Tray forming apparatus and method

A tray forming apparatus for forming a tray from a paperboard blank having a plurality of cuts and fold lines, the blank having a bottom panel, a pair of major side panels connected to the bottom panel along a common fold line, front and rear panels, each connected to the bottom panel along respective common fold lines, a pair of front minor side panels each respectively connected along common fold lines to the front panel, a pair of rear minor side panels each respectively connected to the rear panel, a pair of top major panels each respectively connected to the front and rear panels along a common fold line, a pair of top minor panels connected to each of the top major panels along common fold lines, the apparatus comprising:

• loading means for loading one of a plurality of blanks to be transported along a predetermined path of travel from a stored position to an initial folding position for folding into a partially formed tray;
• folding means for folding the blank into a partially formed condition wherein front and rear panels are in a folded position generally perpendicular to the bottom panel thus placing the minor side panels in contact with the bottom panel, said folding means biasing each of the top major panels downwardly and inwardly such that the inner surface of each of the top major panels overlies the inner surface of the bottom panel and placing each of the top major panels in contact with an edge of the minor side panels, said folding means further folding the pair of major side panels at an obtuse angle to the bottom panel;
• a pair of spaced-apart adhesive applicators adjacent and along a downstream path of travel from said folding means, said pair of applicators operable for applying adhesive only to the outer surface of each of the forward minor side panels and the rearward minor side panels during downstream travel thereof, said folding means cooperating with said applicators for holding the minor side panels in their fully folded position;
• and
• compressing means positioned adjacent and downstream from the adhesive applicators for compressing the partially formed blank having adhesive thereon and forming the blank into a tray.

A tray forming apparatus for forming a tray from a paperboard blank having a plurality of cuts and fold lines, the blank having a bottom panel, a pair of major side panels connected to the bottom panel along a common fold line, front and rear panels, each connected to the bottom panel along respective common fold lines, a pair of front minor side panels each respectively connected along common fold lines to the front panel, a pair of rear minor side panels each respectively connected to the rear panel, a pair of top major panels each respectively connected to the front and rear panels along a common fold line, a pair of top minor panels connected to each of the top major panels along common fold lines, the tray forming apparatus comprising:

• first folding means for folding the blank into a partially formed condition by folding the front and rear minor side panels to a position generally perpendicular to their respective front and rear panels, folding the front and rear panels of the blank upwardly from the bottom panel and inwardly to a partially upright position, and folding the major side panels to a partially folded position at an obtuse angle to the bottom panel, said first folding means positioning the bottom panel onto a shuttle surface of said apparatus;
• shuttle means for conveying the partially formed blank downstream from said first folding means along a shuttle surface of said apparatus;
• second folding means positioned downstream from said first folding means, second folding means cooperating with said shuttle means for folding the front and rear panels to a fully folded position placing the minor side panels in contact with the bottom panel, said second folding means comprising top major panel biasing means for biasing each of the top major panels downwardly and inwardly such that the inner surface of each of the top major panels overlies the inner surface of the bottom panel and for generally placing each of the top major panels in contact with an edge of the minor side panels;
• adhesive applicator means for applying adhesive only to the outer surface of each of the forward minor side panels and the rearward minor side panels during downstream travel thereof as the partially folded blank is guided downstream by said shuttle means and travels between each of said pair of spaced-apart adhesive applicators, said second folding means cooperating with said applicators for holding the minor side panels in their fully folded position;
• and
• compressing means positioned downstream from the adhesive applicator means for compressing the partially folded blank to thereby adhesively secure the blank into an erected tray.

A method for forming a tray from a flat paperboard blank having a plurality of cuts and fold lines, the blank having a bottom panel, a pair of major side panels connected to the bottom panel along a common fold line, front and rear panels, each connected to the bottom panel along respective common fold lines, a pair of front minor side panels each respectively connected along common fold lines to the front panel, a pair of rear minor side panels each respectively connected to the rear panel, a pair of top major panels each respectively connected to the front and rear panels along a common fold line, a pair of top minor panels connected to each of the top major panels along common fold lines, the tray forming method comprising the steps of:

• loading a blank by conveying it along a predetermined path from a stored position to an initial folding position for folding into a partially formed tray;
• initially folding the blank into a partially formed condition comprising the steps of:
• folding the front and rear minor side panels to a position generally perpendicular to their respective front and rear panels;
• folding the front and rear panels of the blank upwardly from the bottom panel and inwardly to a partially upright position;
• and
• folding the major side panels to a partially folded position at an obtuse angle to the bottom panel, said initially folding step positioning the bottom panel onto a shuttle surface of the apparatus;
• conveying the partially formed blank downstream along a shuttle surface;
• folding the front and rear panels to a fully folded position for placing the minor side panels in contact with the bottom panel, the front and rear panel folding step comprising the step of biasing each of the top major panels downwardly and inwardly such that the inner surface of each of the top major panels overlies the inner surface of the bottom panel and for generally placing each of the top major panels in contact with an edge of the minor side panels;
• applying adhesive from a single pair of spaced-apart applicators only to the outer surface of each of the forward minor side panels and the rearward minor side panels during downstream travel thereof as the partially folded blank is guided downstream and travels between each of said pair of spaced-apart adhesive applicators;
• and
• compressing the top minor panels and the major side panels against the minor side panels having adhesive thereon so that the inner surfaces of the top minor panels and the major side panels press against the outer surface of the minor side panels of the blank, thereby adhesively securing the blank in an erect tray forming position.

A method for forming a tray comprising the steps of:

• initially folding a flat paperboard blank into a partially formed condition comprising the steps of:
• folding front and rear minor side panels of the blank to a position generally perpendicular to each of their respective front and rear panels;
• folding front and rear panels of the blank upwardly from the bottom panel and inwardly to a partially upright position;
• and
• folding major side panels to a partially folded position at an obtuse angle to the bottom panel, said initially folding step positioning the bottom panel onto a shuttle surface of the apparatus;
• conveying the partially folded blank downstream along a shuttle surface;
• folding the front and rear panels to a fully folded position for placing the minor side panels in contact with the bottom panel;
• applying adhesive only to the outer surface of each of the forward minor side panels and the rearward minor side panels;
• and
• compressing the top minor panels and the major side panels against the minor side panels having adhesive thereon so that the inner surfaces of the top minor panels and the major side panels press against the outer surface of the minor side panels of the blank, thereby adhesively securing the blank in an erect tray forming position.