Automatic utensil wrapping machine
The automatic utensil wrapping machine is an apparatus for wrapping a napkin around one or more utensils for use as a place setting. The apparatus comprises a housing, a support frame and an assembly of elements mounted to the support frame. The assembly of elements includes a napkin lifting station, a napkin wrapping station, a napkin transfer station, a utensil transfer station, and a napkin folding station. The apparatus wraps each napkin around a predetermined amount of utensils without the need for human contact. The napkins are wrapped by first positioning a stack of napkins on the lifting station, then individually transferring napkins from the lifting station to the wrapping station. The utensils are then transferred from the individual cartridges and placed onto the napkin. Two opposing corners of the napkin are then folded over and the napkin is subsequently wrapped around the utensils.
1. Field of the Invention
The present invention relates to equipment for the food service industry and more particularly to an automated device for wrapping utensils in a napkin for use as a place setting.
2. Description of the Related Art
Restaurants and other food service establishments often roll utensils such as forks, knives and spoons in napkins before presenting them to their customers. Rolling the utensils in this manner serves several purposes, including enhancing the decor of the table and providing a convenient way to prepare a table prior to the customers' arrival. In addition, rolling the utensils in the napkin provides an easy way for the servers to handle the utensils without contacting them and thereby ensuring that the utensils remain clean. Currently, a napkin must be rolled around the utensils one at a time by hand by a waiter, waitress or bus person. This process is time consuming and inefficient. There is currently a need to provide a method and apparatus for increasing the efficiency of this process. A number of automatic utensil packaging devices have been developed in the past in an attempt to reduce the cost associated with wrapping utensils in napkins. Examples of these devices are disclosed in the following patent documents.
U.S. Pat. No. 3,659,394 issued to Hartleib et al. discloses a method and machines for wrapping articles. The method and machine involve withdrawing a sheet of material from a supply reel and leading it into engagement with an article that is to be wrapped. The article is then rotated so that the sheet material is wrapped around the article. The method and machine are used for wrapping and labeling general articles.
U.S. Pat. No. 5,469,688 and International Application number WO 97/08052 issued to Dunbar et al. disclose a method for wrapping silverware in a napkin. The method and apparatus for automatically wrapping at least one eating utensil in a napkin includes a receiving area for the utensils and napkin and a wrapping mechanism. The wrapping mechanism includes a frame, a belt and a belt manipulator. The belt has a first surface that frictionally contacts the napkin. A portion of the belt is movable to form a trough in which the napkin and utensil are manipulated and urged by frictional contact with the belt. The belt urges the napkin and folds and rolls it, automatically wrapping the utensils.
U.S. Pat. No. 6,023,908 issued to Vetsch, K.R. discloses a method and apparatus for folding a napkin around an eating utensil. The device comprises a housing having a conveyor belt system for advancing the napkin through the device along a horizontal path. As the napkin passes through the device it contacts a folding belt that causes a corner of the napkin to be folded back onto it. Pieces of silverware are delivered from storage bins in timed relation to the movement of the napkin and are placed on top of the napkin. The napkins and silverware then contact a rolling belt that rolls the napkin around the silverware. The rolled napkin is transported out of the device and into an external holding bin.
U.S. Pat. No. 6,023,913 issued to Gray et al. discloses an apparatus and method for wrapping silverware within a napkin. The apparatus includes a worktable with an upwardly opening trough for accepting a napkin and silverware items. The napkin is automatically placed over the trough and silverware is then directed onto the napkin so that the silverware falls to the bottom of the trough and positions the napkin between the silverware and the bottom of the trough. A rotatable blade is positioned within the trough for spinning the napkin and silverware until the napkin is wrapped around the silverware.
U.S. patent application Ser. No. 2002/0112445 discloses a device for automatically wrapping eating utensils in a napkin. The device includes a number of hoppers for sortingly holding eating utensils, a tray for holding the napkins, a staging assembly for receiving the napkins from the tray and the utensils from the hopper, a wrapping assembly for wrapping the napkin around the utensils and a banding assembly for placing a band around the wrapped napkin. The device further includes an ultraviolet light assembly for sanitizing the utensils while they are in the hoppers.
U.S. patent application Ser. No. 2002/0124534 discloses an apparatus and method for automatically wrapping silverware in a napkin. The utensil wrapping apparatus includes a utensil-manipulating device for placing the utensils adjacent a napkin. Two utensil engaging devices are provided for releasably engaging the ends of the utensils and the portions of the napkins that are adjacent the utensils. The napkin and utensils are held in a fixed relative position. A napkin guide is provided for wrapping the napkin around the utensils.
European Patent EP 0841247 discloses a device for packing cutlery in a serviette. The serviette is supplied to a conveyor belt that is not as wide as the serviette. At a loading station the cutlery is loaded onto the serviette. In the packing station of the device, two coaxial winding rollers are set spaced by the length of the cutlery at the sides of the belt. The looping angle of the rollers can be increased by a guide roller, placed on the belt underside, so that the paper can roll around the winding rollers to enclose the silverware. The rollers are then raised so the belt stretches. Once the rollers are removed from the winding body, the paper lies on the belt and is moved to the side closing devices to close the ends of the wrapped body.
None of the above inventions and patents, taken either singly or in combination, is seen to describe the instant invention as claimed. Thus an automatic silverware wrapping machine solving the aforementioned problems is desired.
SUMMARY OF THE INVENTIONThe automatic utensil wrapping machine is an apparatus for wrapping a napkin around one or more pieces of utensils for use a place setting. The apparatus comprises a housing, a support frame and an assembly of elements mounted to the support frame. The assembly of elements includes a napkin lifting station, a napkin wrapping station, a napkin transfer station, a utensil transfer station, and a napkin folding station. The apparatus wraps each napkin around a predetermined amount of utensils without the need for human contact.
The housing has a generally rectangular, hollow structure having an output opening, a utensil access and a napkin access disposed on the structure. The output opening is an open port in the side of the housing that allows the wrapped napkins to pass out of the apparatus. The utensil access comprises a door that provides access to the interior of the apparatus for loading the apparatus with utensils. The napkin access comprises a door that provides access to the interior of the apparatus for loading the apparatus with napkins. The support frame is positioned inside of the housing and comprises an assembly of vertically oriented beams and horizontally oriented support rails.
The napkin lifting station receives and supports a stack of napkins. The napkins are placed onto the lifting station through the napkin access door. The napkin lifting station includes a platform with a flat top, a plurality of platform supports and a platform lift for incrementally lifting the platform after a predetermined number of napkins are removed from the platform. The stack of napkins is supported by the platform. As napkins are removed from the top of the stack and the height of the stack is thus decreased, the platform lift raises the platform to accommodate the decreased stack height. The apparatus is further equipped with a napkin stack sensor that alerts the user of the apparatus once the entire stack of napkins has been removed from the lifting station platform.
The napkin wrapping station has a plurality of conveyor belts for wrapping a napkin around a predetermined amount of utensils. The napkin wrapping station has a pair of sidewalls, a horizontally oriented, elongated output conveyor belt disposed between the pair of sidewalls, a pair of counter-rotating napkin wrapping belts, a wrapping carriage having a plurality of winding rollers, a wrapping carriage shifter assembly and a plurality of actuators for powering the wrapping station. The combination of wrapping belts and winding rollers wrap each napkin around the predetermined amount of utensils.
The napkin transfer station individually transfers napkins from the lifting station to the wrapping station. The napkin transfer station comprises a base plate with a flat bottom and area that is generally equivalent to the size of the napkins. A plurality of suction devices are disposed along the bottom surface of the base plate. The suction devices are adapted for releasably engaging the napkins. The napkin transfer station also includes a pair of guide rails and a shifter assembly for repositioning the base plate along the guide rails. Once the suction devices engage an individual napkin the shifter transfer station raises the napkin and the shifter assembly moves the base plate along the guide rails until the base plate reaches the wrapping station. At this point the suction devices release the napkin onto the wrapping station.
The utensil transfer station simultaneously places a plurality of different types of utensils onto each individual napkin while the napkin is positioned on the napkin wrapping station. The utensil transfer station comprises a plurality of cartridges for sortingly storing stacks of utensils. Each cartridge contains a different type of utensil and the number of cartridges may vary depending on the amount of different utensils used. The utensil transfer station further comprises a plurality of lifters for lifting each of the stacks of utensils. The lifters force the stacks of utensils upwards so one at a time the utensils may be removed from its cartridge. Once the utensil is forced out of the top of the cartridge a plurality of utensil grippers simultaneously remove a utensil from each stack of utensils. The utensil grippers comprise pneumatic grippers having a pair of fingers that releasably engage the sides of each utensil. The utensil transfer station also includes a shifter assembly for transporting the utensils away from the cartridges, a feed conveyor for receiving the utensils and transferring them to the napkins on the wrapping station and a bracket for mounting the utensil transfer station to the support frame.
Finally, the napkin folding station folds over two opposing corners of the napkin prior to it being wrapped by the wrapping station. Once the utensils are placed onto the napkin the folding station folds over two corners of the napkin to cover the utensils. The folding station comprises a folding arm, a vacuum lift and a shifter assembly. The folding arm has at least one suction device disposed on its bottom surface for releasably engaging the corners of the napkins. The vacuum lift acts to raise and lower the folding arm into contact with the napkin. The shifter assembly allows the folding arm to manipulate the corners of the napkin once they are engaged by the suction device.
According to another aspect of the present there is a method for wrapping a napkin around one or more pieces of utensils. The method includes the steps of first positioning a stack of napkins on the napkin lifting station, then individually transferring napkins from the lifting station to the napkin wrapping station. The different utensils are then transferred from their individual cartridges and placed on the napkin. Two opposing corners of the napkin are then folded over itself and the napkin is subsequently wrapped around the utensils.
The napkin transfer step includes releasably engaging the napkins individually with the napkin transfer plate and then lifting and carrying each napkin to the wrapping station. Each individual utensil is removed from its cartridge by the utensil grippers and transferred to the utensil feed conveyor. The feed conveyor then transports the utensils to the wrapping station and drops the utensils onto the napkin. Two corners of the napkin are then folded over towards the center of the napkin by the folding arm. Finally, the counter-rotating wrapping belts feed the napkin onto a pair of winding rollers that wrap the napkin around the utensils. Once the napkin is wrapped the winding rollers are lowered to allow the wrapped napkin to drop onto the exit conveyor belt and exit out of the apparatus.
Accordingly, it is a principal object of the invention to provide an apparatus and method for wrapping a napkin around eating utensils for use in the food services industry.
It is another object of the invention to provide an apparatus and method for wrapping a napkin around utensils that does not require human handling of the utensils.
It is a further object of the invention to provide an apparatus and method of wrapping a napkin around utensils that is fully automated.
Still another object of the invention is to provide an apparatus and method of wrapping a napkin around utensils that improves restaurant efficiency by allowing food servers to concentrate on other tasks while the apparatus automatically wraps all of the utensils in napkins.
It is an object of the invention to provide improved elements and arrangements thereof for the purposes described which is inexpensive, dependable and fully effective in accomplishing its intended purposes.
These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT The present invention is an apparatus for wrapping a napkin around one or more utensils for use as a place setting. The apparatus will be commonly used in the food service industry for automating the process of preparing utensil table settings by providing an apparatus and method of wrapping the utensils without the need for human involvement. The apparatus generally comprises an exterior housing, an interior framework and an assembly of parts disposed on the framework for receiving and wrapping the napkins around one or more utensils.
A plurality of openings are disposed along the housing 20. An output opening 22 is disposed on a first side of the housing 20. The output opening 22 is adapted to allow wrapped utensils to exit the wrapping machine 10 and drop down to a holding area. A utensil access assembly 30 is disposed on the front of the housing 20. The utensil access assembly 30 comprises a door 32, a door frame 36, a plurality of hinges 38 and a handle 34. The door 32 may be opened to gain access to the interior of the wrapping machine 10. The door 32 is adapted to allow utensils to be loaded into the wrapping machine 10. While the wrapping machine 10 is in use the door 32 remains closed to prevent contact with the moving parts inside of the housing 20.
The napkin lifting station 60 is configured according to the size of the napkin being used. The stack of napkins are placed on the top surface 62 of the platform 61. The platform 61 is oriented so that the napkins are turned 45 degrees to the wrapping station 110.
The shifter assembly 68 operates to adjust the height of the stack of napkins by raising or lowering the platform 61. The shifter assembly 68 preferably uses a compressed air cylinder to incrementally lift or lower the platform 61. The compressed air cylinder uses a five-three way control valve to initiate the raising of the platform 61. Once a predetermined number of napkins are removed from the stack, the air cylinder raise the platform 61 to adjust the height of the napkin stack accordingly. This ensures that a napkin will always be available for the wrapping process. The lifting platform may additionally comprise a sensor that will activate a “napkins out” display on the housing 20 of the wrapping machine 10 to signal that the stack of napkins has run out and needs to be replaced. The sensor is preferably an IR sensor, but is not limited in this manner and any suitable sensor may be used.
While the napkin lifting station 60 and the napkin transfer station 70 are active, the utensil transfer station 100 is also operating.
The cartridges 130 comprise front and back walls 132, side walls 136, a bottom surface 134 and an open top 138.
The utensil lifters 104 simultaneously lift utensils U, one at a time, out of the top opening 138 of the cartridges 130. The lifters 104 have compressed air cylinders that control the raising of the utensils U. The lifters 104 push the utensils U the top of the cartridges using a five-three way valve to initiate each incremental rise of the stack of utensils U. The cartridges 130 may also comprise a sensor that activates a “cartridge empty” signal to alert the users of the wrapping machine 10 that the utensils U need to be replaced.
The utensil grippers 101 engage the utensils U when they are pushed out of the top opening 138 of the cartridges 130. The plurality of grippers 101 simultaneously engage one utensil U from each of the cartridges 130. The utensil grippers 101 comprise a pair of pneumatic fingers 102 that engage each of the utensils U by gripping the utensils U on either side and pinching the utensil U to secure it between the pneumatic fingers 102. Once the utensil grippers 101 engage the utensils U the utensil grippers 101 are raised and the shifter assembly 108 simultaneously transports the grippers 101 along the guide rails 105 until they are above the feed conveyor 90. The utensil grippers 101 release the utensils U onto the feed conveyor 90 and the shifter assembly 103 returns the grippers back to their original position.
The shifter assembly 81 and the vacuum lift 85 are both compressed air cylinders that control the movement of the folding arm 82. The vacuum lift 85 raises and lowers the arm 82, while the shifter assembly 81 extends the arm 82.
Referring to
Napkins N are then individually removed from the lifting station 60 by the napkin transfer station 70. The napkin transfer station 70 lowers so that the suction devices 120 disposed along the bottom surface 74 of the base plate 72 can engage the napkins N. The napkin transfer station 70 rises and transports the napkin N to the napkin wrapping station 110. At the napkin wrapping station 110 the transfer station 70 lowers, the suction devices 120 release the napkin N onto the wrapping belts 140,141 of the wrapping station 110, and the transfer station 70 returns to its original position.
While the napkin lifting station 60 and the napkin transfer station 70 are active, the utensil transfer station 100 is transporting utensils U to the feed conveyor (shown in
It is to be understood that the present invention is not limited to the embodiment described above, but encompasses any and all embodiments within the scope of the following claims.
Claims
1-13. (canceled)
14. A method of wrapping a napkin around one or more utensils, said method comprising the steps of:
- positioning a stack of napkins on a napkin lifting station;
- individually transferring napkins from said lifting station to a napkin wrapping station;
- transferring a plurality of utensils from a plurality of utensil storage cartridges to said napkin wrapping station and positioning the utensils on the napkin;
- folding two opposing comers of the napkin over itself; and
- wrapping the napkin around the utensils.
15. The method according to claim 14 wherein said napkin transfer step includes releasably engaging the napkins individually with a napkin transfer plate having a plurality of suction devices disposed on its bottom surface and then lifting and carrying each napkin to said napkin wrapping station.
16. The method according to claim 14 wherein said utensils transfer step includes gripping an individual utensil from each of said utensil storage cartridges and transporting them to a utensil feeding conveyor belt that transfers the utensils onto a napkin positioned on the napkin wrapping station.
17. The method according to claim 14 wherein said wrapping step includes placing the napkin across a gap between adjacent, counter-rotating wrapping belts that feed the napkin onto a pair of winding rollers that roll the napkin around the utensils and then once the napkin is rolled, lowering the winding rollers so the napkin falls onto an exit conveyor and exits said napkin wrapping station.
18. The method according to claim 17, further including the step of transporting the wrapped napkins along said exit conveyor through an output opening.
Type: Application
Filed: Jul 19, 2005
Publication Date: Feb 16, 2006
Inventors: Rebecca Heilman (Ponte Vedra Beach, FL), Eric Heilman (Ponte Vedra Beach, FL), Andre LeBlanc (Saskatoon)
Application Number: 11/184,087
International Classification: B65B 11/00 (20060101);