angle relative to the walls 904, 906, 908, 910, and 920. Alternatively, the flange 914 can extend in any direction and have any suitable shape that enables the container 900 to function as described herein.

[0071] The container 900 is formed by folding the various panels and tabs of the blank 800 along respective fold lines. Specifically, the corner panel 834 is rotated inward (toward the bottom panel 810) about fold line 836, and the interior corner panel 838 is rotated inward (toward its respective corner panel 834) about fold line 840. The first side panel 806 is rotated toward the interior surface of the bottom panel 810 about approximately fold line 858, and the second side panel 808 is rotated toward the interior surface of the bottom panel 810 about fold line 860. Each of the first side panel 806 and the second side panel 808 is coupled to the two respective interior corner panels 834 using an adhesive (e.g., a hot melt adhesive, etc.) to form side walls 908, 910. The first end panel 802 is rotated toward the interior surface of the bottom panel 810 about fold line 854, and the second end panel 804 is rotated toward the interior surface of the bottom panel 810 about fold line 856. Each of the first end panel 802 and second end panel 804 is coupled to two respective interior corner panels 838 using an adhesive (e.g., a hot melt adhesive, etc.) to form end walls 904, 906. The first side panel 806, second side panel 808, first end panel 802, and second end panel 804 can be rotated about fold lines 858, 860, 854, 856, respectively, and attached to the interior corner panels 838 in any order that enables the blank 800 and / or container 900 to function as described herein.

[0072] Additionally, substantially simultaneously with the formation of the walls of the container 900 (e.g., during the same formation step), the end flange panels 812, 814 and side flange panels 816, 818 are rotated outward (e.g., away from the bottom wall 902) until the flange panels 812, 814, 816, 818 are parallel to the bottom wall 902. This rotation of the flange panels 812, 814, 816, 818 results in the simultaneous rotation of the flange tabs 820, 822, 824, 826 to a parallel orientation relative to the bottom wall 202.

[0073] In a separate step (e.g., after a predetermined amount of time, which may be from a few milliseconds to a few seconds), corner flange panel 842 is rotated outward about fold line 844 until corner flange panel 842 is substantially parallel to bottom panel 810. The rotation of corner flange panel 842 results in a simultaneous rotation of corner flange tab 846 to a parallel orientation relative to bottom wall 202. Moreover, this rotation of corner flange panel 842 connects corner flange tab 846 in an overlapping relationship with end and side flange tabs 820, 822, 824, 826 (which are already in their final positions because they were previously rotated).

[0074] In particular, in the exemplary embodiment, an adhesive (e.g., a hot melt adhesive, etc.) is applied to the interior surfaces of the end and side flange tabs 820, 822, 824, 826 prior to formation of the container 900. Thus, when the end and side flange panels 812, 814, 816, 818 are rotated followed by the corner flange panel 842, the exterior surfaces of the corner flange tabs 846 are coupled and adhered to the interior surfaces of the corresponding end and side flange tabs 820, 822, 824, 826.

[0075] When formed using the methods described herein, container 900 includes the same advantages as container 200. Specifically, flange 914 (also referred to as the "top flange") is substantially flat or planar and is more sturdy compared to conventional flanges that are not glued (or are not glued until the container is sealed). In at least some cases, if any flange tabs 820, 822, 824, 826, and / or 846 feature a reduced thickness, the overall flange 914 can be even more desirably planar, which can improve the sealing qualities and / or rigidity of container 900.

[0076] Once formed, the containers 900 are nested or stacked for storage and / or transportation. In some cases, these containers 900 are ultimately used to hold various objects. In some embodiments, a stack of containers 900 is delivered to a filling location, where individual containers 900 are removed from the stack. As described herein, flange corners 918 of the containers 900 (including flange tabs 820, 822, 824, 826, and / or 846 that are embossed and / or feature reduced thickness) can improve the de-nesting characteristics of the containers 900.

[0077] The open, empty, de-nested container 900 is then filled with product (e.g., produce). A film (not shown) is placed across the top of the container 900 and sealed against the flange 914 to form a seal. The film can be connected and adhered to the flange 914 using any suitable method or material (e.g., adhesive, heat sealing, etc.). As described elsewhere herein, the flange 914 of the container 900 provides a structural advantage over the flanges of similar conventional containers. That is, applying adhesive to the end and side flange tabs 820, 822, 824, 826 to connect the corner flange tabs 846 to the end and side flange tabs 820, 822, 824, 826 during the initial formation of the container 900 improves both the structural integrity and sealing capabilities of the container 900. Conventional containers may have an upper flange, but as explained above, such conventional containers are not formed in the same manner as container 900 (i.e., do not include a formed flange or do not have adhesive applied to join the flange tabs during initial container formation), and therefore container 900 provides an improvement over known conventional containers.

[0078] Applying adhesive when connecting the end and side flange tabs 820, 822, 824, 826 to the corner flange tab 846 reinforces and strengthens the corners 918 of the flange 914, thus improving the structural rigidity of the container 900. For example, the container 900 may be able to hold a heavier weight of product and / or more effectively prevent liquid leakage. Such improvements may also reduce the risk of structural failure of the container 900 when filled and sealed. Additionally, such reinforcement promotes improved sealing of the container 900. Moreover, the flange 914 may be substantially flatter than flanges of conventional containers. Such a flange 914 allows for easier, faster, simpler, and / or more cost-effective (e.g., using less sealing material) application of a sealing film to the sealed container 900. These improvements allow the container 900 to function more effectively than other conventional containers.

[0079] FIG. 22 is a top view of an alternative blank 1700 for forming a container 1800 (see FIG. 23).

[0080] In the exemplary embodiment, similar to blank 800, blank 1700 includes a first end panel 1702, a second end panel 1704, a first side panel 1706, a second side panel 1708, and a bottom panel 1710. Bottom panel 1710 has a generally rectangular shape with chamfered corners, giving it eight edges in the exemplary embodiment. Blank 1700 also includes a first end flange panel 1712, a second end flange panel 1714, a first side flange panel 1716, and a second side flange panel 1718.

[0081] The blank 1700 also includes corner panels 1720 extending from chamfered corner fold lines 1722 of the bottom panel 1710. An interior corner panel 1724 extends from a respective side edge 1726 of each corner panel 1720. Each corner panel 1720 further includes a corner flange tab 1728 that includes a curved outer edge 1730 and additionally forms a notch 1732 on an inner edge adjacent the corner panel 1720. The corner flange tabs 1728 can have any suitable shape that enables the blank 1700 and / or container 1800 to function as described herein. Each of the first and second end panels 1702, 1704 and the first and second side panels 1706, 1708 further includes a de-nesting tab 1736 positioned on either side of the respective panel 1702, 1704, 1706, 1708. The de-nesting tabs 1736 are provided adjacent the flange panels 1712, 1714, 1716, 1718. In the exemplary embodiment, eight de-nesting tabs 1736 are included, although other embodiments may include any suitable number of de-nesting tabs. The de-nesting tabs 1736 extend along the flange panels 1712, 1714, 1716, 1718 away from the respective panels 1702, 1704, 1706, 1708. A recess 1738 is defined along a bottom edge 1740 of the de-nesting tab 1736.

[0082] FIG. 23 is a perspective view of an exemplary octagonal container 1800 formed from blank 1700 (shown in FIG. 22 ). Container 1800 is substantially similar to container 900 (shown in FIG. 8 ) and is formed from blank 1700 using a method similar to forming container 900 from blank 800. Container 1800 may have different dimensions than container 900 and further includes a de-nesting tab 1736. Container 1800 includes a bottom wall (not shown), first and second end walls 1802, 1804, first and second side walls 1806, 1808, and four corner walls 1810. The bottom wall (not shown) includes a bottom panel 1710. The first end wall 1802 includes a first end panel 1702 and two interior corner panels 1724. The second end wall 1804 includes a second end panel 1704 and two interior corner panels 1724. The first side wall 1806 includes a first side panel 1706 and two interior corner panels 1724. The second side wall 1808 includes a second side panel 1708 and two interior corner panels 1724. The end walls 1802, 1804, side walls 1806, 1808, corner walls 1810, and a bottom wall (not shown) form a cavity 1812. The container 1800 also has a flange 1814 extending from the tops of the walls 1802, 1804, 1806, 1808, and 1810. The flange 1814 extends transversely outward from the cavity 1812.

[0083] The container 1800 includes a de-nesting tab 1736 that extends from each end of a respective wall 1802, 1804, 1806, 1808 at an acute angle in the plane of the respective wall 1802, 1804, 1806, 1808 relative to the corner wall 1810. The de-nesting tab 1736 does not extend beyond the plane 1816 defined by the edge of the flange 1814.

[0084] FIG. 20 is a perspective view of a stack 1900 of multiple containers 1800, where the containers 1800 are nested or stacked for storage and / or transport. The bottom edge 1740 of each de-nesting tab 1736 rests along the top surface of the flange 1814 of the underlying container 1800. This arrangement creates a space 1902 between each flange 1814 of each container 1800. The space 1902 is essentially equal between each container 1800 and is defined by the height of the de-nesting tab 1736. The space 1902 prevents the flanges 1814 from directly contacting each other. In some cases, the flanges 1814 may have excess glue from the process of forming the containers 1800. Preventing the flanges from contacting each other prevents any excess glue from causing the containers 1800 to stick together in this stacked configuration. In other cases, the spaces 1902 can prevent the containers 1800 from being compressed together. Once the containers are compressed, it can result in additional friction between the surfaces of the containers 1800, making it more difficult to separate the containers 1800. Additionally, the sizing of the spaces 1902 can be selected to provide sufficient clearance for a worker or machine to pull individual containers 1900 from the stack 1900, allowing the containers 1800 to be separated by the worker or machine.

[0085] FIG. 25 is a top view of an alternative blank 2000 for forming a container 2100 (see FIG. 26).

[0086] In the exemplary embodiment, similar to blank 800 and / or blank 1700, blank 2000 includes a first end panel 2002, a second end panel 2004, a first side panel 2006, a second side panel 2008, and a bottom panel 2010. Bottom panel 2010 has a generally rectangular shape with chamfered corners, giving it eight edges in the exemplary embodiment. Blank 2000 also includes a first end flange panel 2012, a second end flange panel 2014, a first side flange panel 2016, and a second side flange panel 2018.

[0087] The blank 2000 also includes corner panels 2020 extending from fold lines 2022 at the chamfered corners of the bottom panel 2010. An interior corner panel 2024 extends from a respective side edge 2026 of each corner panel 2020. Each corner panel 2020 further includes a corner flange tab 2028, which includes a curved outer edge 2030 and additionally forms a notch 2032 on an inner edge adjacent the corner panel 2020. The corner flange tab 2028 can have any suitable shape that enables the blank 2000 and / or container 2100 to function as described herein. Each of the first and second end panels 2002, 2004 and the first and second side panels 2006, 2008 further includes a de-nesting tab 2036 positioned on either side of the respective panel 2002, 2004, 2006, 2008. The de-nesting tabs 2036 are provided adjacent the flange panels 2012, 2014, 2016, 2018. In the exemplary embodiment, eight de-nesting tabs 2036 are included, although other embodiments may include any suitable number of de-nesting tabs. The de-nesting tabs 2036 extend along the flange panels 2012, 2014, 2016, 2018 away from the respective panels 2002, 2004, 2006, 2008. A recess 2038 is defined along a bottom edge 2040 of the de-nesting tab 2036.

[0088] FIG. 26 is a side view of an exemplary eight-sided container 2100 formed from blank 2000 (shown in FIG. 25). Container 2100 is substantially similar to container 900 (shown in FIG. 8) and / or container 1800 (shown in FIG. 23) and is formed from blank 2000 using a method similar to forming container 900 from blank 800. Container 2100 may have different dimensions than container 900 and further includes a de-nesting tab 2036. Container 2100 includes a bottom wall 2101, a first end wall 2102, an opposing second end wall (not shown), first and second side walls 2106, 2108, and four corner walls 2110 (only two of which are shown in FIG. 26). Bottom wall 2101 includes a bottom panel 2010. The first end wall 2102 includes a first end panel 2002 and two interior corner panels 2024. The second end wall (not shown) includes a second end panel 2004 and two interior corner panels 2024. The first side wall 2106 includes a first side panel 2006 and two interior corner panels 2024. The second side wall 2108 includes a second side panel 2008 and two interior corner panels 2024. The end walls, side walls, corner walls, and bottom wall form a cavity 2112. The container 2100 also has a flange 2114 extending from the tops of the end walls, side walls, and corner walls 2102, 2106, 2108, 2110. The flange 2114 extends transversely outward from the cavity 2112.

[0089] The container 2100 includes a de-nesting tab 2036 that extends from each end of each end wall and side wall in the plane of the respective wall at an acute angle to the corner wall 2110. The de-nesting tab 2036 does not extend beyond the plane 2116 defined by the edge of the flange 2114.

[0090] 9 is a flow diagram of a method 1000 for forming a container from a blank. In some embodiments, the blank includes a bottom panel, two opposing side panels, two opposing end panels, respective end flange panels extending from a top edge of each end panel, respective end flange tabs extending from a respective side edge of each end flange panel, respective side flange panels extending from a top edge of each side panel, and respective side flange tabs extending from a respective end edge of each side flange panel. Method 1000 includes step 1002 of applying hot melt adhesive to an inner surface of the side flange tabs, step 1004 of rotating the end panels inward toward the bottom panel, and step 1006 of rotating the side panels inward toward the bottom panel. Method 1000 also includes step 1008 of rotating the side flange panels outwardly to a parallel orientation relative to the bottom panel, and step 1010 of rotating the end flange panels to a parallel orientation relative to the bottom panel after rotating step 1008. Method 1000 also includes step 1012 of connecting the end flange tabs to the side flange tabs to form a container having a fully formed top flange.

[0091] In some embodiments, the blank further includes respective interior side panels extending from respective side edges of the respective end panels. In some such cases, the method 1000 further includes applying a hot melt adhesive to a portion of the interior surface of the side panels, rotating the interior side panels inwardly, performing a rotating step 1008 after the step of rotating the interior side panels, and coupling the side panels to the interior side panels.

[0092] Method 1000 may include additional, fewer, and / or alternative steps, including steps disclosed elsewhere herein.

[0093] 10 illustrates an exemplary container-forming apparatus 1100 for forming blanks into fully formed containers or trays. For clarity, reference will be made to blank 100 (shown in FIG. 1) and its features when describing the blank or its features. Similarly, for clarity, reference will be made to container 200 (shown in FIG. 2) and its features when describing the container or its features. This discussion is not limiting of the disclosed apparatus 1100, as apparatus 1100 may be applicable to any blank or container described herein, as well as additional or alternative blanks and containers.

[0094] The container forming apparatus 1100 generally includes a frame 1102, a blank feed station 1104, a transfer station 1106, a compression station 1108, a stacking station 1110, and a control system 1112. Direction X, generally referred to herein as the blank transport direction X, indicates the overall path taken by the blanks 100 through the apparatus 1100. Direction Y, perpendicular to the blank transport direction X, is referred to herein as the lateral direction Y or transverse direction Y. Direction Z, perpendicular to both the blank transport direction X and the lateral direction Y, is referred to herein as the vertical direction Z.

[0095] 11-15 illustrate in more detail the blank feeder station 1104. The blank feeder station 1104 broadly includes a conveyor belt 1120, a guide fence 1122, a pick and place assembly 1124, and a deck 1126.

[0096] 12, the blanks 100 are stacked so that each blank 100 extends in a vertical direction Z, with one face facing toward the blank transport direction X and the other face facing away from the blank transport direction X. In other words, the blanks 100 are stacked "upright" on the belt 1120 on their side or end edges.

[0097] The belt 1120 is fed (e.g., by a motor (not shown) operated by the control system 1112) in the blank transport direction X at a parameterized rate to feed single blanks 100 one at a time toward the pick window 1128. It should be readily understood that this rate can be adjusted virtually infinitely between predefined minimum and maximum rates based on various parameters of the apparatus 1100 and the blanks in question (e.g., the size of the blank may affect how fast the apparatus 1100 can operate). As the blanks 100 are fed by the belt 1120, they are maintained in their upright position by a guide fence 1122.

[0098] In an exemplary embodiment, the blank supply station 1104 also includes any suitable number and location of sensors to ensure that the blank supply station 1104 is operating in accordance with instructions from the control system 1112. For example, a sensor 1130 can monitor the number of blanks 100 in a blank stack and send an alert when the number of blanks 100 falls below a threshold. In this manner, uninterrupted operation can be promoted (e.g., by promoting the replenishment of blanks 100 before the stack is emptied, which would prevent operation of the apparatus 1100). Other sensors can also be used for operational and / or safety purposes, for example, to ensure that the blanks 100 do not fall from their "upright" position, are moving in the proper direction, and are moving at the proper speed.

[0099] The blanks 100 are transported from their vertical orientation and deposited in a horizontal orientation on a deck 1126 by a pick-and-place assembly 1124. The pick-and-place assembly 1124 includes a stationary arm 1132 coupled at its first end 1134 to the frame 1102 and a pivot arm 1136 pivotally coupled at its first end 1138 to the frame 1102. In particular, the first end 1138 of the pivot arm 1136 is coupled to the frame 1102 via a first pivot rod 1140, which rotates about a first pivot axis 1142 defined in the lateral direction Y. A servo motor 1144 controls the pivotal movement of the pivot arm 1136 about the first pivot axis 1142.

[0100] A second pivot rod 1146 is connected between second ends 1148 of the stationary arms 1132 and rotates in the lateral direction Y about a second pivot axis 1150 defined parallel to the first pivot axis 1142. A vacuum assembly 1152 is connected to the second pivot rod 1146 and pivotally connected to the second ends 1154 of the pivot arms 1136 via a cylinder 1156. The cylinder 1156 pivots about a third pivot axis 1157. A bar 1158 connects the cylinder 1156 to the second pivot rod 1146. The vacuum assembly 1152 includes a plurality of vacuum suction cups 1160 that are activated to initiate a suction operation when picking up a blank 100 and are deactivated when dropping or placing the blank 100. The vacuum suction cup 1160 is operably connected to an internal conduit (not shown), the internal pressure of which is monitored and controlled, for example, by the control system 1112 .

[0101] 14 , for example, the pick and place assembly 1124 is shown in a first “pick” configuration. The pivot arm 1136 is in a first position, and the vacuum assembly 1152 is in a first position in which the vacuum suction cup 1160 faces a vertically oriented blank 100. The vacuum suction cup 1160 is positioned and activated to engage the face of a single blank 100 such that the blank 100 is drawn to and maintained against the vacuum suction cup 1160.

[0102] 15 , once a blank 100 is picked from the blank stack, the pivot arm 1136 is pivoted about the first pivot axis 1142 to a second position and the vacuum assembly 1152 is rotated to a second position. In particular, the vacuum assembly 1152 is lowered by the pivot arm 1136 and pivoted about the second and third pivot axes 1150, 1157 (due to the connection between the cylinder 1156, the bar 1158, and the second pivot rod 1146) so that the vacuum suction cup 1160 faces downward and the blank 100 is positioned horizontally.

[0103] The vacuum suction cup 1160 is deactivated and the blank 100 is released onto the deck 1126. Although not specifically shown, when the blank 100 is deposited on the deck 1126, the leading edge 102 (see FIG. 1) faces in the blank transport direction X and the inner surface 101 (see FIG. 1) faces upward in the vertical direction Z (such that the outer surface 103 (see FIG. 1) faces downward relative to the deck 1126).

[0104] 16 , the deck 1126 extends in the blank transfer direction X from the blank supply station 1104 through the blank transfer station 1106. In the illustrated embodiment, the deck 1126 includes two parallel legs 1162 that extend in the blank transfer direction X and define a transfer surface 1164 thereon. The blank transfer station 1106 may include, as part of the deck 1126, a conveyor belt, chains, lugs, or any other suitable mechanism coupled to the legs 1162 to advance the blank 100 along the deck 1126 and over the transfer surface 1164. Additionally or alternatively, the blank transfer station 1106 may include a push-out mechanism (not shown) that engages the trailing edge 104 (see FIG. 1 ) of the blank 100 to push the blank 100 in the blank transfer direction X.

[0105] The blank 100 is advanced in a blank transfer direction X through a blank transfer station 1106 toward a compression station 1108. As the blank 100 is advanced, the blank 100 is transferred through an adhesive assembly 1170 within the blank transfer station 1106. The adhesive assembly 1170 includes a plurality of adhesive applicators 1172 configured to apply adhesive to specific locations on the blank 100 (specifically, to the interior surface 101 of the blank 100), as described elsewhere herein. In the exemplary embodiment, the adhesive is a hot melt adhesive, although other adhesive types are contemplated within the scope of the present disclosure. The adhesive assembly 1170 also includes one or more sensors (e.g., optical sensors (not shown)) to detect the position of the blank 100 within or relative to the adhesive assembly 1170. The adhesive applicator 1172 is activated (e.g., by the control system 1112) based on signals from sensors and / or servo motor encoder positions to ensure accurate and precise placement of the adhesive on the blank 100.

[0106] Although a variety of adhesives can be used, the adhesive can be a hot melt adhesive, preferably having a viscosity of 2000 cps or greater, a non-limiting commercially available example of which is "Technomelt Supra 100 Plus-22" manufactured by Henkel Corporation. The control system 1112 can use scheduled high speed outputs driven from motion cycles in the processor and high-speed glue solenoids to achieve the level of precision needed to place the adhesive on the blank 100 at the predetermined flange targets.

[0107] Once the adhesive is applied to the blank 100, the blank 100 is advanced from the blank transfer station 1106 to a compression station 1108. The timing of the application of adhesive onto the blank and the movement to the compression station 1108 is set to ensure that the adhesive is molten until compression is applied, and the compression timing is set to allow for rapid curing. Referring now to FIG. 17 , the compression station 1108 includes a plunger mechanism 1180 configured to drive a mandrel 1182 upward and downward along the vertical direction Z. In the exemplary embodiment, the plunger mechanism 1180 includes a subframe 1184 and a post 1186. The subframe 1184 is raised and lowered along two vertical tracks 1188, and the post 1186 is coupled to the subframe 1184 and maintains the position of the mandrel 1182 relative thereto. The mandrel 1182 includes an outer profile having a shape complementary to the inner profile of the shape of the container to be formed. The mandrel 1182 is interchangeable based on the particular container to be formed therewith. The mandrel 1182 includes a plurality of side plates 1190 (see FIG. 18A ) and a bottom plate (not shown) that collectively define the outer surface of the mandrel 1182. Although not shown, the bottom plate has holes therein through which a suction force is applied to the blank 100 to maintain its position relative to the mandrel 1182 during formation of the container 200. Alternatively, the mandrel 1182 does not include a bottom plate but has one or more vacuum suction cups (not shown) at its bottom that are oriented downward to receive and hold the blank 100 against the mandrel 1182. In some embodiments, one or more of the side plates 1190 can include holes to apply a suction force to the walls of the formed container, as described further herein.

[0108] A plurality of compression plates 1192, as further described herein, are coupled to the posts 1186 and are operable independently of the vertical movement of the plunger mechanism 1180 to raise and lower the mandrel 1182. Among other things, the compression station 1108 includes side compression plates 1194 and end compression plates 1196 (see FIG. 18A ). Each compression plate 1192 defines a respective compression surface on a bottom or lower surface thereof. Each compression plate 1192 is raised and lowered by a respective actuator (e.g., pneumatic, spring-based, etc.). The movement of the side compression plates 1194 is independent of the movement of the end compression plates 1196.

[0109] 18A, the compression station 1108 further includes a forming tool 1198 positioned vertically below the mandrel 1182. The forming tool 1198 includes a plurality of sidewalls and a bottom wall that define a cavity 1202 therebetween. The forming tool 1198 includes an inner profile having a shape complementary to the outer profile of the shape of the container to be formed, and thus the inner profile of the forming tool 1198 is also complementary to the outer profile of the mandrel 1182. Additionally, the forming tool 1198 is interchangeable based on the particular container to be formed in the apparatus 1100.

[0110] In operation, the container 200 is formed from the blank 100 by driving the mandrel 1182 downward into the forming tool 1198, with the blank 100 coupled to the mandrel 1182. More specifically, the blank 100 is advanced into the compression station 1108 to a position below the mandrel 1182. Even more specifically, the blank 100 is positioned so that the bottom panel 108 of the blank 100 is below the bottom surface of the mandrel 1182 (e.g., the bottom plate of the mandrel 1182 or the bottom edge of the side plate 1190 that forms the mandrel 1182). A suction feature of the mandrel 1182 is activated to maintain the blank 100 properly positioned relative to the mandrel 1182. The mandrel 1182 is then driven downward by actuating the plunger mechanism 1180 , which forces the blank 100 into the cavity 1202 of the forming tool 1198 .

[0111] The forming tool 1198 is specifically shaped to cause folding of the side panels 116, 122 and end panels 106, 110 of the blank 100 to form the outer perimeter of the container 200. For example, the end walls of the forming tool 1198 may extend slightly higher than the side walls of the forming tool 1198 to ensure that the end panels 106, 110 are folded inward before the side panels 116, 122. The complementary shapes of the forming tool 1198 and mandrel 1182 promote predictable and accurate folding of the side panels 116, 122, glue panel 130, and end panels 106, 110 around the mandrel 1182 in their respective fully folded configurations. Moreover, when the blank 100 is fed into the forming tool 1198 and folded against the mandrel 1182, the complementary relationship of the forming tool 1198 and the mandrel 1182 causes compression of the glue panel 130 against the inner surfaces 101 of the side panels 116, 122, securing these panels in an overlapping, face-to-face relationship.

[0112] Once the mandrel 1182 is fully lowered, the side compression plates 1194 are lowered, rotating the side flange panels 150, 152 outward and folding the side flange panels 150, 152 against the top edge of the forming tool 1198, thereby folding the side flange panels 150, 152 into their fully folded configuration parallel to the bottom panel 108 of the blank 100. Thereafter, the end compression plates 1196 are lowered, rotating the end flange panels 134, 138 outward and folding the end flange panels 134, 138 against the top edge of the forming tool 1198. This rotation causes the end flange tabs 142, 144 to fold over the side flange tabs 158, 160 into an overlapping, face-to-face relationship. Additionally, the end compression plate 1196 exerts sufficient force to compress the end flange tabs 142, 144 against the side flange tabs 158, 160, ensuring that the flange tabs are adhered to one another, thereby completely forming and securing the top flange 214 of the container 200.

[0113] 18B, in some example implementations, the mandrel 1182 is lowered to engage the tray 200 and is held in place by vacuum cups positioned at the bottom of the mandrel 1182. The tray flaps (or glue panels) 130 can be first engaged by forming ears 1191 to force them into the interior cavity of the tray 200. As the mandrel 1182 is lowered into the cavity 1202, the walls 106, 110, 116, 122 are folded upward. When the forming ears 1191 are inside the perimeter of the flanges of the tray 200, a cam 1193 mounted on the mandrel 1182 engages a cam follower bearing 1195, which uses a liner bearing, and forces the tab folding ears mounting plates 1197 and 1199 to open above the plane 1189 and beyond the perimeter of the tray 200. When the tray 200 is disposed between the mandrel 1182 and the female cavity 1202, the tab 130 is under compression against and adhered to the side walls 116, 122. The side flanges 150, 156 are folded into position for a folding anvil 1194 mounted on the mandrel 1182. The end flanges 134, 138 will still be vertical at this point. When the mandrel 1182 reaches the bottom of the cavity 1202, the folding anvil 1196, which is connected to a separate, spring-loaded, floating shaft, moves downward as the axis continues to drop, thereby folding the upper end flanges 134, 138 of the side flanges 150, 156 into their formed positions. The axis then moves downward a small amount to engage the main compliance spring, applying pressure to the flanges and curing the adhesive.

[0114] 27 depicts an alternative embodiment of a compression station of apparatus 1100, referred to using reference numeral 2200. Among other things, compression station 2200 is suitable for forming eight-sided containers (e.g., containers 900, 1800, and / or 2100, etc.) from their respective blanks. Where elements of compression station 1108 and compression station 2200 are similar, the same reference numerals may be used, and the associated functionality may be similar to that described above with respect to compression station 1108.

[0115] The compression station 2200 includes a plunger mechanism 1180 (shown and described with respect to FIG. 17 ) configured to drive a mandrel 2202 upward and downward along the vertical direction Z. The mandrel 2202 includes an outer profile having a shape complementary to an inner profile of the shape of a container to be formed (e.g., an eight-sided container). The mandrel 2202 is interchangeable based on the particular container to be formed therewith. The mandrel 2202 includes a plurality of side plates 2202 and a bottom plate (not shown) that collectively define the outer surface of the mandrel 2202. Although not shown, the bottom plate has holes therein through which a suction force is applied to the blank to maintain its position relative to the mandrel 2202 during formation of the corresponding container. Alternatively, the mandrel 2202 does not include a bottom plate but has one or more vacuum suction cups (not shown) at its bottom, which are oriented downward to receive and hold a blank against the mandrel 2202. In some embodiments, one or more of the side plates 2204 can include holes to apply a suction force to the walls of the formed container, as described herein.

[0116] The multiple compression plates 2206 are operable independently of the vertical movement of the plunger mechanism 1180 to raise and lower the mandrel 2202, as described further herein. Among other things, the compression station 2200 includes side compression plates 2208, end compression plates 2210, and corner compression plates 2212. Each of these compression plates defines a respective compression surface on a bottom or lower surface thereof. The compression plates 2206 can be raised and lowered collectively or individually by respective actuators (e.g., pneumatic, spring-based, etc.). In one embodiment, the movement of the side compression plates 2208, end compression plates 2210, and corner compression plates 2212 is independent of each other.

[0117] The compression station 2200 further includes a forming tool 2220 positioned vertically below the mandrel 2202. The forming tool 2220 includes a plurality of side walls 2222, a plurality of corner walls 2224, and a bottom wall 2226, as shown in both FIG. 27 and FIG. 28. The side walls 2222, the corner walls 2224, and the bottom wall 2226 define a cavity 2228 (shown in FIG. 28) therebetween. The forming tool 2220 includes an inner profile having a shape complementary to the outer profile of the shape of the container to be formed, and thus the inner profile of the forming tool 2220 is also complementary to the outer profile of the mandrel 2202. Additionally, the forming tool 2220 is interchangeable based on the particular container to be formed in the apparatus 1100.

[0118] In the exemplary embodiment, the forming tool 2220 further includes a gap 2230 defined between adjacent side walls 2222 and corner walls 2224. Additionally, the corner walls 2224 include channels 2232 defined in their upper surfaces, as shown in FIG. 28. As described further herein, these channels 2232 accommodate de-nesting tabs (e.g., de-nesting tab 1736 (shown in FIGS. 22-24) or de-nesting tab 2036 (shown in FIGS. 25 and 26)) when a container is formed from the corresponding blank. The channels 2232 have a depth (e.g., measured vertically downward from the upper surface of the corner walls 2224) that is equal to or greater than the height of the de-nesting tabs.

[0119] The forming tool 2220 further includes a plurality of forming plates 2240 including a side forming plate 2242 , an end forming plate 2244 , and a corner forming plate 2246 .

[0120] During operation of the compression station 2200, and referring to the blank 2000 and the container 2100 for purposes of illustration, the container 2100 is formed from the blank 2000 by driving the mandrel 2202 downward into the forming tool 2220, with the blank 2000 coupled to the mandrel 2202. More specifically, the blank 2000 is advanced into the compression station 2200 to a position below the mandrel 2202. Even more specifically, the blank 2000 is positioned so that the bottom panel 2010 of the blank 2000 is below the bottom surface of the mandrel 2202 (e.g., the bottom plate of the mandrel 2202 or the bottom edge of the side plate 2204 that forms the mandrel 2202). A suction feature of the mandrel 2202 is activated to maintain the blank 2000 properly positioned relative to the mandrel 2202. The mandrel 2202 is then driven downward by actuating the plunger mechanism 1180 , which forces the blank 2000 into the cavity 2228 of the forming tool 2220 .

[0121] As the blank 2000 is lowered toward the forming tool 2220, the forming plate 2240 (e.g., its angled surface) engages the panels of the blank 2000 in a predetermined sequence, rotating the panels inward toward the mandrel 2202. The forming tool 2220 is specifically configured to cause folding of the side panels 2002, 2004, end panels 2006, 2008, and corner panels 2020 of the blank 2000 to form the outer perimeter of the container 2100. Additionally, the channels 2232 accommodate de-nesting tabs that extend substantially vertically downward as the side panels, end panels, and corner panels are folded upward. The complementary shapes of the forming tool 2220 and mandrel 2202 promote predictable and precise folding of the side panels 2006, 2008, corner panel 2020, glue panel 2024, and end panels 2002, 2004 in their respective fully folded configurations around the mandrel 2202. Moreover, as the blank 2000 is driven into the forming tool 2220 and folded about the mandrel 2202, the complementary relationship of the forming tool 2220 and mandrel 2202 causes compression of the glue panel 2024 against the interior surfaces of the side and end panels of the blank 2000, securing these panels in an overlapping, face-to-face relationship.

[0122] Once the mandrel 2202 is fully lowered, the side compression plates 2208 are lowered, rotating the side flange panels 2016, 2018 outward and folding them against the top edge of the forming tool 2202. The end compression plates 2210 are lowered, rotating the end flange panels 2012, 2014 outward and folding them against the top edge of the forming tool 2202. Thereafter, the corner compression plates 2212 are lowered, rotating the corner flange panels 2028 outward and folding them against the top edge of the forming tool 2202. This rotation causes the corner flange panels 2028 to fold over and into an overlapping, face-to-face relationship with the end and side flange panels 2012, 2014, 2016, 2018. Additionally, the corner compression plates 2212 exert sufficient force to compress the corner flange panels 2028 against the end and side flange panels 2012, 2014, 2016, 2018 to ensure that these panels are adhered to one another, thereby completely forming and securing the top flange 2114 of the container 2100.

[0123] As described elsewhere herein, containers formed using apparatus 1100 include a planar top flange with flange tabs secured using a hot melt adhesive. These containers exhibit improved stacking and unstacking (or unnesting) characteristics, are stronger than conventional trays without glued or secured flanges, and further exhibit improved functionality when sealed with a top film.

[0124] Once the container is formed, the mandrel 1182 is raised by actuating the plunger mechanism 1180. The suction function of the mandrel 1182 remains active, and the container 200 is raised with and remains coupled to the mandrel 1182. The tray collection assembly 1210 is actuated to retrieve the formed container 200 from the mandrel 1182. The tab folding mechanisms 1197, 1199 return to their home position when the cam 1193 exits the cam follower bearing 1195 and is pulled into position by the spring 1187.

[0125] 19 and 20 , the stacking station 1110 includes a tray collection assembly 1210, which itself includes a horizontal linear track 1212 (e.g., a belt drive) extending along the blank transport direction X. A clamping tool 1214 is driven along the track 1212 parallel to the blank transport direction X. The clamping tool 1214 includes a subframe 1216 and an articulating clamping mechanism 1218 coupled to an upstream end of the subframe 1216. In operation, the clamping tool 1214 is driven toward the compaction station 1108 while the mandrel 1182 is lifted from its lowered position in the forming tool 1198 (not specifically shown) to its raised position (shown in FIG. 17 ) until the articulating clamping mechanism 1218 engages the container 200. The clamping tool 1214, plunger mechanism 1180, and mandrel 1182 are operated in conjunction with one another such that the articulating clamping mechanism 1218 clamps the formed container 200 while the mandrel 1182 is raised by the plunger mechanism 1180, and simultaneously the suction function of the mandrel 1182 is deactivated. Thus, the container 200 is released from the mandrel 1182 as the mandrel 1182 is raised, and the clamping tool 1214 is driven back in the blank transport direction X, pulling the container 200 from the vertical path of the mandrel 1182 out of the compaction station 1108 and into the stacking station 1110.

[0126] The clamping tool 1214 can take the form of fixed metal fingers that have corresponding cutouts in the mandrel 1182, allowing the fingers to be positioned inside the periphery of the mandrel 1182 as the mandrel 1182 is lifted vertically upward (in the z-direction), and thus inside the tray 200. Based on the position of the mandrel 1182 (which can be determined from the servo motor encoder position), a pneumatic cylinder with a clamping surface can operate to hold the tray 200 in place until the mandrel 1182 is withdrawn from the cavity in the tray 200, at which point the clamping tool can be driven horizontally (in the x-direction) to a stacking position where the tray 200 is released.

[0127] A trough or channel 1220 is disposed within the stacking station 1110. The channel 1220 is formed by a plurality of vertically extending plates 1222 and is configured to receive a plurality of containers 200 therein. Among other things, the channel 1220 receives the containers 200 and arranges them into stacks 300 (as shown in FIG. 3 ).

[0128] In operation, the clamping tool 1214 is driven in the blank transfer direction X until the container 200 is positioned above the channel 1220. The articulated clamping mechanism 1218 is actuated to release the container 200 into the channel 1220. In some embodiments, the container 200 is actively transferred into the channel 1220, for example, by a controlled burst of air (not shown). This arrangement can promote improved stacking of the containers in the channel 1220. In other embodiments, the container 200 is passively transferred (or dropped) into the channel 1220.

[0129] The stacking station 1110 further includes one or more sensors (e.g., weight sensors, optical sensors, etc. (not shown)) that detect when a full stack of containers has formed. For example, the sensors may sense the weight of the stack, the height of the stack, or the number of containers in the stack. The stack is considered "full" according to parameters entered into and / or stored in the control system 1112, which can be easily adjusted by an operator. Once a full stack is detected, the side plates 1224 of the channel 1220 are opened and a discharge plate (not shown) is actuated to advance the stack from the channel 1220 to the subsequent station.

[0130] In the exemplary embodiment, the apparatus 1100 is designed for high throughput and is configured to form up to 30 containers per minute according to the operations described above. It is recognized that the apparatus 1100 is highly customizable. For example, the blank supply station 1104 includes an adjustment mechanism (not shown) to accommodate blanks of different lengths and widths. The adjustment mechanism can be operated manually. Additionally or alternatively, the adjustment mechanism can be operated via a user interface of the control system 1112. For example, an operator can use the user interface to input the length and width of the blank, and the control system 1112 can automatically control the adjustment mechanism accordingly. In some cases, one or more of the adjustment mechanisms, whether manually or computer-controlled, can cause adjustment of one or more components of the apparatus 1100. For example, one adjustment mechanism (that operates to accommodate the width of the blank) can control components throughout the apparatus 1100 (e.g., at the blank supply station 1104, the transfer station 1106, the compression station 1108, and / or the stacking station 1110).

[0131] Additionally, with respect to the blank supply station 1104, the control system 1112 can be used to adjust the position of the vacuum suction cup 1160 and / or the vacuum pressure generated in the vacuum assembly 1152 to accommodate blanks of different sizes and weights. With respect to the blank transfer station 1106, the control system 1112 can be used to adjust the position and activation control of the adhesive applicator 1172 to accommodate blanks of different sizes, shapes, and configurations. The amount and temperature of the adhesive applied can also be precisely controlled.

[0132] With respect to the compression station 1108, the mandrel 1182 and forming tool 1198 are interchangeable to accommodate various sizes and configurations of blanks / containers (e.g., four-sided, eight-sided, etc.). Additionally, the control system 1112 can be used to adjust the vacuum pressure generated in the mandrel 1182 to accommodate various blanks. At the stacking station 1110, the positions of various components (e.g., articulated clamping mechanism 1218, plates 1222 of channel 1220) can be adjusted manually or via the control system 1112 to accommodate containers of various sizes and shapes. Additionally or alternatively, the apparatus 1100 can not include a stacking station (e.g., formed containers can be discharged from the apparatus 1100 and stacked elsewhere or filled with product without being stacked), or the apparatus 1100 can include additional stations (e.g., a product filling station, a container sealing station, a container packaging station, etc.).

[0133] Additionally, the operation of the components of device 1100 (e.g., their timing, speed, position, etc.) is virtually infinitely customizable via control system 1112. That is, any component can be independently operated via its respective servo motor (or other servo mechanism), which is controlled by control system 1112 under instructions provided to control system 1112 by an operator through a user interface.

[0134] In one exemplary embodiment, the apparatus 1100 includes a blank transfer station including an adhesive assembly with multiple adhesive applicators. The blank is transported in a blank transfer direction through the adhesive assembly, where at least one of the adhesive applicators applies hot melt adhesive to the inner surfaces of the side flange tabs. The apparatus 1100 also includes a compression station downstream of the blank transfer station, which includes a vertically movable mandrel and a forming tool below the mandrel. The forming tool defines a cavity therein and has an inner profile complementary in shape to the outer profile of the mandrel. The blank is positioned below the mandrel, which feeds the blank downward into the forming tool cavity, and the forming tool rotates the end panels inward to engage with the mandrel and rotates the side panels inward to engage with the mandrel and the end panels. The compression station also includes end compression plates and side compression plates coupled to the mandrel. The side compression plates rotate the side flange panels outward to engage the top edge of the forming tool, after which the end compression plates rotate the end flange panels outward to engage the top edge of the forming tool, and the end compression plates further compress the end flange tabs against the side flange tabs to form a container with a fully formed top flange.

[0135] Additionally or alternatively, the device 1100 may include any of the following features or components in any combination.

[0136] (A) when the blank further includes respective interior side panels extending from respective side edges of the respective end panels, at least one of the plurality of adhesive applicators is further configured to apply hot melt adhesive to a portion of an interior surface of the side panel as the blank is transported through the adhesive assembly, and when the mandrel feeds the blank into the cavity of the forming tool, the forming tool rotates the interior side panel inwardly to engage with the mandrel before rotating the side panel to engage with the mandrel, and the forming tool compresses the side panel in an overlapping, face-to-face relationship against the interior side panel;

[0137] (B) the compression station further includes a plurality of forming ears positioned around a periphery of the folding tool, each forming ear extending partially inwardly into the cavity to engage the interior side panel as the blank is lowered toward the folding tool;

[0138] (C) the compression station further includes a cam mounted on the mandrel, the cam engaging the cam follower bearing to rotate the forming ear away from the cavity as the mandrel lowers the blank further than the folding tool;

[0139] (D) the blank transfer station is configured to advance the blank (including the hot melt adhesive applied to the blank) from the adhesive assembly to the compression station while the hot melt adhesive remains molten;

[0140] (E) the timing of the compression station is controlled using a control system so that the hot melt adhesive cures during compression of the blank to form the container;

[0141] (F) the adhesive applicator is configured to apply a hot melt adhesive having a viscosity of at least 2000 centipoise (cps);

[0142] (G) the mandrel includes a vacuum assembly configured to hold the blank against the mandrel;

[0143] (H) further including a clamping tool configured to transfer the formed container from the compression station to a stacking station;

[0144] (I) The movement of the side compression plates and end compression plates is controlled independently from the movement of the mandrel using a control system.

[0145] 21 depicts a schematic block diagram of the control system 1112. In the exemplary embodiment, the control system 1112 includes a control panel 1302, a processor 1304, a memory 1306, and a communication interface 1308. In certain embodiments, a preprogrammed recipe or protocol embodied on a non-transitory computer-readable storage medium (e.g., stored in memory 1306) is programmed into and / or uploaded to the processor 1304, such recipe including, but not limited to, predetermined speed and timing profiles, each profile associated with forming a container from a blank having a predetermined size and shape.

[0146] In certain embodiments, control system 1112 is configured to facilitate selecting the speed and / or timing of movement and / or activation of any of the disclosed components of device 1100. Components can be either independently controlled or controlled as part of one or more linked mechanisms.

[0147] The control panel 1302 includes one or more input devices 1310 or components (e.g., a touchscreen, a keyboard, a mouse, a microphone, and / or other input controls) and one or more output devices 1312 or components (e.g., a touchscreen, a non-touchscreen (e.g., an LCD monitor), a speaker, a light, and / or other output devices). In certain embodiments, the control panel 1302 allows an operator to select an appropriate recipe for a particular blank and / or container. Each recipe is a set of computer instructions that directs the apparatus 1100 regarding forming a container. In embodiments in which one or more actuators in the apparatus 1100 are servo mechanisms, the control system 1112 can independently control the movement of each such actuator relative to any other component of the apparatus 1100. This allows the operator to maximize the number of containers that can be formed by the apparatus 1100, easily change the size of the blanks and / or containers being formed on the apparatus 1100, and automatically change the type of blanks and / or containers being formed on the apparatus 1100 while reducing or eliminating manual adjustments of the apparatus 1100.

[0148] In the exemplary embodiment, control system 1112 is shown as centralized within device 1100; however, control system 1112 can be a distributed system throughout device 1100, within the building housing device 1100, and / or at a remote control center. Control system 1112 includes processor 1304 configured to control device 1100 to perform the methods and / or steps described herein (e.g., the steps of method 1000 shown in FIG. 9 ). As used herein, the term “processor” is not limited to integrated circuits referred to in the art as computers, but refers broadly to controllers, microcontrollers, microcomputers, programmable logic controllers (PLCs), application-specific integrated circuits, and other programmable circuits, and these terms are used interchangeably herein. It should be understood that the processor and / or control system can also include memory, input channels, and / or output channels.

[0149] In the embodiments described herein, memory 1306 may include, but is not limited to, computer-readable media (such as, for example, random access memory (RAM)) and computer-readable non-volatile media (such as, for example, flash memory). Alternatively, floppy disks, compact disks-read only memories (CD-ROMs), magneto-optical disks (MODs), and / or digital versatile disks (DVDs) may also be used.

[0150] Communications interface 1308 is used to send instructions from control system 1112 to various components (e.g., actuators) of device 1100 and to receive information from various components (e.g., actuators, sensors, etc.) of device 1100 and / or from remote devices. Communications interface 1308 can be any suitable wired or wireless communication interface to facilitate any suitable communication format among control system 1112 and device 1100 (e.g., Wi-Fi, BLUETOOTH, cellular data connection, etc.).

[0151] The processors described herein process information transmitted from multiple electrical and electronic devices, which may include, but are not limited to, sensors, actuators, compressors, control systems, and / or monitoring devices. Such processors may be physically located, for example, in a control system, a sensor, a monitoring device, a desktop computer, a laptop computer, a PLC cabinet, and / or a distributed control system (DCS) cabinet. RAM and storage devices store and transfer information and instructions to be executed by the processor. RAM and storage devices may also be used to store and provide temporary variables, static (i.e., non-changing) information and instructions, or other intermediate information to the processor during execution of instructions by the processor. The instructions executed may include, but are not limited to, flow control system control commands. Execution of a sequence of instructions is not limited to any specific combination of hardware circuitry and software instructions.

[0152] In an exemplary embodiment, method 1000 (shown in FIG. 9 ) is implemented by control system 1112 sending commands and / or instructions to components of device 1100. Processor 1304 is programmed with code segments configured to implement method 1000. Alternatively, method 1000 is encoded on a computer-readable medium stored in memory 1306 and readable by control system 1112.

[0153] The steps of the container forming method performed by the apparatus 1100 under the operation of the control system 1112 may include, for example, (i) transporting a blank through an adhesive assembly; (ii) applying hot melt adhesive to the interior surfaces of the side flange tabs using a plurality of adhesive applicators; (iii) positioning the blank under a mandrel; and (iv) using the mandrel to feed the blank downward into a cavity of a forming tool, the feeding steps including: (a) rotating the end panels inward to engage the mandrel; and (b) rotating the side panels to engage the mandrel and to engage the end panels. (v) using side compression plates coupled to the mandrel to rotate the side flange panels outward to a parallel orientation relative to the bottom panel; (vi) after the step of rotating the side flange panels, using end compression plates coupled to the mandrel to rotate the end flange panels to a parallel orientation relative to the bottom panel; and (vii) using the end compression plates to compress the end flange tabs against the side flange tabs to form a container having a fully formed top flange.

[0154] Additionally or alternatively, the method may include any of the following steps in any combination thereof:

[0155] (A) When the blank further includes respective interior side panels extending from respective side edges of the respective end panels, the method further includes the steps of applying hot melt adhesive to portions of the interior surfaces of the side panels using a plurality of adhesive applicators; rotating the interior side panels inwardly using a forming tool; performing the step of rotating the side panels inwardly after the step of rotating the interior side panels; and compressing the side panels against the interior side panels between the mandrel and the forming tool;

[0156] (B) the compression station further includes a plurality of forming ears positioned around a periphery of the folding tool, each forming ear extending partially inwardly into the cavity, and the method further includes using the forming ears to engage the interior side panel as the blank is lowered toward the folding tool;

[0157] (C) the compression station further includes a cam mounted on the mandrel, the method further including the steps of: engaging the cam with the cam follower bearing; and rotating the forming ear away from the cavity as the mandrel lowers the blank further than the folding tool:

[0158] (D) advancing the blank (including the hot melt adhesive applied to the blank) from the adhesive assembly to a compression station while the hot melt adhesive remains molten;

[0159] (E) using a control system to control the timing of the compression station so that the hot melt adhesive cures during compression of the blank to form the container;

[0160] (F) applying a hot melt adhesive having a viscosity of at least 2000 centipoise (cps);

[0161] (G) Using a vacuum assembly to hold the blank against the mandrel;

[0162] (H) using a clamping tool to transfer the formed container from the compression station to a stacking station;

[0163] (I) Using a control system to control the movement of the side compression plates and end compression plates independently from the movement of the mandrel.

[0164] Exemplary embodiments of containers and blanks for making the same are described above in detail. The containers and blanks are not limited to the specific embodiments described herein; rather, blanks and / or container components can be utilized independently and separately from other components described herein. Additionally, embodiments of apparatus for forming containers from blanks are described above in detail. The apparatus is not limited to the specific embodiments described herein, nor is the apparatus limited to forming containers from the specific blanks described herein. Rather, the apparatus can be used to form containers in addition to or alternative to those described herein.

[0165] Although specific features of various embodiments of the present disclosure may be shown in some drawings and not in others, this is for convenience only, and in accordance with the principles of the present disclosure, any feature of a drawing may be referenced and / or claimed in combination with any feature of any other drawing.

[0166] This written description uses examples to disclose various embodiments (including the best mode) and to enable any person skilled in the art to practice the disclosure (including making and using any device or system, and practicing any incorporated methods). The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims. [Explanation of symbols]

[0167] 100 blank 101 Internal surface 102 leading edge 103 External Surface 104 Trailing edge 105 Free edge 106 first end panel 107 Free edge 108 bottom panel 110 second end panel 112 Bending line 114 Folding Line 116 First Side Panel 118 first side edge 120 Folding line 122 Second Side Panel 124 second side edge 126 Bending Line 128 cutouts 130 Inner Side Panel 132 Bending line 134 first end flange panel 136 Bending line 138 Second End Flange Panel 140 Folding Line 142 first end flange tab 144 Second End Flange Tab 146 Free outer edge 148 Free inner edge 150 first side flange panel 152 Second side flange panel 154 Free edge 156 Free edge 158 First Side Flange Tab 160 Second Side Flange Tab 162 Free outer edge 164 Free inner edge 166 Bending Line 168 Bending Line 170 Side edge 172 End edge 178 Free edge 180 fold line 182 Bending line 184 notches 186 Notch 200 containers 202 Bottom wall 204 first end wall portion 206 Second end wall portion 208 first side wall 210 second end wall portion 212 Cavity 214 flange 216 Free edge 218 Corner 220 Film 300 stacks 400 blank 402 Cutout 404 Notch 430 Inner side edge 500 containers 600 blank 602 Cutout 604 Bending line 606 Interior End Panel 608 Free edge 610 notch 612 Notch 800 blank 802 first end panel 804 Second End Panel 806 First Side Panel 808 Second Side Panel 810 bottom panel 812 First End Flange Panel 814 Second End Flange Panel 816 First side flange panel 818 Second Side Flange Panel 820 First End Flange Tab 822 Second End Flange Tab 824 First Side Flange Tab 826 Second Side Flange Tab 828 Free end edge 830 notch 832 Inner edge 834 Corner Panel 836 Bending line 838 Interior Corner Panel 840 Bending line 842 Corner flange panel 844 Bending line 845 Free edge 846 Corner flange tab 848 Bending line 849 Free edge 850 notches 852 Cutout 854 Bending line 856 Bending line 858 Bending line 860 Bending line 900 containers 902 Bottom wall 904 first end wall portion 906 Second end wall 908 First side wall 910 second end wall portion 912 cavity 914 flange 916 Free edge 918 Corner 920 Corner wall 1100 Container forming equipment 1102 frames 1104 Blank supply station 1106 Transfer Station 1108 Compression Station 1110 Stacking Station 1112 Control System 1120 Conveyor Belt 1122 Guide Fence 1124 Pick and Place Assembly 1126 Deck 1128 Pick Window 1130 Sensor 1132 Stationary Arm 1134 first end 1136 Pivoting arm 1138 first end 1140 first pivot rod 1142 first pivot axis 1144 Servo Motor 1146 Second pivot rod 1148 Second End 1150 Second Pivot Axis 1152 Vacuum Assembly 1154 Second end 1156 Cylinder 1157 Third Pivot Axis 1158 Bar 1160 Vacuum Suction Cup 1162 Legs 1164 Transfer surface 1170 Adhesive Assembly 1172 Adhesive Applicator 1180 plunger mechanism 1182 Mandrel 1184 subframe 1186 posts 1187 Spring 1188 Vertical Track 1189 plane 1190 Side Plate 1191 Ear formation 1192 Compression Plate 1193 Cam 1194 Side Compression Plate 1195 Cam follower bearing 1196 End Compression Plate 1197 Tab bending ear mounting plate, tab bending mechanism 1198 Shaping Tools 1199 Tab bending ear mounting plate, tab bending mechanism 1202 Cavity 1210 Tray Collection Assembly 1212 Horizontal Linear Track 1214 Clamping Tool 1216 Subframe 1218 Articulated Clamping Mechanism 1220 Trough, Channel 1222 Vertically extending plate 1224 Side Plate 1302 Control Panel 1304 processor 1306 memory 1308 Communication Interface 1310 Input Devices 1312 output devices 1700 Blank 1702 First End Panel 1704 Second End Panel 1706 First Side Panel 1708 Second Side Panel 1710 bottom panel 1712 First End Flange Panel 1714 Second End Flange Panel 1716 First side flange panel 1718 Second Side Flange Panel 1720 Corner Panel 1722 Bending line 1724 Interior Corner Panel 1726 Side edge 1728 Corner flange tab 1730 curved outer edge 1732 Notch 1736 Unnesting Tab 1738 recess 1740 bottom edge 1800 containers 1802 first end wall 1804 Second end wall 1806 First side wall 1808 Second side wall 1810 Corner wall 1812 cavity 1814 flange 1816 plane 1900 stacks 1902 Interval 2000 blank 2002 First End Panel 2004 Second End Panel 2006 First Side Panel 2008 Second Side Panel 2010 bottom panel 2012 First End Flange Panel 2014 Second End Flange Panel 2016 First Side Flange Panel 2018 Second Side Flange Panel 2020 Corner Panel 2022 bending line 2024 Interior Corner Panel 2026 Side edge 2028 Corner Flange Tab 2030 curved outer edge 2032 notch 2036 Nesting Elimination Tab 2038 recess 2040 Bottom edge 2100 container 2101 Bottom wall 2102 first end wall portion 2106 First side wall 2108 Side wall of 2 2110 Corner wall 2112 Cavity 2114 flange 2116 plane 2200 Compression Station 2202 Mandrel 2204 Side Plate 2206 Compression Plate 2208 Side Compression Plate 2210 End Compression Plate 2212 Corner Compression Plate 2220 Shaping Tools 2222 Side wall 2224 Corner wall 2226 Bottom wall 2228 Cavity 2230 Gap 2232 Channel 2240 Forming Plate 2242 Side forming plate 2244 End forming plate 2246 Corner forming plate H1 height H2 height H3 height H4 height L1 length W1 width X Blank transport direction Y horizontal, transverse direction Z vertical direction

Claims

1. 1. A container forming apparatus for forming a container from a blank, comprising: the blank includes a bottom panel, two opposing side panels, two opposing end panels, four corner panels, and respective flange panels extending from a top edge of each of the end panels, the side panels, and the corner panels; The container forming device includes: a blank transfer station including an adhesive assembly with a plurality of adhesive applicators; a compression station downstream of the blank transfer station; It is equipped with At the blank transfer station, the blank is transferred through the adhesive assembly in a blank transfer direction, and at least one of the adhesive applicators applies hot melt adhesive to an outer surface of the flange panel extending from the top edge of the corner panel; the compression station includes a vertically movable mandrel and a forming tool below the mandrel, the forming tool defining a cavity therein and having an inner profile complementary in shape to an outer profile of the mandrel; At the compression station, the blank is positioned under the mandrel, which feeds the blank downwardly into a cavity of the forming tool, which rotates the corner panels inwardly to engage the mandrel and rotates the side panels and the end panels inwardly to engage the mandrel; the compression station further includes a compression plate coupled to the mandrel; The compression plate rotates the flange panel outward to engage the upper edge of the forming tool, and the compression plate further compresses the flange panel extending from the upper edge of the corner panel against the flange panels extending from the upper edges of the side panels and end panels to form the container having a fully formed upper flange.

2. The container forming apparatus of claim 1 , wherein the forming tool includes side walls, end walls, and corner walls.

3. 3. The container forming apparatus of claim 2, wherein the corner wall has a channel defined in an upper surface thereof.

4. 4. The container forming apparatus of claim 3, wherein the side panels and the end panels of the blank include de-nesting tabs, and the channels defined in the corner walls of the forming tool are configured to receive the de-nesting tabs therein when the container is formed from the blank.

5. The container forming device of claim 4 , wherein the channel has a depth equal to or greater than the height of the de-nesting tab.

6. 2. The container forming apparatus of claim 1, wherein the compression station further includes a plurality of forming plates coupled to the forming tool, the forming plates configured to rotate the side panels, the end panels, and the corner panels inwardly as the mandrel is lowered into the forming tool.

7. The container forming apparatus of claim 1 , further comprising a clamping tool configured to transfer the formed container from the compression station to a stacking station.

8. 2. The container forming apparatus of claim 1, wherein the blank transfer station is configured to advance the blank with the hot melt adhesive applied to the blank from the adhesive assembly to the compression station while the hot melt adhesive remains molten.

9. 9. The container forming apparatus of claim 8, wherein the timing of the compression station is controlled using a control system so that the hot melt adhesive cures while compressing the blank to form the container.

10. 10. The container forming apparatus of claim 1, wherein the adhesive applicator is configured to apply the hot melt adhesive having a viscosity of at least 2000 centipoise (cps).

11. 1. A method of forming a container from a blank using a container-forming device, comprising: the blank includes a bottom panel, two opposing side panels, two opposing end panels, four corner panels, and respective flange panels extending from a top edge of each of the end panels, the side panels, and the corner panels; The container forming device includes: (i) a blank transfer station including an adhesive assembly having a plurality of adhesive applicators; (ii) a compression station downstream of the blank transfer station, the compression station including a vertically movable mandrel and a forming tool below the mandrel, the forming tool having an inner profile defining a cavity therein and complementary in shape to the outer profile of the mandrel; Including, The method comprises: transporting the blank through the adhesive assembly; applying hot melt adhesive to exterior surfaces of the flange panels extending from the top edges of the corner panels using the plurality of adhesive applicators; positioning the blank below the mandrel; Using the mandrel, feeding the blank downwardly into the cavity of the forming tool, wherein the feeding step comprises: rotating the corner panel inwardly to engage the mandrel; and rotating the side panels and the end panels inwardly to engage the mandrel; causing the forming tool to using a compression plate coupled to the mandrel to rotate the flange panel outwardly into engagement with a top edge of the forming tool; using the compression plate to compress the flange panels extending from the top edges of the corner panels against the flange panels extending from the top edges of the side panels and end panels to form the container having a fully formed top flange; A method comprising:

12. The method of claim 11 , wherein the forming tool includes side walls, end walls, and corner walls.

13. The method of claim 12 , wherein the corner wall has a channel defined in an upper surface thereof.

14. 14. The method of claim 13, wherein the side panels and the end panels of the blank include de-nesting tabs, and the channels defined in the corner walls of the forming tool are configured to receive the de-nesting tabs therein when the container is formed from the blank.

15. The method of claim 14 , wherein the channel has a depth equal to or greater than the height of the de-nesting tab.

16. the compression station further includes a plurality of forming plates coupled to the forming tool; The method of claim 11 , further comprising rotating the side panels, the end panels, and the corner panels inwardly as the mandrel is lowered into the forming tool.

17. The method of claim 11 further comprising the step of transferring the formed container from the compression station to a stacking station using a clamping tool.

18. 12. The method of claim 11, further comprising advancing the blank with the hot melt adhesive applied thereto from the adhesive assembly to the compression station while the hot melt adhesive remains molten.

19. 20. The method of claim 18, further comprising using a control system to control the timing of the compression station so that the hot melt adhesive cures during compression of the blank to form the container.

20. 12. The method of claim 11, wherein applying a hot melt adhesive comprises applying the hot melt adhesive having a viscosity of at least 2000 centipoise (cps).

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