Patent Publication Number: US-2007113599-A1

Title: Laundry machine with loading hopper

Description:
TECHNICAL FIELD AND BACKGROUND OF THE INVENTION  
      The present invention relates to laundry machines, such as washing, drying, dyeing machines or the like, and the equipment related to laundry machines, such as a loading hopper. In particular, the invention relates to a laundry machine having a loading hopper that is predisposed in a loading position such that the hopper can receive launderable items from above without any tilting of the laundry machine.  
      Commercial/industrial machines used for laundering items are well known in the art. For example, U.S. Pat. No. 5,357,772, incorporated herein by reference, discloses a laundry machine with a combination drum door/loading hopper. Such machines are often quite large, holding up to 800 lbs. or more of laundry. Thus, the steps of loading and unloading the launderable items from these machines are usually time consuming and, when performed manually, can present awkward and hazardous conditions.  
      Prior art laundry machines, such as that disclosed in U.S. Pat. No. 5,357,772, are generally supported on a floor-mounted structural frame and tilted relative to the horizontal into various operating positions. Prior art laundry machines typically include a drum having an opening through which the launderable items are delivered into and withdrawn from the drum. An access door is pivotally mounted on the front end of the machine to cover the opening and enclose the drum during the washing cycles, and to permit access to the drum opening during loading and unloading.  
      Prior art laundry machines, such as the machine disclosed in U.S. Pat. No. 5,357,772, typically include a loading hopper mounted on the drum. The hopper has an upper open end for receiving launderable items, and a lower open end for communicating with the drum opening. The upper open end of the hopper is mounted on the drum at an angle of about forty-five degrees in relation to the ground surface on which the laundry machines sits. While such an angle is conducive to a person manually depositing laundry into the hopper, it is not suitable to receiving laundry being dropped from directly above by an automated laundry conveyor as the upper opening is not vertically aligned with the laundry positioned above. The forty-five degree angle of the hopper would result in a significant amount of laundry missing the hopper and not making it into the drum. As such, the laundry machine must be tilted rearward to move the hopper so that it is not angled in relation to the ground surface, but instead is in a completely upwardly facing position to receive laundry being dropped from above. Such tilting is generally performed by hydraulic or pneumatic actuators.  
      Following this loading stage, the prior art laundry machine is tilted back to its original position and the items are laundered. When this stage is complete, the machine is tilted forward such that the front of the drum and the drum opening are angled downward to aid in the removal of the laundered items from the drum after the access door is again opened. Thereafter, the process is repeated. A laundry machine that does not need to be tilted prior to the hopper receiving laundry dropped from above would provide an efficient advantage over prior art laundry machines.  
     SUMMARY OF THE INVENTION  
      Therefore, it is an object of the invention to provide a laundry machine with a loading hopper in which it is not necessary to tilt the machine or hopper prior to the hopper receiving laundry dropped from above.  
      It is another object of the invention to provide a laundry machine in which laundry placed in the hopper moves into the drum of the machine without tilting of the machine or hopper.  
      It is yet another object of the invention to provide a laundry machine that is particularly suited to receive laundry from an automated conveyor line positioned above the laundry machine.  
      These and other objects are achieved by the present invention, which in one embodiment includes a hopper for use in a laundry machine having a first open end for receiving launderable items therethrough, and a second open end for communicating with an opening defined by a laundry machine drum. The first and second open ends define a passage therebetween for the launderable items, and the hopper is adapted for mounting on the laundry machine such that the first open end faces upwardly and is substantially parallel to a ground surface supporting the laundry machine.  
      According to a preferred embodiment of the invention, the first open end is substantially perpendicular to the second open end, and the second open end is substantially perpendicular to the ground surface when positioned on the laundry machine.  
      According to yet another preferred embodiment of the invention, the hopper is movably mounted to the laundry machine drum, such that the hopper can be moved between a loading position in which the first open end faces upwardly and is substantially parallel with a ground surface supporting the laundry machine, and an unloading position in which the second open end is at least partially removed from the laundry machine drum to allow the launderable items to be unloaded from the drum.  
      According to yet another preferred embodiment of the invention, the first open end is rectangular.  
      According to yet another preferred embodiment of the invention, a laundry machine includes a drum having an opening for receiving launderable items to be laundered by the laundry machine, and a hopper mounted on the drum. The hopper includes a first open end for receiving the launderable items therethrough, and a second open end for communicating with an opening defined by the drum. The first and second open ends define a passage therebetween for the launderable items, and the hopper is movable from a loading position in which the first open end is positioned substantially parallel to a ground surface supporting the laundry machine and an unloading position in which the hopper is at least partially removed from the laundry machine drum to allow the launderable items to be unloaded from the drum.  
      According to yet another preferred embodiment of the invention, the first open end is substantially perpendicular to the second open end, and the second open end and the drum opening are substantially perpendicular to the ground surface when the hopper is in the loading position.  
      According to yet another preferred embodiment of the invention, the drum is not tilted relative to the ground surface when the hopper is in the loading position.  
      According to yet another preferred embodiment of the invention, the laundry machine includes means for tilting the drum opening downwardly relative to the ground surface when the hopper is in the unloading position.  
      According to yet another preferred embodiment of the invention, the drum opening is tilted downwardly approximately 21 degrees when in the unloading position.  
      According to yet another preferred embodiment of the invention, the laundry machine includes a base frame for positioning on the ground surface, and the drum is pivotally mounted on the base frame. At least one hydraulic cylinder is connected to the base frame, and a rod is positioned within the hydraulic cylinder and supports the drum, so that the upward extension of the rod from the cylinder tilts the drum opening downward.  
      According to yet another preferred embodiment of the invention, the laundry machine includes means for delivering a stream of liquid into the hopper for facilitating movement of launderable items from the hopper into the drum.  
      According to yet another preferred embodiment of the invention, tubing is positioned on an internal surface of the hopper proximate the first open end, and the tubing has at least one opening. The tubing delivers a stream of liquid onto the internal surface that facilitates movement of the launderable items in the hopper into the drum.  
      According to yet another preferred embodiment of the invention, at least one linear member is rotatably mounted to the drum and connected to the hopper so that rotation of the member moves the hopper between the loading and unloading positions.  
      According to yet another preferred embodiment of the invention, the hopper rotates about 87 degrees when moving from the loading position to the unloading position.  
      According to yet another preferred embodiment of the invention, a closure member is connected to the hopper and is movable between a closed position in which the passage defined by the first and second open ends is obstructed and an open position in which the passage is unobstructed.  
      According to yet another preferred embodiment of the invention, the closure member includes a first segment pivotally connected to a second segment and slidably connected to the hopper proximate the first open end of the hopper. The first segment can slide toward and away from the second segment such that the closure member is moved between the open position and the closed position.  
      According to yet another preferred embodiment of the invention, the first open end of the hopper is rectangular and includes a rear side proximate the drum, a front side opposite the rear side, and left and right sides connecting the rear and front sides.  
      According to yet another preferred embodiment of the invention, a first slide track is mounted on an interior surface of the left side of the first open end of the hopper, and a second slide track is mounted on an interior surface of the right side of the first open end. The closure member includes a first segment pivotally connected to a second segment connected to the front side of the first open end of the hopper, and first and second shafts are mounted on opposing sides of the first segment of the closure member. The first shaft engages the first slide track and the second shaft engages the second slide track to facilitate sliding movement of the closure member toward and away from the rear side of the first open end of the hopper such that the closure member is moved between the closed position and the open position.  
      According to yet another preferred embodiment of the invention, the first segment and the second segment extend upwardly from the hopper proximate the front side when in the closed position.  
      According to yet another preferred embodiment of the invention, at least one linear actuator member is connected to the hopper and the closure member for moving the closure member between the closed and open positions.  
      According to yet another preferred embodiment of the invention, the linear actuator member includes a pneumatic cylinder mounted on the hopper proximate the rear side of the first open end, and a rod positioned within the pneumatic cylinder and connected to the second segment of the closure member. The rod cooperates with the pneumatic cylinder so that extension of the rod from the cylinder moves the closure member away from the rear side of the first open end of the hopper and retraction of the rod into the cylinder moves the closure member toward the rear side. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      Some of the objects of the invention have been set forth above. Other objects and advantages of the invention will appear as the invention proceeds when taken in conjunction with the following drawings, in which:  
       FIG. 1  is a perspective of view of a prior art laundry machine;  
       FIG. 2  is a perspective view of a laundry machine according to a preferred embodiment of the invention;  
       FIG. 3  is a side elevation showing the laundry machine of  FIG. 2  in a loading position to receive laundry from above;  
       FIG. 4  is a perspective view of the laundry machine of  FIG. 2 , showing the loading hopper separated from the drum;  
       FIG. 5  is a side elevation showing the laundry machine of  FIG. 2  unloading laundry;  
       FIG. 6  is a side elevation of the laundry machine of  FIG. 2 ;  
       FIG. 7  is another side elevation of the laundry machine of  FIG. 2 ;  
       FIG. 8  is a perspective view of a loading hopper according to a preferred embodiment, showing the hopper door closed;  
       FIG. 9  is another perspective view of the loading hopper of  FIG. 8 , showing the hopper door partially open;  
       FIG. 10  is yet another perspective view of the loading hopper of  FIG. 8 , showing the hopper door fully open;  
       FIG. 11  is a top plan view of the hopper of  FIG. 8 , showing the hopper door fully open;  
       FIG. 11A  is an enlarged partial top plan view of the hopper taken from  FIG. 11 ;  
       FIG. 12  is a perspective view of a loading hopper according to another preferred embodiment of the invention; and  
       FIG. 12A  is an enlarged partial perspective view of the loading hopper of  FIG. 12 . 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT AND BEST MODE  
      Referring now specifically to the drawings, a prior art laundry machine is illustrated in  FIG. 1  and shown generally at reference numeral  10 . The prior art laundry machine  10  comprises a rotatable drum  11  for washing launderable items, and a loading hopper  12  mounted on the drum  11  for receiving the launderable items and delivering them into the drum  11 . The drum  11  is mounted on a base frame  13  sitting on a ground surface. The hopper  11  has an upper open end  14  for receiving launderable items, and a lower open end  15  for communicating with an opening  16  in the drum  11 . The hopper  12  is mounted on the front face of the drum  11 , and the upper end  14  of the hopper  12  is positioned at an angle of about forty-five degrees in relation to the ground surface on which the base frame  13  sits.  
      One of ordinary skill in the art will recognize that if laundry is deposited from above the hopper  12 , a significant amount of laundry will miss the hopper  12  and not be delivered into the drum  11  due to the angle of the hopper  12 , as shown in  FIG. 1 . As such, the prior art laundry machine  10 , when receiving laundry positioned above the hopper  12 , must be tilted rearward to move the hopper  12  so that the upper end  14  of the hopper  12  is not angled in relation to the ground surface, and can receive the laundry being dropped from above.  
      Following this loading stage, the prior art laundry machine  10  is tilted back to its original position, shown in  FIG. 1 , and the launderable items are laundered. When this stage is complete, the machine  10  is tilted forward such that the front of the drum  11  and the drum opening  16  are angled downward to aid in the removal of laundered items.  
      Referring specifically to the drawings, a laundry machine according to a preferred embodiment of the invention is illustrated in  FIG. 2  and shown generally at reference numeral  20 . The laundry machine  20  comprises a rotatable drum  31  for washing, drying or performing some other laundry operation on launderable items “L”, shown in  FIG. 3 , and a loading hopper  22  mounted on the drum  31  for receiving the launderable items “L” and delivering them into the drum  31 . The drum  31  is mounted on a base frame  43  sitting on a ground surface “G”. As used throughout this application, the term “ground surface” is not limited to any particular kind of surface, but refers generally to any surface on which the laundry machine  20  can be supported, including any floor, ground, and/or earth, etc. As shown in  FIG. 2 , the base frame  43  includes first and second elongated members  44 ,  45  joined by a cross member  46 . Four feet  47  are positioned under the base members  44 ,  45 ,  46  at the four corners of the machine  20 .  
      As shown in  FIGS. 2-4 , the hopper  22  has an upper open end  24  for receiving launderable items “L”, and a lower open end  25  for communicating with an opening  36  in a front plate  35  of the drum  31 . As shown in  FIG. 2 , the upper end  24  and the lower end  25  define an internal passage through which the laundry “L” is delivered into the drum  31 . The upper open end  24  is preferably rectangular, and comprised of a front side  24   a , a rear side  24   b , a left side  24   c  and a right side  24   d . The rear side  24   b  of the hopper  22  is adjacent the front plate  35  of the drum  31 . The front side  24   a  of the hopper  22  is opposite the rear side  24   b , and the front and rear sides  24   a ,  24   b  are joined by the left and right sides  24   c ,  24   d . Preferably, the upper open end  24  is preferably perpendicular to the lower open end  25 , as shown in  FIG. 4 .  
      As shown in  FIGS. 2 and 3 , the hopper  22  is mounted on the front plate  35  of the drum  31 , and the upper open end  24  is substantially parallel with the ground surface “G”. As such, the upper open end  24  faces completely upwardly and is in a proper position to receive laundry “L” that is dropped from an automated conveyor line positioned above the hopper  22 , as shown in  FIG. 3 . The front side  24   a  of the upper end  24  of the hopper  22  is not angled downwardly in relation to the ground surface “G”, as in the prior art laundry machine  10 . All four sides  24   a - d  of the upper end  24  of the hopper  24  preferably reside in the same horizontal plane. As such, laundry “L” being dropped from above the hopper  22  falls directly into the hopper  22 , without significant spillage as would occur in the prior art machine  10 . Furthermore, the hopper  22  need not be tilted in any direction to receive laundry “L” from above.  
      The laundry machine  20  is movable between a loading position, shown in  FIG. 3 , and an unloading position, shown in  FIG. 5 . In the loading position shown in  FIG. 3 , the hopper  22  is positioned such that the lower open end  25  of the hopper  22  is adjacent the front plate  35  of the drum  31  so that the lower open end  25  communicates with the drum opening  36 . In this loading position, the upper end  24  of the hopper  22  receives launderable items “L” which travel through the internal passage of the hopper  22 , passing out of the lower end  25  of the hopper, through the drum opening  36  and into the interior of the drum  31  where the items “L” can be washed, dried, dyed or subjected to some other laundry-related process.  
      When the machine  20  has finished the particular laundry operations, the machine can be moved to the unloading position, shown in  FIG. 5 . The hopper  22  is pivotally mounted on the drum  31  to move between the loading and unloading positions. Preferably, the hopper  22  is connected to the drum  31  by rotatable linear members, such as a pair of arms  37   a ,  38   a  connected to a pivot rod  39   a  mounted on the front plate  35  of the drum  31 . One end of each arm  37   a ,  38   a  is connected to the rod  39   a , while the other end of each arm  37   a ,  38   a  is connected to the left side  24   c  of the hopper  22 . When moving from the loading position, shown in  FIG. 3 , to the unloading position, shown in  FIG. 5 , the arms  37   a ,  38   a  are rotated clockwise to move the hopper  22  away from the drum  31 . Preferably, the hopper  22  is rotated approximately eighty-seven degrees from the loading to the unloading positions. An identical pair of arms  37   b ,  38   b  can be mounted on the opposite side  24   d  of the hopper  22  on a pivot rod  39   b , as shown in  FIG. 11 .  
      The drum  31  can be tilted forward to position the drum opening  36  at a downward angle relative to the ground surface “G” when in the unloading position, as shown in  FIG. 5 . Preferably, the means for tilting the drum comprises a hydraulic cylinder  41  mounted on. the base frame  43 , and an actuator rod  42  positioned within the cylinder  41  and connected to the drum  31 . Pivot points  49  are mounted on the base frame  43 . Extension of the rod  42  from the hydraulic cylinder  41  pushes the drum  31  forward about the pivot points  49 , as shown in  FIGS. 6 and 7 , thereby directing the drum opening  36  downward. Preferably, the drum  31  is tilted at an angle of approximately twenty-one degrees when in the unloading position. By tilting the drum opening  36  downward, the laundered items “L” can be easily unloaded from the drum  31 . The means for tilting the drum  31  can include other known actuator arrangements, such as pneumatic actuators and the like. As shown in  FIG. 5 , the laundered items “L” can be unloaded from the drum  31  and deposited onto a conveyor line  70  for further processing.  
      As shown in  FIGS. 8-10 , the hopper  22  preferably includes a closure member, such as a door  26 , for selectively closing and opening the upper open end  24  of the hopper  22 . The door  26  is opened to receive laundry being deposited into the hopper  22 , and closed while laundry operations, such as washing or drying, are taking place. The door  26  comprises first and second segments  26   a ,  26   b  that are pivotally connected, such as by a hinge  27 . The second segment  26   b  of the door  26  is mounted to the front side  24   a  of the upper open end  24 .  
      As shown in  FIGS. 11 and 11 A, slide tracks  28   a ,  28   b  are mounted on the interior surface of the left and right sides  24   c ,  24   d  of the upper open end  24  of the hopper  22 . Shafts  29   a ,  29   b  are mounted on opposite sides of the first segment  26   a  of the door and are positioned within the slide tracks  28   a ,  28   b  to enable sliding movement of the door  26 . The slide tracks  28   a ,  28   b  can be constructed of any suitable material, and are preferably made of a polymer such as polyoxymethylene, sold under the trademark DELRIN®.  
      A pair of linear actuator members, such as pneumatic cylinders  51   a ,  51   b  with actuator rods  52   a ,  52   b , respectively, are mounted on opposite sides  24   c ,  24   d  of the hopper  22 . The actuator rods  52   a ,  52   b  are connected to opposite sides of the second segment  26   b of the door  26 . Extension of the actuator rods  52   a ,  52  from the cylinders  51   a ,  51   b , causes the first segment  26   a  of the door  26  to slide away from the rear side  24   b  of the upper end  24  of the hopper  22 , and the first segment  26   a  folds against the second segment  26   b , thereby moving the door  26  from the closed position to the open position, as illustrated in  FIGS. 8-10 . In the open position shown in  FIG. 10 , the first and second segments  26   a ,  26   b  of the door  26  extend upwardly from the front side  24   a  of the upper end  24  of the hopper  22 . The upwardly extending segments  26   a ,  26   b  help in guiding laundry dropped from above into the hopper  22 .  
      As shown in  FIGS. 12 and 12 A, the machine  20  preferably includes tubing  60  positioned on the internal surface of the hopper  22 . The tubing  60  is mounted proximate the upper end  24  of the hopper  22 , on all four sides  24   a - d . The tubing  60  receives a supply of liquid, preferably water “W”. The tubing  60  has a plurality of holes  61  through which the water “W” is dispersed into the hopper  22 . When laundry is deposited into the hopper  22 , the flow of water “W” from the tubing  60  at the upper end  24  of the hopper  22  facilitates movement of the laundry down the hopper  22  and into the drum  31 .  
      A laundry machine with a loading hopper, and a method for using the machine are disclosed above. Various details of the invention may be changed without departing from its scope. Furthermore, the foregoing description of the preferred embodiment of the invention and the best mode for practicing the invention is exemplary in nature and provided for the purpose of illustration only, and not for the purpose of defining the outer limits of the invention—the invention being defined by the claims.