Abstract:
An apparatus that wraps dinner flatware in a paper napkin in an automated manner and secures it with a paper label is disclosed. The apparatus includes input hoppers for knives, forks, spoons, and napkins which are located on the front and top part of the unit. Additionally, a roll of paper napkins and a roll of securing paper labels are provided on top with their own automatic dispensing means. A plastic cover secures the entire top of the invention to protect it from dust and dirt as well as accidental contact during operation. A series of ultraviolet radiation sources reduces and/or eliminates microbes and viruses either on the surface of the flatware or airborne inside the apparatus. Internal mechanisms then take one of each piece of flatware and fold and roll it in a napkin. The completed napkin unit then drops out the bottom where it is collected for use.

Description:
RELATED APPLICATIONS 
   The present invention is a Continuation in Part of U.S. Ser. No. 10/968,779, filed on Oct. 20, 2004, now U.S. Pat. No. 6,976,348 issued on Dec. 20, 2005, which was a Continuation in Part of U.S. Ser. No. 10/641,357, filed on Aug. 15, 2003, now U.S. Pat. No. 6,837,028 issued on Jan. 4, 2005, which claimed the benefit of U.S. Provisional Patent 60/407,574 filed on Sep. 3, 2002. 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates generally to automated assembling apparatuses and, more particularly, to an automated flatware and napkin assembling apparatus. 
   2. Description of the Related Art 
   In many restaurants, silverware or flatware, is folded or rolled up in a paper napkin and secured with an adhesive paper strap. This has many advantages from increased sanitary conditions, less chance of falling on the floor, a more professional presentation and so forth. This presentation technique is also finding favor in cafeteria environments where bins of flatware were often used before. These previously used bins forced patrons to touch more flatware than was necessary to remove just one piece, resulting in more unsanitary conditions, especially in environments such as schools and hospitals. However, the practice of rolling flatware in a napkin is not without its disadvantages. Perhaps the biggest is the cost of paying a restaurant or cafeteria employee to roll them. Even if an employee is efficient at such a task, he or she will almost certainly produce non-consistent rolled napkins thus reducing that professional image. Accordingly, a need exists for a means by which silverware or flatware can be folded in a paper napkin without the disadvantages of the folding methods that are currently used. 
   A search of the prior art did not disclose any patents that read directly on the claims of the instant invention; however, the following references were considered related. 
   Accordingly, a need exists for a means by which silverware/flatware can be rolled up into a napkin without the disadvantages of the methods that are currently used. 
   SUMMARY OF THE INVENTION 
   It is therefore an object of the present invention to provide an improved napkin rolling apparatus. 
   It is a feature of the present invention to provide an improved apparatus that wraps silverware/flatware (the terms silverware and flatware are synonymous herein) into a napkin and fastens the roll with an optional paper band that is plain or printed with any name, logo or advertising message. Briefly described according to one embodiment of the present invention, the silverware and napkin rolling apparatus, is an apparatus that wraps silverware/flatware (the terms silverware and flatware are synonymous herein) into a napkin and fastens the roll with a paper band. The silverware and napkin rolling apparatus has input hoppers for knives, forks and/or spoons and has input feed slots for napkins and paper containment bands. Additionally, as the silverware/flatware are wrapped, they are exposed to ultraviolet radiation thus killing and/or eradicating any remaining germs and bacteria. 
   The apparatus has a cover to protect users from physical injury when the apparatus is in operation and to protect the loaded silverware and napkins from dust and debris when not in operation, as well as protect the user from exposure to ultraviolet radiation during operation of the apparatus. Internal mechanisms work to transfer one knife, one fork and if desired one spoon to a trough where they meet with the napkin that is caused to cover the silverware. 
   A paper band is also passed through the machine and is forced around the napkin-silverware combination. If used, the paper band is caused to be sealed and the rolled silverware is then dispensed through the discharge chute and collected in an output tray. 
   The output tray is capable of holding up to fifty completed sets of rolled silverware. 
   The present invention is also equipped with sensors that halt operations when a necessary component is not available or when cover is opened during operation or when objects become lodged. 
   It is an object of the present invention to provide an apparatus that automatically wraps silverware into napkins. 
   It is another object of the present invention to provide an apparatus that quickly and conveniently wrap silverware in napkins. 
   It is yet another object of the present invention to sterilize silverware via ultraviolet radiation exposure to further aid in the elimination of microbiological bacterial contamination. 
   It is yet another object of the present invention to provide an apparatus that consistently results in near identical aesthetic wraps of silverware in napkins. 
   It is yet another object of present invention, which greatly reduces the amount of silverware having human contact thereby reducing the level of microbiological bacterial contamination. 
   It is yet another object of present invention which provides an institution an apparatus that quickly and conveniently wraps silverware into a napkin and continues to bind the rolled napkin with an optional plain or printed paper band. 
   
     
       
             
           
             
             
           
         
             
                 
             
             
               DESCRIPTIVE KEY 
             
             
                 
             
           
           
             
                 
             
           
        
         
             
               10 
               automated flatware and 
             
             
                 
               napkin assembling apparatus 
             
             
               15 
               automation enclosure 
             
             
               20 
               start switch 
             
             
               25 
               stop switch 
             
             
               30 
               napkin reset switch 
             
             
               35 
               rolled paper napkins 
             
             
               40 
               label reset switch 
             
             
               45 
               rolled paper adhesive labels 
             
             
               50 
               mounting feet 
             
             
               55 
               spoon hopper 
             
             
               60 
               fork hopper 
             
             
               65 
               knife hopper 
             
             
               70 
               cover 
             
             
               75 
               limit switch 
             
             
               80 
               exit slot 
             
             
               85 
               power cord 
             
             
               90 
               power plug 
             
             
               95 
               spoon 
             
             
               100 
               fork 
             
             
               105 
               knife 
             
             
               110 
               first upper indexing plate 
             
             
               115 
               first lower indexing plate 
             
             
               120 
               sliding chute 
             
             
               125 
               first travel path 
             
             
               130 
               second travel path 
             
             
               135 
               second upper indexing plate 
             
             
               140 
               second lower indexing plate 
             
             
               145 
               third travel path 
             
             
               150 
               napkin stream 
             
             
               155 
               first indexing rollers 
             
             
               160 
               label stream 
             
             
               165 
               second indexing rollers 
             
             
               170 
               flatware trough 
             
             
               171 
               first ultraviolet lamp tube 
             
             
               172 
               first ultraviolet lamp tube 
             
             
                 
               shield 
             
             
               173 
               second ultraviolet lamp tube 
             
             
               174 
               second ultraviolet lamp tube 
             
             
                 
               shield 
             
             
               175 
               fourth travel path 
             
             
               180 
               rotational travel path 
             
             
               190 
               ink jet printer head 
             
             
                 
             
           
        
       
     
   

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The advantages and features of the present invention will become better understood with reference to the following more detailed description and claims taken in conjunction with the accompanying drawings, in which like elements are identified with like symbols, and in which: 
       FIG. 1  is a front view of the automated flatware and napkin assembling apparatus  10 , according to a preferred embodiment of the present invention; 
       FIG. 2  is a side view of the automated flatware and napkin assembling apparatus  10 ; 
       FIG. 3  is a sectional view of the automated flatware and napkin assembling apparatus  10  as seen along a line I-I as shown in  FIG. 2 ; 
       FIGS. 4   a - 4   e  are a series of sectional views as the flatware is assembled and wrapped as seen along the line I-I as shown in  FIG. 1 ; 
       FIG. 5  is a partial sectional view of the automated flatware and napkin assembling apparatus  10  according to a first alternate embodiment; and 
       FIG. 6  is a sectional view of the automated flatware and napkin assembling apparatus  10  according to a second alternate embodiment. 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   The best mode for carrying out the invention is presented in terms of its preferred embodiment, herein depicted within the  FIGS. 1 through 4   e.    
   1. Detailed Description of the Figures 
   Referring first to  FIG. 1 , a front view of the automated flatware and napkin assembling apparatus  10 , according to a preferred embodiment of the present invention is shown. An automation enclosure  15  encloses the moving automatic components of the automated flatware and napkin assembling apparatus  10 , thus protecting them from accidental contact and a possible safety hazard from the user. Controls mounted on the front of the automation enclosure  15  include a start switch  20  for activating the automated flatware and napkin assembling apparatus  10  and a stop switch  25  for a corresponding stopping function. A napkin reset switch  30  provides for the resetting of a roll of rolled paper napkins  35 , such as after a jam or after a new roll of rolled paper napkins  35  is installed. Similarly, a label reset switch  40  provides for the resetting of a roll of rolled paper adhesive labels  45 . The rolled paper napkins  35  is a pre-manufactured roll of paper napkins, similar in design to a roll of paper towels commonly found in a kitchen. The rolled paper adhesive labels  45  is a perforated roll of paper labels with pre-applied adhesive along one edge. A series of four mounting feet  50  (two of which are shown in this FIG. for sake of clarity), provide a suitable mounting base and prevent the automated flatware and napkin assembling apparatus  10  from moving along the horizontal surface such as a counter or table upon which it is set during operation. Also located on the top of the automation enclosure  15  is a spoon hopper  55 , a fork hopper  60  and a knife hopper  65  that holds stacked silverware or flatware prior to wrapping. It is envisioned that the three hoppers along with the rolled paper napkins  35  and the rolled paper adhesive labels  45  have adequate capacity to wrap  50  bundles of flatware at one time prior to refilling. A cover  70 , envisioned to be of a material type that blocks passage of ultraviolet radiation, provides protection against dust and dirt from contaminating the flatware contained in the spoon hopper  55 , the fork hopper  60  and the knife hopper  65  as well as the rolled paper napkins  35  and the rolled paper adhesive labels  45 . It also protects the operator or user from safety hazards, by requiring it to be in place prior to activation by the presence of a limit switch  75  which is wired to stop the process if the cover is removed. Said limit switch  75  also deactivates ultraviolet radiation sources, described in greater detail hereinbelow, as well as activates a cooling fan, not shown in this FIG., to remove excess heat generated by the ultraviolet radiation sources. Finally, an exit slot  80 , on which the fully wrapped and secured flatware exits the automated flatware and napkin assembling apparatus  10  is provided at the bottom of the automation enclosure  15 . 
   Referring now to  FIG. 2 , a side view of the automated flatware and napkin assembling apparatus  10  is depicted. This FIG. more clearly details the cover  70  and how it completely encases the top of the automation enclosure  15  protecting it from dust and dirt. The spoon hopper  55  is visible in this view of the left side of the automation enclosure  15 . Power for the automated flatware and napkin assembling apparatus  10  will be provided via a power cord  85  and a power plug  90  which will connect to commercially available AC power. 
   Referring next to  FIG. 3 , an internal sectional view of the automated flatware and napkin assembling apparatus  10 , as seen along a line I-I as seen in  FIG. 2  is depicted. The spoon hopper  55 , the fork hopper  60  and the knife hopper  65  are supplied and stocked with spoons  95 , forks  100 , and knives  105  respectively. A first upper indexing plate  110  working in conjunction with a first lower indexing plate  115 , provides for the dropping of one spoon  95  and one fork  100  at a time on a sliding chute  120 , as defined by a first travel path  125  and a second travel path  130 . Similarly a second upper indexing plate  135  working in conjunction with a second lower indexing plate  140 , provides for the dropping of one knife  105  at a time on the flatware trough  170 , as defined by a third travel path  145 . A napkin stream  150  is fed from the rolled paper napkins  35  by a series of first indexing rollers  155  working in a pinch roller arrangement. Similarly, a label stream  160  is fed from the rolled paper adhesive labels  45  by a series of second indexing rollers  165  working in a pinch roller arrangement. The first upper indexing plate  110 , the first lower indexing plate  115  the second upper indexing plate  135 , the second lower indexing plate  140 , the first indexing rollers  155 , the second indexing rollers  165  are all mechanically powered by a series of stepper motors. The stepper motors are activated by a logic controller such as Programmable Logic Controller (PLC) or a basic stamp module. The logic controller receives inputs from the start switch  20  (as shown in  FIG. 1 ), the stop switch  25  (as shown in  FIG. 1 ), the napkin reset switch  30  (as shown in  FIG. 1 ), the rolled paper napkins  35  (as shown in  FIG. 1 ) and a series of sensors such as proximity sensors, photoelectric eyes or the like. The logic controller, stepper motors, and sensors are well-known in the art, and can be designed, located, and programmed by those skilled in the art based upon this description of operation. The napkin stream  150  is routed into a flatware trough  170  located at the bottom of the sliding chute  120 . Finally, a first ultraviolet lamp tube  171  is located is between hoppers  55  and  60 , and underneath index plate  115 , and a second ultraviolet lamp tube  173  is located between hoppers  60  and  65 , and underneath index plate  140 . Said first ultraviolet lamp tube  171  and second ultraviolet lamp tube  173  provide an ultraviolet radiation source which provides a second level of sanitization by using a Ultra-Violet radiation process on all silver ware, napkins, bands and surrounding internal working components. The first ultraviolet lamp tube  171  and second ultraviolet lamp tube  173  are surrounded by a first ultraviolet lamp tube shield  172  and a second ultraviolet lamp tube shield  174  respectively, to contain glass shards in case of accidental breakage. The practice of using ultraviolet radiation to reduce and/or eliminate microbiological contamination is well known in the art. 
   Referring finally to  FIGS. 4   a - 4   e , a series of sectional views of the actual flatware assembly process is depicted. The sectional views are also taken along a line I-I as seen in  FIG. 2 , and detail the area including and immediately adjacent to the flatware trough  170  as seen in  FIG. 3 . The sequence defined by these FIGS. define the operation of one cycle that occurs during one set of flatware assembly. In  FIG. 4   a , the condition immediately after the knife  105  has fallen upon the napkin stream  150  is depicted. The napkin stream  150 , under the weight of the knife  105  has taken the shape of the flatware trough  170  at the end of the sliding chute  120 . In  FIG. 4   b , the spoon  95  and the fork  100  have been dropped on the sliding chute  120  and are sliding toward the flatware trough  170  as defined by a fourth travel path  175 . In  FIG. 4   c , the fork  100  has just contacted the leading edge of the napkin stream  150  and is proceeding to fold it over in the general momentum direction of the fourth travel path  175 . In  FIG. 4   d , the fork  100  is in its final position in the flatware trough  170 , and has pinched the napkin stream  150  against the knife  105 . The spoon  95  is still continuing to slide down the sliding chute  120  as defined by the fourth travel path  175 . Finally, in  FIG. 4   e , the knife  105 , the fork  100 , and the spoon  95  are in their final position in the flatware trough  170 , with the napkin stream  150  firmly secured in between them. At this point, a series of automatically engaging jaws (not shown for clarity) grab the flatware bundle and rotate them in a direction defined by a rotational travel path  180  for multiple rotations. This action secures the flatware stack inside of the napkin stream  150 . Additional actions secure the label stream  160  (as seen in  FIG. 3 ) about the napkin stream  150  and the completed and secured bundle is ready for discharge through the exit slot  80  (as seen in  FIG. 1 ) 
   In alternate embodiments, it is envisioned that the capacity for on-demand printing can be easily integrated into the present invention such as to eliminate the need for pre-printing of labels  45 . As shown in  FIG. 5 , an ink jet printer head  190  is incorporated in line with the label stream  160  between the feed from the rolled paper adhesive labels  45  and the second indexing rollers  165 . In such an arrangement, a print-on-demand capacity can be added within the label stream  160 , with individual labels being printed as the label stream  160  is indexed passed the ink jet printer head  190 . Similarly, as shown in  FIG. 6  the ink jet printer head  190  can be incorporated in line with the napkin stream  150  between the feed from the rolled napkins  35  and the first indexing rollers  155 . In such an arrangement, a print-on-demand capacity can be added within the napkin stream  150 , with individual advertising or communication messages being printed directly to the napkins  35  as the napkin stream  150  is indexed passed the ink jet printer head  190 . 
   2. Operation of the Preferred Embodiment 
   The preferred embodiment of the present invention can be used by the common restaurant or cafeteria worker in a simple and effortless manner with minimal training. After acquisition of the automated flatware and napkin assembling apparatus  10 , it is placed on a suitable horizontal surface such as a counter and table and connected to a source of electrical power using the power cord  85  and the power plug  90 . Next, the spoon hopper  55 , the fork hopper  60 , and the knife hopper  65  are stocked with a suitable supply of spoons  95 , forks  100  and knives  105 , envisioned to be up to the quantity of 50 each. Finally, an adequate supply of rolled paper napkins  35  and rolled paper adhesive labels  45  is verified, the cover  70  is set into position, and the automated flatware and napkin assembling apparatus  10  is ready for use. 
   The automatic wrapping operation is begun by pressing the start switch  20 . At this point in time, the first ultraviolet lamp tube  171  and second ultraviolet lamp tube  173  illuminate. Said illumination sterilizes the underside of all the flatware as they sit in the bottom of the flatware guides. As the flatware is dropped each passes by the first ultraviolet lamp tube  171  and second ultraviolet lamp tube  173 , it is exposed on all sides to UV light energy. This ultraviolet energy is also applied to all interior components and supplies of the automated flatware and napkin assembling apparatus  10  including the rolled paper napkins  35  and the rolled paper adhesive labels  45 , thereby killing all microbes and viruses either on the surface of the flatware or airborne inside the appliance. The internal mechanisms as defined in  FIG. 3  and  FIGS. 4   a  through  4   e  then allow for the wrapping of a set of flatware in a paper napkin and securing each set with an adhesive label. The completed set is then discharged via the exit slot  80 . This process continues until all of the flatware contained in the automated flatware and napkin assembling apparatus  10  is wrapped, or the stop switch  25  is pressed. 
   The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the Claims appended hereto and their equivalents. Therefore, the scope of the invention is to be limited only by the following claims.