Method and apparatus for forming containers

A method for forming a container from a generally flat re-configurable blank using a blank support device, said blank support device comprising an outward facing surface, said outward facing surface of said blank support device configured for forming a tubular shaped blank around said outward facing surface of said blank support device, wherein the blank comprises a first side surface and a second side surface on an opposite side of said blank to said first side surface, and wherein said blank further comprises first, second, third and fourth blank portions interconnected together in series, said method comprising:

• (a) engaging the first blank portion of the blank on the first side surface of the blank with a blank movement sub-system and wrapping the first blank portion with the second blank portion joined thereto around a first portion of the outward facing surface of the blank support device to hold the first side surface of the first portion of the blank against the first portion of the outward facing surface of the blank support device in a face-to-face relation to each other;
• (b) engaging the third blank portion of the blank on the first side surface of the blank with said blank movement sub-system and wrapping the third blank portion with the fourth portion joined thereto, in an opposite direction to the wrapping of the first and second portions of the blank, around a second portion of the outward facing surface of the blank support device to hold the first side surface of the third portion of the blank against the second portion of said outward facing surface of said blank support device in a face-to-face relation to each other;
• (c) reconfiguring the second and fourth portions of the blank with said blank movement sub-system to form said tubular shaped blank from the first, second, third and fourth blank portions around the outward facing surface of the blank support device, said tubular shaped blank having opposed first and second end openings, and fixedly connecting the second and fourth blank portions together to secure the blank in the tubular shaped blank around the outward facing surface of said blank support device;
• wherein an inward facing tubular surface of the tubular shaped blank is formed from the first side surface of the blank;
• wherein said outward facing surface of said blank support device has a first recess, said first recess being configured to receive a portion of a first movement apparatus portion of said blank movement sub-system therein;
• and wherein upon said blank movement sub-system wrapping said first blank portion of said blank around the first portion of the outward facing surface of said blank support device, the first blank portion of the blank is held substantially against the first portion of the outward facing surface of the blank support device and a portion of said first movement apparatus portion of said blank movement sub-system is received in said first recess;
• wherein said outward facing surface of said blank support device has a second recess, said second recess being configured to receive a portion of a second movement apparatus portion of said blank movement sub-system therein;
• and wherein when said blank movement sub-system wraps said third blank portion of said blank around the second portion of the outward facing surface of said blank support device, the third blank portion of the blank is held substantially against the second portion of the outward facing surface of the blank support device and a portion of said second movement apparatus portion of said blank movement sub-system is received in said second recess;
• and wherein the reconfiguring of the second and fourth portions of said blank with the blank movement sub-system comprises (i) engaging the second blank portion of the blank on an opposite second side surface of the blank to the first side surface of the blank with a third blank movement apparatus portion of said blank movement sub-system and wrapping the second blank portion around a third portion of the outward facing surface of the blank support device to hold the first side surface of the second portion of the blank against the third portion of the outward facing surface of the blank support device in a face-to-face relation to each other and (ii) engaging the fourth blank portion of the blank on an opposite second side surface of the blank to the first side surface of the blank with a fourth blank movement apparatus portion of said movement sub-system and rotating the fourth blank portion around a fourth portion of the outward facing surface of the blank support device to hold the first side surface of the fourth portion of the blank against the fourth portion of the outward facing surface of the blank support device in a face-to-face relation to each other.

An apparatus for forming a container from a generally flat re-configurable blank wherein the blank comprises a first side surface and a second side surface on an opposite side of said blank to said first side surface, and wherein said blank further comprises first, second, third and fourth blank portions joined together in series, said apparatus comprising:

• (i) a blank support device comprising an outward facing surface, said outward facing surface of said blank support device configured for forming a tubular shaped blank around said outward facing surface of said blank support device;
• (ii) a blank moment sub-system comprising a first blank movement apparatus portion, a second blank movement apparatus portion, a third blank movement apparatus portion, and a fourth blank movement apparatus portion;
• (iii) an attachment mechanism;
• said apparatus being operable to:
• (a) engage the first blank portion of the blank on the first side surface of the blank with the blank movement sub-system and wrap the first blank portion with the second blank portion joined thereto around a first portion of the outward facing surface of the blank support device to hold the first side surface of the first portion of the blank against the first portion of the outward facing surface of the blank support device in a face-to-face relation to each other;
• (b) engage the third blank portion of the blank on the first side surface of the blank with said blank movement sub-system and wrapping the third blank portion with the fourth portion joined thereto, in an opposite direction to the wrapping of the first and second portions of the blank, around a second portion of the outward facing surface of the blank support device to hold the first side surface of the third portion of the blank against the second portion of said outward facing surface of said blank support device in a face-to-face relation to each other;
• (c) reconfigure the second and fourth portions of the blank with said blank movement sub-system to form said tubular shaped blank from the first, second, third and fourth blank portions around the outward facing surface of the blank support device, said tubular shaped blank having opposed first and second end openings,
• wherein said outward facing surface of said blank support device has a first recess, said first recess being configured to receive a portion of a first movement apparatus portion of said blank movement sub-system therein;
• and wherein during operation, upon said blank movement sub-system wrapping said first blank portion of said blank around the first portion of the outward facing surface of said blank support device, the first blank portion of the blank is held substantially against the first portion of the outward facing surface of the blank support device and a portion of said first movement apparatus portion of said blank movement sub-system is received in said first recess;
• wherein said outward facing surface of said blank support device has a second recess, said second recess being configured to receive a portion of a second movement apparatus portion of said blank movement sub-system therein;
• and wherein during operation, when said blank movement sub-system wraps said third blank portion of said blank around the second portion of the outward facing surface of said blank support device, the third blank portion of the blank is held substantially against the second portion of the outward facing surface of the blank support device and a portion of said second movement apparatus portion of said blank movement sub-system is received in said second recess;
• and wherein the reconfiguring of the second and fourth portions of said blank with the blank movement sub-system comprises (i) engaging the second blank portion of the blank on an opposite second side surface of the blank to the first side surface of the blank with a third blank movement apparatus portion of said blank movement sub-system and wrapping the second blank portion around a third portion of the outward facing surface of the blank support device to hold the first side surface of the second portion of the blank against the third portion of the outward facing surface of the blank support device in a face-to-face relation to each other and (ii) engaging the fourth blank portion of the blank on an opposite second side surface of the blank to the first side surface of the blank with a fourth blank movement apparatus portion of said blank movement sub-system and wrapping the fourth blank portion around a fourth portion of the outward facing surface of the blank support device to hold the first side surface of the fourth portion of the blank against the fourth portion of the outward facing surface of the blank support device in a face-to-face relation to each other;
• said attachment mechanism operable to attach the second and fourth blank portions together to secure the blank in the tubular shaped blank around the outward facing surface of said blank support device such that an inward facing tubular surface of the tubular shaped blank is formed from the first side surface of the blank.