# US 11,897,652 B2 · Devices, systems and processes for facilitating opening of boxes

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- Number: US 11,897,652 B2
- Document ID: US11897652B2
- Status: Granted
- Kind: B2
- Application number: 17/035,966
- Filed: 2020-09-29
- Published: 2022-03-31
- Granted: 2024-02-13
- Earliest claimed: 2020-09-29
- Assignees: DISH Network L.L.C.
- Applicants: DISH Network L.L.C.
- Inventors: Jimmy A. Pollard, Jr.; Zachary Morrison
- Web page: https://patentgrep.com/patent/US11897652B2

## CPC

- B65B 69/0041: {by puncturing}
- B26D 9/00: Cutting apparatus combined with punching or perforating apparatus or with dissimilar cutting apparatus
- B26F 1/04: with selectively-operable punches
- B65B 59/003: {Arrangements to enable adjustments related to the packaging material}
- B65B 59/02: Arrangements to enable adjustments to be made while the machine is running
- B26D 5/007: {Control means comprising cameras, vision or image processing systems}
- B26F 1/10: Roller type punches
- B26F 1/24: Perforating by needles or pins
- B65B: MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING (bundling and pressing devices for cigars A24C1/44; devices for tensioning and securing binders adapted to be supported by the article or articles to be bound B25B25/00; applying closure members to bottles, jars or similar containers B67B1/00-B67B6/00; concurrent cleaning, filling and closing of bottles B67C7/00; emptying bottles, jars, cans, casks, barrels or similar containers B67C9/00)
- B26D: CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING (for growing crops or plants A01D, A01G; for fodder or straw A01F; for bulk butter A01J; for dough A21C; slaughtering A22B; for tobacco, cigars or cigarettes A24; marking-out, perforating or making buttonholes A41H25/00; manufacturing footwear A43D; brushmaking A46D; surgery A61B; disintegrating, mincing or shredding in general B02C; cutting wire, making pins or nails B21F, B21G; of the kind used formetal B23; cutting by abrasive fluid jets B24C5/02; hand-held cutting tools B26B; perforating, cutting-out, stamping-out or punching, or severing by means other than cutting B26F; for wood B27; for stone B28D; working of plastics or substances in a plastic state B29; making boxes, cartons, envelopes or bags, of paper or similarly worked materials, e.g. metal foil, B31B; article or web delivery apparatus incorporating cutting or line-perforating devices B65H35/00; for leather or upholstery B68, C14B; for glass C03B; making matches C06F; for peat C10F; for sugar C13B45/00; for textile materials D06H; civil engineering, building, mining, see Section E; for light guides G02B6/25; cutting processed photographic material G03D15/04)
- B26F: PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING (marking-out, perforating or making buttonholes A41H25/00; shoemaking A43D; surgery A61B; punching metal B21D; drilling metal B23B; cutting of metal by applying heat locally, e.g. flame cutting, B23K; cutting by abrasive fluid jets B24C5/02; details common to machines for severing B26D; drilling wood B27C; drilling stone B28D; working of plastics or substances in a plastic state B29; making boxes, cartons, envelopes or bags, of paper or similarly worked materials, e.g. metal foil, B31B; of glass C03B; of leather C14B; of textile materials D06H; for light guides G02B6/25; of tickets G07B)

## 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.

## Claims

### Claim 1

A system, for facilitating automated opening of a box, comprising:
a scanning station configured to measure one or more of a length, height, and width of a box;
wherein the box has a length L, a height H, and a width W;
wherein the box is formed in substantially one of a square or rectangular configuration by:
a top portion;
a bottom portion;
wherein each of the top portion and the bottom portion having L by W dimensions;
two side portions having L by H dimensions; and
two edge portions having H by W dimensions;
an edge opening station configured to perform 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; and
wherein at least one of the edge leading plate and edge trailing plate further comprise an edge guide slot;
a first edge adjustment mechanism coupled to the edge leading plate and the edge trailing plate; and
a conveyor assembly configured to contact the bottom portion of the box and facilitate movement of the box through each of the scanning station and the edge opening station;
an edge perforating wheel;
an edge perforating wheel holding block coupled to the edge perforating wheel and configured to facilitate movement of the edge perforating wheel within the edge guide slot;
a second edge adjustment mechanism coupled to the first edge adjustment mechanism; and
a third edge adjustment mechanism coupled to the edge perforating wheel block and to the second edge adjustment mechanism.

### Claim 2 (depends on 1)

The system of claim 1, further comprising:
a side opening station configured to perforate the side portion of the box; and
wherein the conveyor assembly is further configured to facilitate movement of the box through the side opening station.

### Claim 3 (depends on 1)

The system of claim 1,
wherein the first edge adjustment mechanism is an edge X axis adjustment mechanism;
wherein the second edge adjustment mechanism is an edge Y axis adjustment mechanism; and
wherein the third edge adjustment mechanism is an edge Z axis adjustment mechanism.

### Claim 4 (depends on 3)

The system of claim 3,
wherein at least one the first edge adjustment mechanism, the second edge adjustment mechanism, and the third edge adjustment mechanism are configured to adjust positions of at least one of the edge leading plate, the edge trailing plate, and the edge perforating wheel during an edge opening station operational phase.

### Claim 5 (depends on 4)

The system of claim 4,
wherein the edge opening station operational phase comprises at least one of:
an edge positioning phase;
an edge perforating phase;
an edge release phase; and
an edge propel phase.

### Claim 6 (depends on 5)

The system of claim 5,
wherein during the edge positioning phase,
the first edge adjustment mechanism is configured to adjust a distance Q between the edge leading plate and the edge trailing plate based on the length L and a longitudinal clearance margin C; and
the second edge adjustment mechanism is configured to adjust the edge leading plate to a height R, where R is the height H of the box plus a first vertical clearance margin D.

### Claim 7 (depends on 5)

The system of claim 5,
wherein during the edge perforating phase,
the first edge adjustment mechanism is configured to adjust a distance Q between the edge leading plate and the edge trailing plate such that Q<=L;
the second edge adjustment mechanism is configured to a adjust the edge trailing plate to substantially a height R such that R H; and
the third edge adjustment mechanism is configured to move the edge perforating wheel a distance S along the width W of the box.

### Claim 8 (depends on 1)

The system of claim 1
wherein the first edge adjustment mechanism applies an edge pinching pressure on the box during an edge perforating phase.

### Claim 9 (depends on 1)

The system of claim 1,
wherein the second edge adjustment mechanism applies an edge compression pressure on the box during an edge perforating phase.

### Claim 10 (depends on 1)

The system of claim 1,
wherein the third edge adjustment mechanism applies an edge perforation pressure on the box during an edge perforating phase.

### Claim 11

A system, for facilitating automated opening of a box, comprising:
a scanning station configured to measure one or more of a length, height, and width of a box;
wherein the box has a length L, a height H, and a width W;
wherein the box is formed in substantially one of a square or rectangular configuration by:
a top portion;
a bottom portion;
wherein each of the top portion and the bottom portion having L by W dimensions;
two side portions having L by H dimensions; and
two edge portions having H by W dimensions;
an edge opening station configured to perform 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; and
wherein at least one of the edge leading plate and edge trailing plate further comprise an edge guide slot
a first edge adjustment mechanism coupled to the edge leading plate and the edge trailing plate; and
a conveyor assembly configured to contact the bottom portion of the box and facilitate movement of the box through each of the scanning station and the edge opening station;
an edge perforating wheel;
an edge perforating wheel holding block coupled to the edge perforating wheel and configured to facilitate movement of the edge perforating wheel within the edge guide slot;
a second edge adjustment mechanism coupled to the first edge adjustment mechanism;
a third edge adjustment mechanism coupled to the edge perforating wheel block and to the second edge adjustment mechanism;
a top opening station configured to perforate the top portion of the box; and
wherein the conveyor assembly is further configured to facilitate movement of the box through the top opening station.

### Claim 12 (depends on 11)

The system of claim 11, further comprising:
a side opening station configured to perforate the side portion of the box; and
wherein the conveyor assembly is further configured to facilitate movement of the box through the side opening station.

### Claim 13 (depends on 11)

The system of claim 11,
wherein the two edge portions of the box comprise at least one of cardboard, wood, plastic, metal, and glass material; and
wherein the edge opening station is further configured to perform the perforation operations on the two edge portions.

### Claim 14

A device, for perforating an edge of a box, comprising:
a leading plate configured to first secure a box during a perforation operation;
wherein the box has a length L, a height H, and a width W;
a trailing plate configured to second secure the box during the perforation operation;
wherein the trailing plate further comprises a guide slot;
a perforating wheel configured to perforate the box during the perforation operation;
a first adjustment mechanism, coupled to and configured to adjust a distance between the leading plate and the trailing plate;
a second adjustment mechanism, coupled to the leading plate and the trailing plate, configured to adjust a first height of the leading plate and a second height of the trailing plate; and
a third adjustment mechanism configured to move the perforating wheel along the guide slot along a portion S of the width W of the box.

### Claim 15 (depends on 14)

The device of claim 14,
wherein the first height and the second height are independently adjusted by the second adjustment mechanism.

### Claim 16 (depends on 14)

The device of claim 14,
wherein the first adjustment mechanism applies a pinching pressure on the box during a perforating phase;
wherein the second adjustment mechanism applies an edge compression pressure on the box during an edge perforating phase; and
wherein the third adjustment mechanism applies an edge perforation pressure on the box during an edge perforating phase.

### Claim 17

A method, for automatically opening a box, comprising:
determining, using a scanning system, dimensions of a box;
wherein the box has a length L, a height H, and a width W;
wherein the box comprises a top portion and a bottom portion;
wherein each of the top portion and the bottom portion are definable by L×W;
wherein the box comprises a proximal side portion and a distal side portion;
wherein each of the proximal side portion and the distal side portion are definable by H×L; and
wherein the box comprises a leading edge portion and a trailing edge portion;
wherein each of the leading edge portion and the trailing edge portion are definable by H×W;
determining whether the box dimensions are acceptable;
when the box dimensions are not acceptable;
identifying the box for manual opening operations; and
when the box dimensions are acceptable,
inserting the box into an edge opening station comprising:
an edge leading plate;
an edge trailing plate;
wherein at least one of the edge leading plate and edge trailing plate further comprise an edge guide slot;
an edge perforating wheel;
an edge perforating wheel holding block coupled to the edge perforating wheel and configured to facilitate movement of the edge perforating wheel within the edge guide slot; and
a first edge adjustment mechanism coupled to the edge leading plate and the edge trailing plate; and
perforating, by the edge perforating wheel, at least one of the leading edge portion and the trailing edge portion of the box.

### Claim 18 (depends on 17)

The method of claim 17,
wherein perforation of at least one of the leading edge portion and the trailing edge portion of the box further comprises:
applying to the box each of an edge pinching pressure, an edge compression pressure, and an edge perforation pressure.

### Claim 19 (depends on 18)

The method of claim 18 further comprising:
perforating at least one of:
the top portion of the box;
the proximal side portion; and
the distal side portion of the box.

### Claim 20 (depends on 1)

The system of claim 1,
wherein the two edge portions of the box comprise at least one of cardboard, wood, plastic, metal, and glass material; and
wherein the edge opening station is further configured to perform the perforation operations on the two edge portions.