Devices, systems and processes for facilitating opening of boxes

Patent metadata

Field	Value
Publication number	US-12415642-B2
Application number	US-202318397267-A
Country	US
Kind code	B2
Filing date	Dec 27, 2023
Priority date	Sep 29, 2020
Publication date	Sep 16, 2025
Grant date	Sep 16, 2025

Abstract

An opening station for facilitating box opening may include a scanning station, an edge opening station, and a conveyor assembly. The scanning station is configured to measure a length “L”, height “H”, and/or width “W” of a substantially square box having a top, a bottom, two sides, and two edge portions. The edge opening station is configured to perform perforation operations on at least one of the two edge portions. A complete box opening system may include the scanning station, edge opening station, conveyor, and at least one of a top opening station and a side opening station.

First claim

What is claimed is:

1. A system, facilitating automated opening of a box, comprising:
a scanning station which measures one or more of a length, height, and width of a box;
wherein the box has box dimensions including a box length L, a box height H, and a box width W;
wherein the box is formed in substantially one of a square or rectangular configuration by:
a top portion;
a bottom portion;
wherein the top portion and the bottom portion have the box length L by the box width W dimensions;

two side portions having the box length L by the box height H dimensions; and
two edge portions, including a leading edge portion and a trailing edge portion;
wherein the two edge portions have the box height H by the box width W dimensions;

an edge opening station that performs perforation operations on at least one of the two edge portions;
wherein the edge opening station further comprises:
an edge leading plate;
an edge trailing plate;
an edge perforating wheel; and
a first edge adjustment mechanism coupled to the edge leading plate and the edge trailing plate;
wherein the first edge adjustment mechanism mechanically adjusts a first distance Q between the edge leading plate and the edge trailing plate;
wherein the first edge adjustment mechanism includes a mechanical adjustment device comprising one of a belt drive, a screw drive, a hydraulic piston, or a gear drive; and

a conveyor assembly, forming a conveyor plane, contacting the bottom portion of the box and facilitating movement of the box forward across the conveyor plane and through the scanning station and the edge opening station; and
wherein the system performs operations during operational phases including an edge positioning phase, an edge perforation phase, an edge release phase, and an edge propel phase;
wherein during the edge positioning phase and the edge release phase, the first edge adjustment mechanism sets the first distance Q by including a minimum longitudinal clearance C such that Q=L+C; and
wherein during the edge perforation phase, the first edge adjustment mechanism sets the first distance Q<=L.

2. The system of claim 1 ,
wherein the minimum longitudinal clearance C is at least two millimeters (2 mm).

3. The system of claim 1 ,
wherein the minimum longitudinal clearance C is predetermined based on the box dimensions.

4. The system of claim 1 , further comprising:
wherein, during at least the edge perforation phase, an edge pinching pressure is applied, by the first edge adjustment mechanism, through the edge leading plate and the edge trailing plate, onto the box.

5. The system of claim 4 ,
wherein, during the edge perforation phase, the edge pinching pressure compresses the box.

6. The system of claim 5 ,
wherein the edge pinching pressure is proportional to a difference between the first distance Q and the box length L.

7. The system of claim 1 ,
wherein, during the edge propel phase, the first edge adjustment mechanism moves the edge trailing plate forward, along the conveyor assembly, and thereby propel the box through the edge opening station.

8. The system of claim 1 , further comprising:
a second edge adjustment mechanism, coupled to the first edge adjustment mechanism, vertically adjusts, relative to the conveyor plane, a second height R of at least one of the edge leading plate and the edge trailing plate; and
wherein the second edge adjustment mechanism includes at least one of a mechanical adjustment device comprising one of a belt drive, a screw drive, a hydraulic piston, and a gear drive.

9. A system, facilitating automated opening of a box, comprising:
a scanning station which measures one or more of a length, height, and width of a box;
wherein the box has box dimensions including a box length L, a box height H, and a box width W;
wherein the box is formed in substantially one of a square or rectangular configuration by:
a top portion;
a bottom portion;
wherein the top portion and the bottom portion have the box length L by the box width W dimensions;

two side portions having the box length L by the box height H dimensions; and
two edge portions, including a leading edge portion and a trailing edge portion;
wherein the two edge portions have the box height H by the box width W dimensions;

an edge opening station that performs perforation operations on at least one of the two edge portions;
wherein the edge opening station further comprises:
an edge leading plate;
an edge trailing plate;
an edge perforating wheel; and
a first edge adjustment mechanism coupled to the edge leading plate and the edge trailing plate;
wherein the first edge adjustment mechanism mechanically adjusts a first distance Q between the edge leading plate and the edge trailing plate; and
wherein the first edge adjustment mechanism includes a mechanical adjustment device comprising at least one of a belt drive, a screw drive, a hydraulic piston, or a gear drive; and

a conveyor assembly, forming a conveyor plane, contacting the bottom portion of the box and facilitating movement of the box forward across the conveyor plane and through the scanning station and the edge opening station; and
wherein the system performs operations during operational phases including an edge positioning phase, an edge perforation phase, an edge release phase, and an edge propel phase;
a second edge adjustment mechanism, coupled to the first edge adjustment mechanism, vertically adjusts, relative to the conveyor plane, a second height R of at least one of the edge leading plate and the edge trailing plate; and
wherein the second edge adjustment mechanism includes at least one of a mechanical adjustment device comprising one of a belt drive, a screw drive, a hydraulic piston, and a gear drive;
wherein, during the edge positioning phase, the second height R of the edge trailing plate is adjusted, by the second edge adjustment mechanism, by a height clearance D above the box height H;
wherein, during the edge perforation phase, the second height R of the edge leading plate and the edge trailing plate are adjusted, by the second edge adjustment mechanism, relative to the box height H and an edge compression pressure is applied downward onto the box by the edge leading plate and by the edge trailing plate; and
wherein, during the edge release phase, the second edge adjustment mechanism:
releases the edge compression pressure, and raises the edge leading plate until R>H.

10. The system of claim 9 ,
wherein, during the edge release phase, the second edge adjustment mechanism raises the edge leading plate by the box height H plus a second vertical clearance margin E and R=H+E.

11. The system of claim 10 ,
wherein, during the edge release phase, the second edge adjustment mechanism raises the edge trailing plate and R=H+E.

12. The system of claim 11 , further comprising:
wherein, during at least the edge perforation phase, an edge compression pressure is applied, by the second edge adjustment mechanism, through the edge leading plate and the edge trailing plate, onto the box.

13. The system of claim 12 ,
wherein the edge leading plate has a first inverted “L” shaped configuration including a vertical member and a first horizontal member extending towards the edge trailing plate;
wherein the edge trailing plate has an opposing inverted “L” shaped configuration including a second vertical member and a second horizontal member extending towards the edge leading plate; and
wherein the edge compression pressure is applied on the box by at least one of the first horizontal member and the second horizontal member.

1

Assignees

• Dish Network Llc

Inventors

• Pollard Jr Jimmy A
• Morrison Zachary

Classifications

• B26F1/10

  Roller type punches · CPC title

• B26D5/007

  Control means comprising cameras, vision or image processing systems · CPC title

• B26F1/24

  Perforating by needles or pins · CPC title

• B65B59/003

  Arrangements to enable adjustments related to the packaging material · CPC title

• B65B59/02

  Arrangements to enable adjustments to be made while the machine is running · CPC title