Information
-
Patent Grant
-
6826856
-
Patent Number
6,826,856
-
Date Filed
Wednesday, August 6, 200321 years ago
-
Date Issued
Tuesday, December 7, 200419 years ago
-
Inventors
-
Original Assignees
-
Examiners
Agents
- Brinks Hofer Gilson & Lione
-
CPC
-
US Classifications
Field of Search
US
- 038 143
- 271 315
- 271 318
- 271 109
- 271 225
- 271 226
- 271 26501
- 271 314
- 271 82
- 198 571
- 198 6781
- 198 8033
- 414 7442
- 414 621
-
International Classifications
-
Abstract
A towel spreader is provided. A trailing corner is clamped to isolate an edge of a towel where the edge is either along a fold in a towel or along an outer extremity of the towel. The towel is then flattened in a single or two layers using motion and gravity while being held along the identified edge. The same or a different trailing corner is then rotated such that a back outer extremity edge of the towel is perpendicular with a direction of movement of a conveyor. By clamping the back edge while continuing to move a downstream conveyor and blow air on the towel, the towel is flattened out. The spread towel is then passed downstream for further processing, such as folding.
Description
BACKGROUND
The present invention relates to automated laundry spreaders. In particular, a spreader for laying articles of laundry out flat is provided.
Many processes in laundries are automated. For example, machines in hotels spread out, iron and fold sheets without operator intervention. To begin the automated process, the operator identifies either corners or an edge of the sheet and places the corners or edge into the first machine. Since sheets have large dimensions with thin fabric, the sheets are often tangled together, necessitating either an automated separator machine or an operator for locating the edges or corners.
Since towels are smaller and thicker, towels may be less likely tangled after removal from a washing or drying machine. However in typical towel processing, an operator still grabs individual towels and places them on folding machines. Where possible, automated processes may save money over a period of time.
Machines for automatically grabbing towels from a load of towels and spreading the towels have been attempted, but find little commercial success. Typically, these machines attempt to isolate diagonal corners and then opposite corners. Such isolation can be difficult and inconsistent when implemented with a machine.
BRIEF SUMMARY
The present invention is defined by the following claims, and nothing in this section should be taken as a limitation on those claims. By way of introduction, the preferred embodiments described below include apparatuses and methods for spreading a towel from a load of towels. A trailing corner is clamped to isolate an edge of a towel where the edge is either along a fold in a towel or along an outer extremity of the towel. The towel is then flattened in a single or two layers using motion and gravity while being held along the identified edge. The same or a different trailing corner is then rotated such that a back outer extremity edge of the towel is perpendicular with a direction of movement of a conveyor. By clamping the back edge while continuing to move a downstream conveyor and blow air on the towel, the towel is flattened out. The spread towel is then passed downstream for further processing, such as folding. Each of the individual stages described above may be used in a different apparatus or used with or without other stages described above. Any of the overall structure, individual stages or combinations of individual stages in the embodiment below may provide advantages and be claimed independently herein.
In a first aspect, an apparatus for spreading a towel from a load of towels is provided. A pivot joint connects with a clamp and a frame. The clamp is operable to grab the towel. A drive is connected with the clamp so as to drive the clamp downward about the pivot joint. At least a portion of the towel is forced away from the clamp in response to the clamp being driven downward.
In a second aspect, a method for spreading a towel from a load of towels is provided. The towel is clamped. The towel is then rotated about an axis spaced away from the towel. The rotation is at least in part downward. The towel flattens in response to the rotation.
In a third aspect, an apparatus for spreading a towel from a load of towels is provided. A downstream conveyor is spaced from an upstream conveyor by a slot. The slot is narrow such that the towel is able to rest on both the upstream and downstream conveyors at a same time. A clamp is positioned to move in the slot between the two conveyors.
In a fourth aspect, a method for spreading a towel from a load of towels is provided. A towel is conveyed on two conveyors. An edge of the towel is clamped between the two conveyors. The clamped edge of the towel is moved closer to a side of the downstream conveyor such that another edge of the towel is positioned more perpendicular to the direction of travel of the downstream conveyor.
In a fifth aspect, an apparatus for spreading a towel for the load of towels is provided. At least two jaw points are positioned above an upstream conveyor. The jaw points are operable to press a first portion of a towel against the first conveyor. A blower is directed towards a second downstream conveyor. The downstream conveyor is operable to continue movement with a portion of the towel on the downstream conveyor while the first portion of the towel is held by the jaw points against the first conveyor. The blower is operable to direct air towards the towel while the downstream conveyor is moving and the jaw points are holding the towel at the upstream conveyor.
In a sixth aspect, a method for spreading a towel from a load of towels is provided. A towel is positioned on upstream and downstream conveyors. The towel is clamped on the upstream conveyor. The downstream conveyor continues to convey while the towel is clamped. The towel is also blown while the towel is
Further aspects and advantages of the invention are disclosed below in conjunction with the preferred embodiments
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
The components and the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views.
FIG. 1
is a front view of an initial clamp mechanism of a towel spreader in one embodiment;
FIG. 2
is a side view of a cutaway portion of the initial stages of a towel spreader in one embodiment;
FIG. 3
is a cutaway front view of some of the same and subsequent stages of the towel spreader of
FIG. 2
;
FIG. 4
is a top view of the portion of the towel spreaders shown in
FIG. 3
;
FIG. 5
is a side view of a rotatable and movable clamp shown in
FIG. 3 and 4
;
FIG. 6
is a top view of the conveyors shown in
FIGS. 3-5
with the towel in a first position;
FIG. 7
is a top view of the conveyors of
FIG. 6
with the towel in a second position;
FIGS. 8A and 8B
are front views of a spreading clamp structure of one embodiment; and
FIG. 9
is a side view of the spreading clamp structure of FIGS.
8
A and
8
B.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1-7
show various aspects of one embodiment. Various stages and aspects of the embodiment may be altered or changed based on now known or later developed devices and methods. The spreader isolates a towel from a load of towels and spreads the towel out flat for subsequent processing. For example, the towel is output to an automated towel folder, such as disclosed in U.S. Pat. No. 5,300,007, the disclosure of which is incorporated herein by reference. Alternatively, the spread towel is output to an operator or stacked for further use.
The towel spreader described herein is adapted for isolating and spreading square hand towels, including napkins. For example, terry cloth hand towel, other hand towels or cotton napkins around 8 to 18 inches on a side are processed. Larger towels or smaller towels may also be processed. In other embodiments, one or more of the stages described herein are used for processing rectangular towels, such as hand, bath and beach towels. Towels with thinner material, such as woven or knit pillowcases, pillow shams or other laundry articles may also be processed. Other articles of laundry, such as sheets or blankets, may also be spread using one, more or all of the stages described herein.
FIGS. 1-7
show one apparatus positioned within a single frame structure. Different portions of the apparatus are shown in different views to illustrate the components and operation of various stages for spreading a towel. In one embodiment, the stages are built together within the frame work in as small a space as possible while providing sufficient volume for spreading towels.
FIG. 2
shows an interior side wall and some related components. In one embodiment,
FIG. 2
shows a left interior side wall.
FIGS. 3 and 4
show side and top views of components adjacent to and extending away from the interior wall of FIG.
2
. Various plates for safety and preventing operators from entanglement within the spreader are included, but not shown. Electrical, hydraulic and air pressure cables and hoses interconnect various components for controlling and operating spreading of the towel. These cables and hoses are configured and routed as is known in the art or later developed. One or more controllers, such as a processor, coordinate thc movement and operation of the various components.
FIG. 1
shows a bin
12
for holding a load of towels
14
. The bin
12
is of various sizes or shapes. In one embodiment, the bin
12
tapers towards one location at the bottom of the bin
12
. As towels are removed from the bin, remaining towels migrate towards the location for clamping. In alternative embodiments, conveyors, vibration, tilting mechanisms or other devices are provided for continually positioning towels near a clamping position. The bin
12
is positioned beneath the system in general such that any towels dropped throughout processing are placed back within the bin
12
. Alternatively, the bin
12
is small enough such that dropped towels and other portions of the system will fall into a separate compartment.
A movable clamp
16
is a chuck, scissor clamp, two opposing plates, jaws, pinch roller, pinch plates, pinching belts or other structure operable to hold a towel. In one embodiment, the clamp
16
includes two metal plates separated by a space for one jaw and an opposing metal jaw operable to move between the two plates of the other jaw. The towel is clamped between the two jaws. Plastic, wood or other materials may be used.
The clamp
16
is actuated by a pneumatic cylinder
18
. One or both jaws of the clamp
16
connect with the pneumatic cylinder
18
or a plurality of cylinders. In alternative embodiments, an electric servo, an air driven cylinder, hydraulic cylinder, a pneumatic actuator, extending screw device with an electric motor or other mechanism is provided for actuating the clamp.
The clamp
16
and the actuator
18
are connected to a drive structure
20
. In one embodiment, the drive structure
20
is a pulley and motor with an endless belt or chain. For example, a timing belt with an inverter is used. The clamp
16
connects to one run of the endless chain to clamp objects in a downward direction. Using an electrical control and sensors, the drive structure
20
is operable to position the clamp
16
adjacent to or in the load of towels
14
. The clamp
16
clamps one or more towels. The clamp
16
is sized to most likely select a single towel, such as by having jaws that extend only about an inch. The clamped towel and clamp
16
are moved away from the load of towels
14
, such as upwards.
FIG. 2
shows the clamp
16
at an upward position with the towel
22
hanging down. Timing on the timing chain of the drive mechanism
20
and/or electric eyes are used to detect that the towel
22
is positioned on the upper location as shown in FIG.
2
. For example, the sensor
23
detects the presence of the towel
22
at the uppermost position or a position ready for the next stage of processing.
A horizontally moving clamp
24
and associated actuator
26
with the same or different structures as discussed above for clamp
16
and actuator
18
grabs the towel
22
. The clamp
24
is connected to a drive mechanism
30
of the same or different structure as the drive mechanism
20
discussed above. The clamp
24
and actuator
26
connect with the drive mechanism
30
by a plate and bolts or other mechanism
28
. In response to the sensor
23
, the drive mechanism
30
positions the clamp
24
against the towel
22
. Once positioned against the towel
22
, the clamp
24
closes to grab the towel
22
. In one embodiment, a sensor is provided to detect contact of the clamp
24
with the towel. In other embodiments, the clamp
24
is positioned to where a towel should be positioned. In response to the closing of clamp
24
, the clamp
16
releases the towel. The clamp
24
grabs the towel just below the clamp
16
or at another location anywhere on the towel
22
.
The drive mechanism
30
moves the clamp
24
and the towel
22
horizontally away from the clamp
16
. Movement up or down or in any other direction may be provided. The towel
22
hangs by force of gravity from the clamp
24
until coming in contact with a plate
32
. In one embodiment, the plate
32
is a flat metal plate, but a plate with a rough surface, irregular shape or curved surface of any material may be used. Two guides
34
are positioned on each side of the plate
32
so that the towel
22
is dragged between the guides
34
over the plate
32
. The plate
32
and guides
34
are sized and positioned to position the towel
22
being dragged by the clamp
24
in the jaws of an additional clamp
36
at the side or end of the plate
32
.
The clamp
36
is of a same or different structure as described above for the clamp
16
. In one embodiment, the clamp
36
has one jaw movable by pneumatic activation and another jaw made of a couple plates separated by a space sufficient to accept the opposing jaw. In one embodiment for increased clamping speed, both jaws connect with separate actuators (e.g., pneumatic cylinders) for coordinated movement to clamp the towel
22
. The clamp
36
is sized and positioned so that as the towel
22
exits off the plate
32
, the towel
22
is between the jaws of the clamp
36
.
As shown in
FIGS. 2-4
, a sensor
38
, such as a light beam sensor for transmitting a beam of light and receiving any reflection, is positioned to detect the towel
28
through a hole in the guide
34
. A hole may be provided in both guides
34
to better distinguish between the presence and absence of the towel
22
. As the towel
22
is dragged across the plate
32
and through the open clamp
36
, the light sensor
38
detects a trailing or end portion of the towel
22
. Since the towel is usually gripped at a position other than the center of the towel by the clamp
24
, the trailing portion of the towel
22
is a corner of the towel. Upon sensing the end of the towel, the clamp
36
is activated to close, grabbing the trailing corner of the towel
22
. As or after the clamp
36
closes, the clamp
24
is opened. As a result, the towel
22
hangs from a corner from the clamp
36
on a front side of the plate
32
.
In one embodiment shown in
FIGS. 8A
,
8
B and
9
, a further spreader is provided. A belt or plate
39
with a plurality of cleats, a rough surface, bristles, or other tacky surface is positioned beyond the claim
36
. When the clamp
24
is opened, the towel
22
drapes over the plate
39
. About 2 to 4 inches of the towel is positioned from the clamp
36
to the plate
39
in a horizontal or other angle from horizontal position. For smaller towels, the plate
39
is positioned more below and/or closer to the clamp
36
to provide more vertical drop. The remainder of the towel
22
hangs from the plate
39
due to gravity. Alternatively, the towel
36
is allowed to hang vertically from the clamp
36
without contacting the plate
39
.
An additional clamp
37
of the same or different structures and actuators as discussed for thc clamp
16
and actuator
18
is provided between the plate
39
and the clamp
36
. The additional clamp
37
slides, such as on a rodless cylinder, or rotates by a rotary actuator to grab the towel
22
adjacent to the clamp
36
. For example, the clamp
37
clamps the towel within about 2 inches from the clamp
36
or the corner of the towel
22
, but other distances may be used.
At a same time as the clamp
37
moves to and grabs the towel
22
, a pressure point
41
is rotated with a small pneumatic cylinder, rotary cylinder or other device to apply pressure to the towel
22
against the plate
39
. The pressure point
41
includes a rubber, plastic, rough surface or other material for slightly gripping the towel
22
. The force of the pressure point
41
applied to the towel
22
is small, such as by providing a minimal or small amount of air pressure to the pneumatic cylinder. As the clamp
37
pulls the gripped towel horizontally over the plate
39
, the cleats of the plate
39
and the pressure point
41
resist but do not prevent the movement of the towel
22
, resulting in wrinkles and folds being pulled out. Also as the claim
37
clamps the towel
22
or pulls the towel
22
, the clamp
36
releases the towel
22
. As shown in
FIG. 8A
, the towel originally hangs from the plate
39
in a bunched position. After the clamp
37
drags part of the towel
22
over the plate
39
and beneath the pressure point
41
, the towel
22
is more spread out as shown in FIG.
8
B. Wrinkles and folds, at least in part, are removed from the towel
22
making the clamps
44
more likely to clamp an outer, actual edge of the towel. While the plate
39
and pressure point
41
are stationary in one embodiment, the plate
39
and pressure point
41
may move in another embodiment. For example, the plate
39
and pressure point
41
are moved in a direction opposite of the clamp
37
to assist in removing wrinkles and folds.
As shown in
FIG. 9
, an air nozzle or bar
43
with a plurality of holes or nozzles is provided beneath the plate
39
. The air bar
43
is connected to a source of pressurized air and directs the air against the towel
22
at a downward angle. The force of the air tends to open folds in the towel
22
. The air is directed at the towel
22
during or after the clamping and movement of the claim
37
. In other embodiments, air is applied from other directions, such as by an air bar positioned above the plate
39
.
A lift
40
is positioned below the plate
32
, clamp
36
, plate
39
and clamp
37
. The lift
40
includes two plates or bars
42
on one end and an electric motor driven pivot point on another end. Pneumatic, chain, gear, air or other drive mechanisms may be provided. In one embodiment, the plates
42
are perpendicular to an arm of the lift
40
. The plates
42
include fibers or bristles for preventing the towel
22
from sliding. In alternative embodiments, metal, rubber or other materials are provided. As an alternative to the plates
42
, a single plate extends along the lift
40
or perpendicular to the lift arm may be used. As yet another alternative, a clamp is positioned on the lift
40
with or without plates
42
. The clamp grabs the towel and holds the towel while the lift moves the towel into position.
The lift
40
begins in a downward position, such as the vertical position shown in
FIGS. 2 and 3
. In response to the completed spreading action by the clamp
37
, the lift
40
is rotated against the towel
22
to lift the towel
22
to a substantially horizontal position as shown in
FIGS. 4 and 5
. As shown in
FIG. 4
, one corner of the towel
22
is held in the clamp
37
and/or draped on the plate
39
and another end or portion of the towel
22
is spaced from the plate
39
or clamp
36
. A minor or major portion of the towel
22
may hang down vertically from the end of the lift
40
. By lifting the towel
22
from a vertical position hanging down from the plate
39
to a horizontal position, the lift
40
positions the towel
22
adjacent to a pair of clamps
44
.
The clamps
44
are of the same or different structure with the same or different actuators as discussed for the clamp
16
and actuator
18
. While two clamps arc shown,
1
,
3
, or other numbers of clamps may be used. Both clamps
44
connect with a rotatable bar or beam
46
. The bar
46
is connected at a pivot joint to two runners
48
connected with the frame. The pivot joint includes ball bearings and gearing connected with a drive. In alternative embodiments, the clamps
44
each include separate pivot mechanisms allowing rotation of the clamps
44
about a stationary bar
46
.
The drive is an electric motor, belt, pneumatic rotary actuator, air driven cylinder or other now known or later developed device for rotating the clamps
44
and bar
46
about the pivot joint. The pivot point and drive are configured to allow rotation of between 70 and 135 degrees. For example, rotation of 90 degrees from a horizontal to a vertical position is provided. Plates, rubber stoppers, other stoppers, pneumatic cylinders or other devices may be used for limiting the rotation of the clamps
44
about the pivot joint. Alternatively, the operation of the drive is used to limit the rotation of the clamps
44
, such as a pneumatic rotary actuator providing about 90 of rotation.
The clamps
44
arc positioned against the towel
22
as the towel is in the clamp
36
and rests on the lift
40
. For example, the pivot joint and bar
46
are mounted on a rack and pinion along the runners
48
. As shown in
FIG. 5
, the bar
46
and clamps
44
are movable in a horizontal position towards and away from the towel
42
and the lift
40
. By rotating the clamps
44
to a horizontal position and moving the clamps
44
towards the towel
22
, the clamps contact the towel
22
. An electric eye or other detector may be used for determining when the clamps
44
are positioned against the towel
22
. Alternatively, the clamps
44
are positioned at a given location under the assumption that the towel
22
is positioned at that location by the lift
40
and clamp
36
.
As shown in
FIG. 4
, one of the clamps
44
is positioned to grab the towel
22
between the two plates
42
of the lift
40
. In alternative embodiments, the clamp
44
grabs the towel on the other side of either of the plates
42
or from a notch in a plate. The other clamp
44
grabs the towel between the plates
42
and the clamp
36
. In one embodiment, the clamp
44
closest to the clamp
36
(inner clamp
44
) is spaced from the clamp
36
, such as by a few inches or about ¼ of the length of a typical towel. Alternatively, the clamp
44
is closer to or further from the clamp
36
. The clamps
44
clamp random locations on the towel. The random locations correspond to either a true or exterior edge of the towel or an edge formed by the towel being folded over. The towel
22
is clamped by the clamps
44
where both the clamp
44
and the towel
22
are in a substantially horizontal position. Substantially is used herein to account for manufacturing tolerances, drooping of the towel
22
, or angles designed to be within 45 degrees of horizontal. Greater angles may be provided in alternative embodiments.
After the clamps
44
grab the towel
22
, the lift
44
is rotated back to a position below the plate
32
and clamp
36
. The clamp
36
also releases the corner of the towel
22
. The clamps
44
and the clamped towel
22
are rotated about the axis of the pivot joint and bar
46
. The rotation is downwards as shown in FIG.
5
. Since the clamps
44
are spaced from the bar
46
, the towel is rotated about an axis spaced away from the towel
22
. As a result, gravity and the rotation extend the towel outward in a more flat position as shown in
FIGS. 3 and 5
. By rotating the lift
40
away from the towel
32
, the towel
22
is allowed to extend out flat without interference from other objects as the towel
22
is rotated by the clamps
44
. As a result, at least a portion of the towel is forced away from the clamps
44
. The rotation and extension flattens out the towel away from the clamps
44
. The swinging helps stretch the towel, removing folds and wrinkles other than any fold clamped by the clamps
44
.
As shown in
FIG. 4
, an actuator
50
is connected with the outermost clamp
44
. The actuator
50
is a small pneumatic cylinder, air driven cylinder, servo driven or other now known or later developed device for moving the outer clamp
44
. Before, during or after rotation of the clamp from the horizontal to the vertical positions, the actuator
50
causes the outward clamp
44
to move away from the inner clamp
44
. The towel
22
is stretched between the clamps
44
. For grabbing a next towel
22
, the actuator
50
positions the outer clamp
44
closer to the inner clamp
44
. The outer clamp
44
is connected by hinge to the bar
46
to allow the stretching movement.
A conveyor
52
is positioned below the pivot joint
46
. The conveyor
52
is a short conveyor, such as associated with less than half, less than a full or more length of the towel
22
. The conveyor
52
includes at least two rollers
54
with one or more belts extending between each roller, such as five straps of fabric, rubber or other material. The conveyor
52
includes a platform beneath the straps in between the rollers
54
in one embodiment, but embodiments may be provided without a platform. The conveyor
52
is driven by a gear, belt or chain connected from a motor to one or both of the pulleys
54
. The conveyor
52
is positioned below the pivot joint and bar
46
such that the clamp
44
in thc vertical position is above one of the rollers
54
. The conveyor
52
may be spaced away from or further underneath the clamps
44
. As shown in
FIGS. 3 and 5
, a portion of the towel
22
extends down below the conveyor
52
and another portion of the towel
22
and the clamps
44
are above the conveyor. In alternative embodiments, the conveyor
52
is long enough such that as the clamps
44
rotate, the towel contacts the top of the conveyor
52
without extending below the conveyor
52
.
As shown in
FIG. 5
, the pivot joint and bar
46
as well as the clamps
44
are moved horizontally over the conveyor
52
in the runners
48
. As a result, the towel
22
is dragged and positioned over at least part of the conveyor
52
and at least partly onto a subsequent conveyor
58
. The clamp
44
is then opened, releasing the towel
22
. Due to the rotation of the clamps
44
as well as the dragging of the towel
22
on the conveyor
52
, the towel
22
is released and laid out on the conveyor
52
and/or
58
in a flat position with a minimal number of folds. The conveyor
52
is operated in a forward or reversed direction or held stationary while the towel
22
is dragged by the clamps
44
. For example, reverse operation may help flatten the towel. Stationary operation may also assist in flattening the towel. Moving the conveyor forwards such that the upper run of the conveyor proceeds towards the downstream conveyor
58
may prevent the towel
52
from getting snagged.
The downstream conveyor
58
is of a same or different structure than the conveyor
52
discussed above. The downstream conveyor
58
is shown as longer than the conveyor
52
, but may be shorter or a same length. The downstream conveyor
58
is spaced from the upstream conveyor
52
by a slot
62
. The slot is narrow or has a width such that the towel is able to rest on both the upstream and downstream conveyors
52
,
58
at a same time. In one embodiment, the slot
62
is about an inch to 2 inches wide, but may be wider or shorter. Since the clamps
44
release one end of the towel
22
on the conveyor
58
, the towel
22
is less likely to fall through the slot. In alternative embodiments, air or other blowers are used with a difference in elevation to allow the towel
22
to convey from the upstream conveyor
52
to the downstream conveyor
58
. As shown in the embodiment of
FIGS. 3 and 5
, the upper surfaces of the upstream conveyor
52
and downstream conveyor
58
are along a substantially same plane, but may be different planes. The conveyors
52
and
58
are aligned to convey the towel
22
in a same direction, such as by shown in the arrows on
FIGS. 6 and 7
. After the clamps
44
release the towel
22
, both conveyors
52
and
58
arc activated to convey the towel
22
along an upper surface in the same direction. In alternative embodiments, the conveyor
52
conveys in a different direction, such as a perpendicular or angled direction relative to the conveyor
58
.
A sensor
64
is positioned adjacent to the upstream conveyor
52
. The sensor
64
is a light sensor, but weight, motion or other now known or later developed sensors may be used. The sensor
64
is positioned to detect a trailing corner of the towel
22
on the upstream conveyor
52
. In one embodiment, the sensor
64
is a plurality of light sensors positioned on a platform beneath the straps of the upper run of the conveyor
52
so as to sense a towel
22
between the straps. By providing a sensor array, the trailing corner of the towel
22
is detected as well as a position of the trailing corner perpendicular to the direction of travel of the conveyor
52
. In alternative embodiments, the sensors
64
are positioned above the conveyor
52
or are positioned to detect the towel
22
on the conveyor
58
or in the slot
62
. When the trailing corner of the towel
22
is detected, such as the last portion of the towel being conveyed off of the last sensor of the array
64
as shown in
FIG. 6
, the conveyors
52
and
58
are slowed. For example, the conveyors
52
and
58
are stopped. The sensor
64
is spaced from an end of the conveyor
52
such that when the conveyors
52
,
58
stop, the towel
22
is positioned on both conveyors. A majority of the towel
22
is positioned on the downstream conveyor
58
while only a trailing corner or a minority of the towel
22
is positioned on the upstream conveyor
52
.
A movable clamp
60
is positioned within or adjacent to the slot
62
. The clamp is of a same or different structure as the clamp
16
described above. The clamp
60
is connected to a drive mechanism, such as the same or different structure as the drive mechanism
20
described above. The clamp
60
is movable through a part, all or other length of the slot
62
. The clamp
60
moves along the plane where the towel
22
is likely to be within the slot
62
, such as the plane defined by the upper surfaces of the conveyors
52
and
58
.
The clamp
60
is responsive to the sensor
64
. The clamp
64
is moved to a position detected as being the position of the trailing corner by the sensor
64
. As a result, the clamp
60
contacts the towel
22
. Since the towel
22
is substantially flat, the clamp
60
grabs an edge of the towel
22
. After clamping the edge of the towel
22
between the two conveyors
52
,
58
as shown in
FIG. 6
, the clamp
60
moves the clamped edge closer to a side of the upstream and downstream conveyors
52
and
58
. As a result of moving the edge of the towel
22
closer to a side of the conveyors, another edge of the towel
22
is more likely squared or made perpendicular to the direction of the travel of the upstream and downstream conveyors
52
and
58
.
FIG. 7
shows the position of the towel
22
after the clamp
60
moves an edge toward the side, making another edge more perpendicular to the direction of travel of the conveyors
52
,
58
. As a result, the trailing edge of the towel
22
is now straight or close to straight along a perpendicular direction to the direction of travel of the towel. As shown in
FIGS. 6 and 7
, one or more folds may occur in the towel
22
. Alternatively, the towel is laid out flat without folds.
Once substantially squared, the towel
22
is conveyed downstream by moving the upper run of the conveyor
58
. The conveyor
52
may also be actuated, but may remain in a stationary position in alternative embodiments.
Two or more jaw points
66
are positioned above the conveyor
58
. The jaw points
66
are plastic, metal, wood, rubber or other now known or later developed materials connected with an actuator
70
in a pivot point. The jaw points
66
act as one end of a clamp. In alternative embodiments, the jaw points
66
comprise a plate or roller that may press against the conveyor
58
in at least the points, such as along a line, to act as a clamp. In alternative embodiments, the jaw points
66
comprise higher clamps operable to clamp the trailing edge or other portion of the towel
22
rather than using the conveyor
58
as one end of the jaw. By actuation of the actuator
70
, the jaw points
62
are operable to press against the conveyor
58
, pressing and clamping the towel
22
between the jaw points
66
and the conveyor
58
. As shown in
FIG. 3
, the jaw points
66
are oriented such that the clamping position is at a roller
72
. In one embodiment, the conveyor
58
includes a plurality of straps and the jaw point
66
are oriented to press against the roller
72
between the straps, such as at a stationary portion of the conveyor
58
. A Teflon, plastic or other guard may be positioned around the roller
72
at the press point
66
to avoid friction engagement and wear on the jaw points
66
or roller
72
. By providing two or more jaw points
66
spread across the conveyor as shown in
FIG. 4
, a trailing edge or portion of the towel
22
may be pressed or clamped against the conveyor
58
.
A sensor
68
is directed towards the conveyor
58
adjacent to a point or location where the jaw points
66
arc operable to contact the conveyor
58
. As shown in
FIG. 3
, the sensor
68
is positioned within the conveyor
58
, such as on a platform below the upper run of the conveyor. In alternative embodiments, the sensor
68
is positioned away from the conveyor
58
, such as below, above, or to the side of the conveyor
58
. While one sensor is shown, an array of sensors may be used. The sensor
68
is a light sensor or other now known or later developed sensor for detecting the presence or absence of the towel
22
. In response to the sensor
68
detecting the trailing edge of the towel
22
, the conveyor
58
is stopped or continues movement. Alternatively, the conveyor
58
continues to operate. Also in response to the detection of the trailing edge, the jaw points
66
are actuated to press the towel
22
against the conveyor
58
, causing the towel
22
to cease forward movement. As a result, conveyance of the towel
22
is stopped. The conveyor
58
is slowed or stopped in response to detection of the trailing edge and during the pressing or clamping of the towel
22
by the jaw points
66
. Alternatively, the conveyor
58
is speed up or maintains a same speed. The conveyor
58
may change speed in response to the operation of the clamp
60
in the slot
62
and not in response to the clamping by the jaw points
66
.
An exit conveyor
74
is disposed downstream from the center conveyor
58
. The exit conveyor
74
comprises a same or different structure as the conveyor
52
. The exit conveyor
74
is of a similar length to the conveyor
58
, but may be longer or shorter. While the term exit is used to describe the conveyor
74
, additional or further conveyors may be provided for conveying the towel
22
from the separator. The exit conveyor
74
is positioned downstream from the center conveyor
58
and has a top surface below the top surface of the center conveyor
58
. In one embodiment, the top surface of the exit conveyor
54
is below the roller
72
. Since the conveyor
58
may be angled downward or upward, and the exit conveyor
74
may also be angled downwards or upwards, the relative positions of the top surfaces described herein is at the roller
72
of the center conveyor
58
and at the roller
76
of the exit conveyor
74
or at the point closest between the center conveyor
58
and the exit conveyor
74
. As shown in
FIG. 3
, the center conveyor
58
overlaps the exit conveyor
74
. In alternative embodiments, the exit conveyor
74
is spaced further from or closer to the center conveyor
58
in either horizontal and/or vertical directions. In one embodiment, the exit conveyor
74
conveys the towel
22
in a same direction as the center conveyor
58
so that an end of the center conveyor
58
is adjacent to a beginning of the exit conveyor
74
.
As the towel
22
is conveyed off of the center conveyor
58
, the towel
22
contacts the exit conveyor
74
and is conveyed away from the center conveyor
58
. In one embodiment, the conveyor
74
operates at a slightly faster speed than the conveyor
58
to avoid wrinkling the towel
22
. In alternative embodiments, the center conveyor
58
is faster or a same speed as the exit conveyor
74
.
The exit conveyor
74
is operable to continue movement while a portion, such as the leading portion or majority of the towel
22
is on the exit conveyor
74
even while the jaw points
66
clamp the trailing edge of the towel
22
. By positioning the towel
22
on both the center conveyor
58
and the exit conveyor
74
and clamping the trailing edge of the towel
22
, any folds in the towel may be removed. By continuing to convey the exit conveyor
74
while the trailing edge is clamped, any folds in the towel
22
are pulled out by the exit conveyor
74
. For example, where a corner of the towel is folded under the majority of the towel
22
, the movement of the conveyor
74
while the trailing edge of the towel
22
is clamped forces the folded under corner to extend out flat or unfold.
One or more blowers
78
are positioned to direct air or other gas towards the exit conveyor
74
. The blowers
78
are valves or other now known or later developed devices connected with a source of pressurized gas for directing a burst of forced air towards the exit conveyor
74
. As shown in
FIGS. 3 and 4
, two blowers
78
are positioned above into each side of the exit conveyor
74
. The blowers are directed towards the towel
22
. In alternative embodiments, the blowers
78
are positioned below the conveyor
74
to direct air through the conveyor
74
, are positioned between the center conveyor
58
and the exit conveyor
74
, or are positioned to the sides on a same plane with the exit conveyor
74
. Other positions and numbers of blowers
78
at one or more of those positions may be used. The blowers
78
direct air towards the towel
22
while the towel
22
is positioned on the exit conveyor
74
and the trailing edge of the towel
22
is clamped by the jaw points
66
. By blowing the towel
22
while the trailing edge is clamped, any folds in the towel are flattened out. For example, the forced air assists in flattening out folds underneath the majority of the towel
22
. As another example, the blast of air causes folds in the towel above the majority of the towel to flatten out. As a result of the continuing movement of the exit conveyor
74
and the blowing while the trailing edge of the towel
22
is held in position, the towel
22
is more likely laid out flat. In an alternative embodiment, the air is directed at a likely center location of the towel
22
so that as the air contacts the towel and spreads outward from the center point, any folds are extended outward. As a result the towel is laid flat.
After the blowing is complete, the jaw points
66
are raised, releasing the clamp on the trailing edge of the towel
22
. The exit conveyor
74
continues to convey the towel
22
towards an exit of the spreader. As a result, the trailing edge of the towel
22
is conveyed off of the center conveyor
58
and downstream on the exit conveyor
74
. At this point, the towel
22
is likely laid out flat and square. For example, two edges of the towel
22
are parallel to the direction of movement and two edges are perpendicular to the direction of movement without any folds in the towel
22
. The towel
22
is then provided to an operator or other automated machine, such as an automatic folder.
While the invention has been disclosed above by reference to various embodiments, it should be understood that many changes and modifications can be made without departing from the scope of the invention. For example, any number of additional stages may be provided. Different clamp, conveyor, sensor, actuator drive structures may be used, including now known or later developed structures.
It is therefore intended that the foregoing detailed description be understood as an illustration of the presently preferred embodiment of the invention, and not as a definition of the invention. It is only the following claims, including all equivalents, that are intended to define the scope of this invention.
Claims
- 1. An apparatus for spreading an article of laundry from a load of articles of laundry, the apparatus comprising:a frame; a clamp operable to grab the article of laundry; a pivot joint connected with the clamp and the frame; and a drive connected with the clamp, the drive connected so as to drive the clamp downward about the pivot joint; wherein at least a portion of the article of laundry is forced away from the clamp in response to the clamp being driven.
- 2. The apparatus of claim 1 wherein an area below at least a portion of the travel of the clamp is free of obstructions such that the article of laundry extends away from the clamp as a result of the clamp being driven downward.
- 3. The apparatus of claim 1 wherein the clamp comprises at least two clamps positioned to grab the article of laundry at two locations, respectively.
- 4. The apparatus of claim 1 wherein the pivot joint is operable to allow rotation between 70 and 135 degrees.
- 5. The apparatus of claim 1 wherein the combination of gravity and movement of the clamp with the article of laundry is operable to extend the article of laundry outward from the clamp in a substantially flat position.
- 6. The apparatus of claim 1 further comprising a lift operable to position the article of laundry in a horizontal position adjacent the clamp, the clamp grabbing the article of laundry from the lift, the clamp operable to grab a random location on the article of laundry.
- 7. The apparatus of claim 1 further comprising a conveyor positioned below the pivot joint such that the clamp deposits the article of laundry on the conveyor after the clamp is driven downward.
- 8. A method for spreading an article of laundry from a load of articles of laundry, the method comprising:(a) clamping a article of laundry; (b) rotating the entire article of laundry about an axis spaced away from the article of laundry, the rotation being at least in part downward; and (c) flattening the article of laundry in response to force of the rotation.
- 9. The method of claim 8 further comprising:(d) avoiding contact with the article of laundry during (b) such that the article of laundry extends away from a clamp as a result of the clamp being rotated.
- 10. The method of claim 8 wherein (b) comprises rotating the article of laundry 70 and 135 degrees.
- 11. The method of claim 8 wherein (b) comprises extending the article of laundry outward in a substantially flat position.
- 12. The method of claim 8 further comprising:(d) lifting the article of laundry to a substantially horizontal position along a least a portion of the article of laundry; wherein (a) comprises clamping the article of laundry while in the substantially horizontal position.
- 13. The method of claim 8 further comprising:(d) releasing the article of laundry on a surface with the article of laundry in a flat position after the rotation of (b).
- 14. An apparatus for spreading a article of laundry from a load of articles of laundry, the apparatus comprising:a first conveyor; a second conveyor spaced from the first conveyor by a slot, the slot narrow such that the article of laundry is able to rest on both the first and second conveyors at a same time; and a clamp positioned to move in the slot between the first and second conveyors.
- 15. The apparatus of claim 14 further comprising a sensor adjacent the first conveyor, the sensor positioned to detect a trailing corner of the article of laundry on the first conveyor, the clamp responsive to the sensor.
- 16. The apparatus of claim 15 wherein the first conveyor is operable to cease conveying in response to the sensor such that the trailing corner is on the first conveyor and at least another portion of the article of laundry is on the second conveyor.
- 17. The apparatus of claim 14 wherein the clamp is operable to grab a first edge of the article of laundry and move the edge closer to one side of the second conveyor.
- 18. The apparatus of claim 17 wherein a second edge is positioned more perpendicular to a direction of travel of the second conveyor in response to the movement by the clamp.
- 19. The apparatus of claim 14 wherein the first and second conveyors are aligned to convey the article of laundry in a same direction at a same level.
- 20. A method for spreading an article of laundry from a load of articles of laundry, the method comprising:(a) conveying a article of laundry on a first conveyor; (b) conveying the article of laundry onto a second conveyor; (c) clamping a first edge of the article of laundry between the first and second conveyors; and (d) moving the clamped first edge of the article of laundry closer to a side of the second conveyor such that a second edge of the article of laundry is more perpendicular to a direction of travel of the second conveyor.
- 21. The method of claim 20 further comprising:(e) sensing a trailing portion of the article of laundry on the first conveyor; and (f) slowing conveyance of the first conveyor in response to the sensing of (c) and prior to performing (c) and (d).
- 22. The method of claim 20 wherein (a) and (b) convey the article of laundry in a substantially same direction.
- 23. An apparatus for spreading an article of laundry from a load of articles of laundry, the apparatus comprising:a first conveyor; a second conveyor disposed downstream from the first conveyor; at least two jaw points positioned above the first conveyor and operable to press a first portion of the article of laundry against the first conveyor; and a blower directed towards the second conveyor; wherein the second conveyor is operable to continue movement with a second portion of the article of laundry on the second conveyor and while the first portion of the article of laundry is held by the jaw points against the first conveyor; and wherein the blower is operable to direct air towards the article of laundry while the second portion of the article of laundry is on the second conveyor and the first portion of the article of laundry is held by the jaw points against the first conveyor.
- 24. The apparatus of claim 23 wherein the first conveyor and second conveyor convey in a same direction, the second conveyor having a second top surface lower than a first top surface of the first conveyor, the first top surface at an end of the first conveyor and the second top surface at a beginning of the second conveyor.
- 25. The apparatus of claim 23 further comprising a sensor directed towards the first conveyor adjacent to a point where the jaw points are operable to contact the first conveyor.
- 26. The apparatus of claim 23 wherein the blower comprises a plurality of blowers directed towards the second conveyor from different directions.
- 27. The apparatus of claim 23 wherein the at least two jaw points are operable to lift from the first conveyor such that the article of laundry is conveyed by the second conveyor off of the first conveyor.
- 28. A method for spreading an article of laundry from a load of articles of laundry, the method comprising:(a) positioning the article of laundry on both first and second conveyors, the second conveyor downstream from the first conveyor; (b) clamping the article of laundry with a first portion of the article of laundry on the first conveyor; (c) continuing to convey with the second conveyor while the article of laundry is clamped; and (d) blowing at a second portion of the article of laundry while the article of laundry is clamped, the second portion on the second conveyor.
- 29. The method of claim 28 wherein (b) comprises pressing at least two points of a trailing edge of the article of laundry against the first conveyor.
- 30. The method of claim 28 further comprising:(e) sensing a trailing edge of the article of laundry on the first conveyor; wherein (b) is performed in response to (e).
- 31. The method of claim 28 wherein (d) comprises blowing the second portion from a plurality of directions.
- 32. The method of claim 28 further comprising:(e) releasing the clamping of (b); and (f) conveying the article of laundry off of the first conveyor and downstream on the second conveyor.
- 33. An apparatus for spreading an article of laundry from a load of articles of laundry, the apparatus comprising:a frame; a first clamp operable to grab the article of laundry; a pivot joint connected with the clamp and the frame; a drive connected with the clamp, the drive connected so as to drive the clamp downward about the pivot joint, the driving operable to force at least a portion of the article of laundry away from the clamp; a first conveyor positioned below the clamp and operable to receive the article of laundry from the first clamp; a second conveyor spaced from the first conveyor by a slot, the slot narrow such that the article of laundry is able to rest on both the first and second conveyors at a same time; a second clamp positioned to move in the slot between the first and second conveyors and adjacent a top portion of the first and second conveyors, the second clamp operable to square the article of laundry to a direction of travel on the second conveyor in response to clamping and moving a first edge of the article of laundry closer to a side of the second conveyor; a third conveyor disposed downstream from the second conveyor; at least two jaw points positioned above the second conveyor and operable to press a trailing portion of the article of laundry against the second conveyor; and a blower directed towards the third conveyor; wherein the third conveyor is operable to continue movement with a leading portion of the article of laundry on the third conveyor and while the trailing portion of the article of laundry is held by the jaw points against the second conveyor; and wherein the blower directs air towards the article of laundry while the leading portion of the article of laundry is on the third conveyor and the trailing portion of the article of laundry is held by the jaw points against the second conveyor.
US Referenced Citations (28)
Foreign Referenced Citations (1)
Number |
Date |
Country |
2219313 |
Dec 1989 |
GB |