Patent ID: 6962558

Claim:
A method of forming a box having a plurality of corner gussets comprising the steps: providing a generally planar box blank having a base wall, four side walls and four gusset corner formation wall sections each having upper and lower portions, said four gusset corner formation wall sections extending from and connected to two of said side walls opposite one another with two of said four gusset corner wall sections connected to and extending from each of said two of said side walls; providing a box forming device including a longitudinally extended box blank track means operative to continually feed said box blank through said box forming device generally free of stoppage of said box blank while in said gusset formation section and further including a gusset formation section having at least one kicker plate, at least one forming blade and at least one adhesive securement means; feeding said box blank into said box forming device on said box blank track means; deflecting each of said gusset corner formation wall sections to a generally perpendicular orientation relative to said base wall via said at least one kicker plate; bending said upper portion of each of said gusset corner formation wall sections towards a connected one of said side walls via said at least one forming blade such that said upper and lower portions of said gusset corner formation wall section form an acute angle therebetween; securing a glue flap section of said upper portion of each of said gusset corner formation wall sections to said connected one of said side walls via said at least one adhesive securement means thereby securing said upper and lower portions of said gusset corner formation wall section to form a gusset; folding said side walls upwards generally perpendicular to said base wall; securing adjacent ones of said side walls to one another whereby said box is formed.