Abstract:
An apparatus and method for automatically rolling a napkin around a set of dining utensils, wherein the apparatus can repeat the method quickly to individually wrap a plurality of sets of utensils in napkins. The apparatus comprises a housing for a first transfer unit for receiving a set of unwrapped utensil and a napkin and configured to automatically deliver the unwrapped utensils and napkin to a platform for wrapping. A lift plate holds a plurality of napkins and delivers a single napkin to unwrapped silverware. A rolling assembly rotatable around the unwrapped utensils and the napkin is configured to hold the utensils and to roll the napkin around the unwrapped utensils and to deliver the wrapped utensils to a second transfer unit configured to provide the wrapped utensils to a bin for storage.

Description:
FIELD OF THE INVENTION 
       [0001]    This invention relates to a device for automatically wrapping a napkin and securing the wrapped napkin around a set of utensils. 
       BACKGROUND OF THE INVENTION 
       [0002]    The bar and restaurant service industry requires tables to be cleaned and reset quickly for customers. In many casual dining establishments, a goal is to provide quick and efficient dine-in service. Many of these dining establishments utilize silverware, or rather, reusable utensils, which reduces waste. Moreover, in many of these establishments, the types of food served cannot be comfortably eaten or cut for eating when using disposable or plastic utensils. To further efficiently provide utensils in a clean manner, many of these establishments provide the utensils pre-wrapped with a napkin when setting a table for customers or diner use. 
         [0003]    In preparation for efficient meal service, reusable utensils (i.e. flatware or silverware including knives, forks and/or spoons) must be cleaned and prepared for diners&#39; use. Most restaurants prepare these utensils for diners&#39; use in large quantities and in advance of busier meal times. The utensils are generally provided along with napkins. The prior art includes devices for folding a plurality of flat materials, such as napkins, and examples of these devices are described in U.S. Pat. Nos. 4,002,331 and 4,349,185. When tables are cleaned and re-set between diners, it is more efficient for the restaurant to provide common utensils, a knife and fork, and occasionally a spoon, pre-wrapped in a napkin. Thus, when re-setting a table, the person setting simply grabs enough wrapped utensils per the seats at the table. 
         [0004]    The prior art also includes automatic devices limited to sorting utensils using a variety of bulky and inefficient methods including liquid reservoirs for sorting utensils by buoyancy as described in U.S. Pat. No. 5,655,663; or the incorporation of vibrating beds to move individual utensils for sorting based on the size or shape of a barrier as described in U.S. Pat. No. 3,956,109. Prior art methods of moving and sorting utensils are also described in U.S. Pat. No. 5,996,809 and include the use of belts having grasping mechanisms and magnetic members to retrieve individual utensils from a bin holding a plurality of utensils. 
         [0005]    Utensils are generally wrapped in a napkin and such preparation is completed manually, by hand rolling. Employees must hand-roll a knife and fork or other utensils, together in a napkin and secure the wrapped utensils in a pre-adhered paper napkin ring. Employees must take a clean knife and fork from separate bins, place them together with a napkin and roll the napkin around the utensils. Many employees may work on this never-ending task during slow times or before a restaurant opens or after the restaurant closes each day. This task is labor intensive and slow. 
       SUMMARY OF THE INVENTION 
       [0006]    The present disclosure relates to an apparatus for automatically and quickly rolling a napkin around utensils and securing the napkin. The apparatus comprises an upper transfer unit for receiving a set of unwrapped utensils and a napkin. The upper transfer unit is configured to automatically deliver the set of unwrapped utensils and the napkin to a rolling unit for wrapping. The apparatus also comprises a lift plate for storing a plurality of napkins, the lift plate is configured to automatically deliver the napkin to the upper transfer unit. The rolling unit is configured to hold the utensils and to fold and roll the napkin around the unwrapped utensils. Once the rolling unit has rolled the napkin around the utensils, the utensils are wrapped and secured in the napkin with a paper band which has pre-adhered adhesive. The apparatus also comprises a lower transfer unit for automatically receiving wrapped utensils from the rolling unit, the lower transfer unit is configured to automatically dispense and place the wrapped utensils into a storage receptacle. 
         [0007]    The present disclosure also relates to a method of automatically rolling and securing a napkin around a set of utensils and dispensing the wrapped set of utensils into a container for storage. The method includes steps which are completed automatically and the steps comprise delivering selected utensils into a first, upper transfer unit and providing a napkin to the first, upper transfer unit. The method further includes the steps of positioning the first, upper transfer unit over a wrapping unit and dispensing the selected utensils and napkin from the first, upper transfer unit onto the wrapping platform wherein rotating a first bar moves a first corner of the napkin over the utensils and secures the utensils and napkin to the wrapping platform and rotating a second bar to wrap the napkin completely around the utensils. The method also includes removing the wrapped utensils from the wrapping platform. The method is repeatable in order to quickly and sequentially wrap a plurality of sets of utensils in a plurality of napkins. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  is a perspective view of an apparatus of the present invention. 
           [0009]      FIG. 2  is an internal perspective view of the apparatus of the present invention. 
           [0010]      FIG. 3A  is a perspective view of a utensil dispenser unit of the apparatus of the present invention. 
           [0011]      FIG. 3B  is a top view of storage containers for the utensil dispensing unit and further illustrating an orientation of individual utensils in respective storage containers of the present invention. 
           [0012]      FIG. 4A  is a perspective view of an upper transfer unit of the apparatus of the present invention. 
           [0013]      FIG. 4B  is a top view of a holding tube as illustrated in  FIG. 4A  and illustrating utensil alignment according to the present invention. 
           [0014]      FIG. 4C  is an internal rear view of the holding tube as illustrated in  FIG. 4B  of the present invention. 
           [0015]      FIG. 4D  is an internal front view of the holding tube as illustrated in  FIG. 4B  and illustrating proper utensil placement of the present invention. 
           [0016]      FIG. 5A  is a perspective view of a napkin platform unit of the apparatus of the present invention. 
           [0017]      FIG. 5B  is a perspective view of a napkin lift as illustrated in  FIG. 5A  of the present invention. 
           [0018]      FIG. 6A  is a perspective view of a rolling unit of the apparatus of the present invention. 
           [0019]      FIG. 6B  is a perspective view of a rolling shaft as illustrated in  FIG. 6A  of the present invention. 
           [0020]      FIG. 7  is a cross-sectional view of an upper transfer loading area of the present invention. 
           [0021]      FIG. 8  is a cross-sectional view of an upper transfer unloading area and rolling area of the present invention. 
           [0022]      FIG. 9A  is an illustrated side view of the wrapping process of the 1 st  fold bar as illustrated in  FIG. 6B  of the present invention. 
           [0023]      FIG. 9B  is an illustrated front view of the wrapping process of the 2 nd  fold bar as illustrated in  FIG. 6B  of the present invention. 
           [0024]      FIG. 9C  is an illustrated front view of the locking system of the 2 nd  fold bar as illustrated in  FIG. 9B . 
           [0025]      FIG. 9D  is an illustrated front view of the wrapping process of the roller arms and band placement as illustrated in  FIG. 6A  of the present invention. 
           [0026]      FIG. 10  is a cross-section view of the wrapped utensil storage area of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0027]    The apparatus of the present invention is a device for automatically wrapping a set of utensils in a napkin by rolling the napkin around selected utensils, generally a pair of utensils including a knife and/or fork and securing the napkin. The apparatus also dispenses the rolled, or napkin wrapped utensils into a receptacle for orderly storage. The automatic napkin roller of the present invention is a self-contained and movable unit. The apparatus generally includes a loading receptacle for unwrapped utensils and napkins, an upper transfer unit, a rolling unit for wrapping the napkin around the utensils, and a lower transfer unit, all of which are configured to cooperate to receive a utensil or a set of utensils, automatically roll the selected utensils in a napkin, secure the napkin as rolled around the utensils and dispense the napkin wrapped utensils into a storage receptacle. The process is repeated in sequence to automatically wrap a plurality of individual sets of utensils in napkins in a short amount of time. The apparatus is computer controlled and wrapping can be initiated automatically or manually. 
         [0028]    As illustrated generally in  FIG. 1  at  10 , the apparatus includes a housing  12  and a control system  14 . The housing  12  may be an aluminum, or other lightweight yet durable casing, to which all components are secured to and/or within. The housing  12  has two openings; one of which is accessible via doors  20  which provides access to the wrapping components of the apparatus and ease of access for servicing the components, as well as filling the napkins  118  and securing bands  120 . The second opening allows access to the wrapped utensil storage receptacle  22 . Moreover, the apparatus  10  is portable within a restaurant or other setting for use. A bottom plate  16  of the housing  12  is secured to casters  18  for uninhibited rolling of the apparatus. The apparatus  10  can be stored in a back area or moved out of the way when not in use. 
         [0029]    The automatic utensil roller  10  has a loading position  24  for the upper transfer unit  44  as illustrated in  FIG. 7 , which is located between the utensil dispensing unit  32  and the napkin lift unit  64 . The upper transfer unit  44  is movable, from a loading position  24 , to a dispensing position  26  directly over the rolling unit  74  as illustrated in  FIG. 8 . A utensil loading receptacle  30  is positioned above the utensil dispensing unit  32  and holds the unwrapped utensils  116  prior to initiating the wrapping process. The utensils  116 , generally knives and forks may be held in separate receptacles  30  prior to wrapping. A napkin lift unit  64  is generally located below the utensil dispensing unit  32 , which also happens to be in the loading area  24  of the upper transfer unit  44 . 
         [0030]    The upper transfer unit  44  is configured to automatically receive unwrapped utensils  116  in the loading area  24  from the loading receptacle  30  via the utensil dispensing unit  32 , and a napkin  118  from the napkin lift unit  64  and to move the utensils  116  and napkin  118  to the rolling area  26  for wrapping. Once the napkin  118  has been rolled around the utensils  116  and secured with a band  120 , the wrapped utensils  122  are then released from the rolling area  26 , or more precisely from the rolling unit  74 , into a wrapped utensil area  28  as illustrated in  FIG. 10 . The wrapped utensil area  28  also positions the wrapped utensils  122  into a wrapped utensil storage receptacle  22  via the lower transfer unit  106 . 
         [0031]    As further illustrated in  FIGS. 3 and 7 , a utensil dispensing unit  32  is positioned below the utensil loading receptacle  30  and removes a single utensil  116  of the set of utensils  116  for wrapping and moves the respective utensil  116  to the upper transfer loading area  24 . The selected utensils  116 , usually a knife followed by a fork, and occasionally a spoon, fall into the upper transfer holding tube  46  which is position in the center of the upper transfer unit  44 . The utensil dispensing unit  32  is a plate  38 , which is slid by a pneumatic piston and/or solenoid  34  via a lever  36 . Once the plate  38  is slid to a retracted position, the plate  38  is secured in a retracted position, by being held to the dispensing unit  32  by a plate guide  40 . When in the extended position, the plate  38  acts to eject a selected utensil  116  from a bottom of a stack of like utensils  116  stored in the receptacle  30 . The utensil dispenser  32  is also adapted with a utensil alignment bar  42  on the unit in which the plate  38  can be adjusted to accommodate utensils  116  of various sizes and shapes. 
         [0032]    The utensils  116  for wrapping are then released into the holding tube  46  in the upper transfer unit  44  as illustrated in more detail in  FIGS. 4B and 4D . The holding tube  46  has a floor that may comprise a plate or doors  55  and  57  which holds the utensils  116  while loading. When loading the first set of unwrapped utensils  116  into the upper transfer holding tube  46 , the upper transfer unit  44  is positioned in a first position. The first position is a loading position  24  and is illustrated in  FIG. 7 . The upper transfer unit  44  is then movable along a track  62  between the first position and a second position, the second position being substantially above or over the rolling unit  74 , and the second position being a dispensing position  26  as illustrated in  FIG. 8 . The upper transfer unit  44  is movable by a motor driven gear  60  to drive the upper transfer unit  44  along the track  62 . The bottom of the upper transfer unit  44  is further adapted such that a bottom plate  58  is a suction plate  58 . A vacuum is generated between the napkin  118  for rolling and the suction plate  58 , such that the suction plate  58  removes the first napkin  118  for wrapping the first set of utensils  116  from the napkin lift unit  64 . The suction plate  58  is adapted with holes or other apertures, to allow vacuum suction to hold the napkin  118  to a surface of the suction plate  58 . 
         [0033]    As illustrated in further detail in  FIGS. 5A and 5B , a napkin lift unit  64  holds a supply of napkins  118  and is movable from a first position, a holding position, to a second position, a dispensing position. The napkin lift unit  64  is a slide mounted plate  66 . The plate  66 , or napkin platform, can be moved or lifted along a length of the slide  68  from a first to the second position, wherein a first napkin  118  in the supply is lifted to a suction plate  58  and removed from the napkin lift unit  64 . The plate, or napkin platform  66  is then lowered to back to the first position. The napkin platform  66  is raised and lowered, from the first position to the second position, by a motor driven gear  70  connected to a screw drive  72  resting on a bearing  71  in the napkin lift slide  68 . 
         [0034]    With the utensils  116  held in the upper transfer holding tube  46  and the napkin  118  suctioned to the suction plate  58 , the upper transfer unit  44  is then automatically moved to a second position  24  which is a dispensing position and is substantially above and proximate to the rolling unit  74  as illustrated in  FIG. 8 . The utensils  116  are then released from the holding tube  46  onto the rolling unit  74 . The weight of the utensils  116  when released onto the napkin  118  also releases the napkin  118  from the vacuum connection with the suction plate  58  so that the set of utensils  116  and the napkin  118  are released onto the roller tongue  80  which is inside the rolling unit  74 . 
         [0035]    In further detail, the mechanism used to release the utensils  116  and napkin  118  onto the rolling unit  74  is a rocker  50  which is rotated by an extending piston and/or solenoid  48  such that the rotating rocker  50  moves a slide  52  from a first position to a second position, which rotates a first and second sway bar  54  and  56  and pins. As the rotating sway bars  54  and  56  open the drop doors  55  and  57  and the utensils  116  and the napkin  118  are then loaded in or released on to the rolling tongue  80  inside the rolling unit  74 . The rotating drop doors  55  and  57  also adjust the utensils  116  inside the upper transfer holding tube  46 , such that the utensils  116  are centered and aligned with respect to one another and the napkin  118 , and can be configured so that preferably, the fork is positioned on top of the knife which is further defined in  FIGS. 4B and 4D . The upper transfer unit  44  is then cleared from the dispensing position  26 , and moved back to the first position, the loading position  24 . 
         [0036]    As illustrated in  FIG. 8 , at the dispensing and/or rolling area  26 , the utensils  116  as positioned on the napkin  118  will be wrapped in the napkin  118  via the rolling unit  74 . The rolling unit  74  includes a rolling platform  76  which is adapted with a rolling assembly, in which all components cooperate to wrap the napkin  118  around the utensils  116  and to eject the wrapped utensils  122  off the rolling unit  74 . The wrapped utensils  122  are then transported from the rolling area  26  to the dispensing area  28  via the wrapped utensil chute  104 . 
         [0037]      FIG. 6A  illustrates the rolling unit  74 , which includes key components and assemblies permitting the wrapping process to occur; the platform  76 , a rotatable rolling shaft  78 , and rolling arms  102 . The platform  76  holds the rotatable rolling shaft  78  which holds three (3) sub-assemblies; a first fold bar  82 , a second fold bar  94  and an ejector piston  100 . The sub-assemblies of the rolling shaft  78  are illustrated in further detail in  FIG. 6B . Further, the rolling shaft  78  includes a roller tongue  80  and a drive gear  101  positioned proximate the rear of the rolling shaft  78  to rotate the rolling shaft  78  in the rolling unit  74 . The sub-assemblies of the rolling shaft  78  are generally positioned within the inside diameter of a bearing  103 , in which the rolling shaft  78  is able to rotate freely. The rolling unit  74  also includes seven (7) rolling arms  102 , which engage around the rolling shaft  78  to keep the napkin  118  pressed tightly around the utensils  116  while the rolling shaft  78  is rotating. 
         [0038]    After the napkin  118  and utensils  116  are placed on the rolling unit  74 , the components of the rolling shaft  78  cooperate to wrap the utensils  116  and wrapping is initiated by movement of the first fold bar  82 , as illustrated in  FIG. 9A . Prior to initiation of wrapping the napkin  118 , the first fold bar  82  is positioned adjacent a back end of the utensils  116  with the back end of the utensils  116  pushed up against the ejector plate  100 . The first fold bar  82  is rotatable by a slide guide  84  to catch a first corner or bottom edge of the napkin  118 . 
         [0039]    The slide guide  84  moves back and forth on the rolling platform  76  to move a slide  86  on the rolling shaft  78 . The slide  86  on the rolling shaft  78  is connected to an extender  88  to slide a bar  90  with a set of grooves. The grooved bar  90  rotates a rocker  92  which is connected to a pin that rotates the first fold bar  82  and facilitates rotation of the first fold bar  82  to fold the napkin  118  over the utensils  116  at the bottom corner of the napkin  118 . When folded over, the napkin  118  and utensils  116  are to some extent locked onto the rolling tongue  80 . 
         [0040]    The second fold bar  94 , once engaged, further holds the napkin  118  and utensils  116  to the rolling tongue  80 . The second fold bar  94  is also rotatable around the rolling tongue  80 . When rotated around the rolling tongue  80  the second fold bar  94  catches and pulls the remainder of the napkin  118  tight around the utensils  116  to complete the fold bars  82  and  94  portion of wrapping the utensils  116  in the napkin  118 . As explained in further detail and illustrated in  FIG. 9B , the second fold bar  94  is rotatable by a motor driven wheel  95  rotating about the rolling shaft  78 . The wheel rotates an assembly of spin plates  96  and  98  holding the second fold bar  94  and a spring with lock pin  97 . Once the locking spin plate  96  rotates far enough around the rolling shaft  78 , the lock pin  97  is pushed via a spring into a hole in the rolling shaft  78  holding the bar  94  in place during rolling, as illustrated in  FIG. 9C . 
         [0041]    Once the second fold bar  94  has been engaged, the rolling arms  102  engage. The rolling arms  102  engage around the rolling tongue  80  to form essentially a closed cylinder about the rolling tongue  80  to hold the napkin  118  and utensils  116  tight to the rolling tongue  80  while the rolling shaft  78  rotates, as illustrated in  FIG. 9D . The rolling shaft  78  may rotate up to five (5) revolutions in order to fully wrap the napkin  118  around the utensils  116  as the size of the napkin and dimensions of the utensils may vary. At the same time, the rolling shaft  78  rotates and wraps the napkin  118  around the utensils  116 , a securing band  120  can be fed into the wrapping cylinder and wrapped around the napkin  118  and utensils  116 . The securing band  120  may be a paper band or made of any material that is pliable and easily removable when the utensils  116  are to be removed from the napkin  118 . The securing band  120  may have an end with pre-applied adhesive and delivered on a continuous roll to the rolling unit  74 . As the securing band  120  is also rolled around the wrapped utensils  122 , the securing band  120  is sealed to its opposing end and the band  120  is wound tightly around the wrapped utensils  122  to lock the utensil  116  set in the napkin  118 . 
         [0042]    After the napkin  118  and utensils  116  are rolled and wrapped, a pneumatic cylinder  100  positioned inside the rolling tongue  80  ejects the wrapped utensil  122  into a chute or tube  104 . The chute  104  is the passageway from the rolling area  26  to the wrapped utensil  122  dispensing area  28 . The fold bars  82  and  94  are then automatically moved back into their first position for rolling subsequent utensils  116  in subsequent napkins  118 . Once the napkin  118  has been rolled completely around the utensils  116  and ejected off the rolling tongue  80 , the first fold bar  94  slide guide  84  retracts which moves the extender  88 . Movement of the extender  88  pushes or displaces a guide pin  99 , which disengages the lock pin  97  of the second fold bar  94  to release the second fold bar  94  into its pre-rolling position. 
         [0043]    As illustrated in further detail in  FIG. 10 , the lower transfer  106  is a unit which is movable along a track  114  via a motor and gear mount  112 . The lower transfer  106  is moveable between a first position and a second position in the direction of arrows  115 . The first position is a receiving position, wherein the lower transfer  106  receives the wrapped utensil set  122  from the rolling area  26  via the wrapped utensil chute  104 . The second position is a dispensing position, wherein the rolled utensils  122  are dispensed into a selected position of the storage receptacle  22  via a lower transfer placement tube  108 . The lower transfer placement tube  108  comprises doors positioned proximate a bottom or lower end of the placement tube  108 . The doors can be opened or closed by a piston and/or solenoid  110  extending and retracting; the mechanics of the doors are similar to that of the upper transfer holding tube  46  as illustrated in  FIG. 4C . Opening of the doors releases the wrapped utensil set  122  into the receptacle  22  for storing. 
         [0044]    The lower transfer unit  106 , and the lower transfer placement tube  108  are movable with respect to the storage receptacle  22  to control delivery of wrapped utensils  122  to a selected location for neat and orderly storage. Once the wrapped utensils  122  are released from the placement tube  108 , the doors are closed and the lower transfer unit  106  is then moved back to the first position for receiving subsequent wrapped utensils  122  from the wrapped utensil chute  104 . A set of utensils  116  can be wrapped quickly; the entire process from loading to storage can be optimally completed in less than six (6) seconds for the first set, and four (4) seconds per set afterwards. The process is quickly repeatable to wrap a plurality of sets of utensils  116  in napkins  118  with a securing band  120  in a more efficient manner. 
         [0045]    Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.