WIDTH-FOLDING SYSTEM AND METHOD FOR FOLDING AN ARTICLE OF CLOTHING

Abstract

An active width folder system configured for article folding within compact article folding machines and includes a holding member with two opposite holding edges which extend in an article motion direction, a conveyor configured for conveying articles in the motion direction and a pair of actuated folding members, each configured for lifting and folding at least a portion of the article. Wherein, each folding member has a retractable lifting surface which has a variable length at least in the width direction which is perpendicular to the motion direction.

Claims

1. A passive width folder (100) configured for article folding and comprising three members stacked in a vertical direction (VD): a first male member (38) comprising two opposite first folding edges (44) extending along a motion direction (MD) perpendicular to the vertical direction (VD); a female member (36) located beneath the first male member (38) and comprising two opposite second folding edges (46) converging in the motion direction (MD); in a bottom view of the with folder parallel to the vertical direction (VD), each second folding edge (46) intersects a respective first folding edge (44) at a first intersection location along the motion direction (MD); and a second male member (40) located opposite the first male member (38) beneath the female member (36) and comprising two opposite third folding edges diverging along the motion direction (MD); in the bottom view, each third folding edge intersects a respective adjacent second folding edge (46) at a second intersection location along the motion direction (MD), wherein in the bottom view, the second intersection locations are located further along the motion direction (MD) than the first intersection locations.

2. The width folder (100) according to claim 1, wherein the width folder (100) further comprises a pulling mechanism which is configured to pull an article throughout the width folder (100) in the motion direction (MD).

3. The width folder (100) according to claim 1, wherein each of the first and second male members (38, 40) comprise respectively adjustable first and second male extensions (39, 50) and the female member (36) comprises adjustable female extensions (42), all of which are configured to allow width adjustment of the width folder (100) in the width direction (WD) to adapt to different article widths.

4. The width folder (100) according to claim 1, wherein each pair of right at left portions are static during folding.

5. The width folder (100) according to claim 1, wherein first fold lines are defined by the narrowest portion between the first folding edges (44) and second fold lines are defined by the narrowest portion between the second folding (46) edges.

6. The width folder (100) according to claim 1, wherein the width folder (100) is configured to perform two consecutive pairs of width folds in the article as it is conveyed in the motion direction (MD)—a first pair of width folds between the first male member (38) and the female member (36), and the second pair of width folds between the female member (36) and the second male member (40).

7. The width folder (100) according to claim 1, wherein a first pair of width folds is defined at the first intersection location and a second pair of width folds is defined at the second intersection location.

8. The width folder (100) according to claim 1, wherein in the bottom view of the width folder (100), a tangent to each first folding edge (44) forms an acute first angle (a1) with the motion direction (MD), and wherein the first angle (a1) is 0 or between 0 and 2 degrees.

9. The width folder (100) according to claim 1, wherein in the bottom view of the width folder (100), a tangent to each second folding edge (46) forms an acute second angle (a2) with the motion direction (MD), and wherein the second angle (a2) ranges between 20 and 45 degrees.

10. The width folder (100) according to claim 1, wherein in the bottom view of the width folder (100), a tangent to each third folding edge (48) forms an acute third angle (a3) with the motion direction (MD).

11. The width folder (100) according to claim 1, wherein the third folding edge (48) is at least partially curved, and when progressing along the curved third folding edge (48) from one end to another, at each point thereof, the tangent progressively changes direction, and the third angle (a2) respectively and progressively ranges between 0 and 90 degrees.

12. The width folder (100) according to claim 1, wherein only the first male member (38) is width-adjustable and comprises width-adjustable first male extensions (39) which are configured to allow width-adjustment of the width folder (100) in the width direction (WD) by changing the distance between the first folding edges (44) to adapt to different article widths.

13. A method of width-folding an article includes the following steps: a) providing the width folder (100) according to claim 1; b) adjusting a female member (36) width to a desired article width according to user input or sensory input; c) adjusting the second male member (40) width to a desired article width according to user input or sensory input; d) Pulling the article on top of the first male member (38) in the motion direction (MD) while the extremities of the article hang respectively over the first folding edges (44), until a two double-folds are created, one on each side of the article.

14. A method of width-folding an article includes the following steps: a) providing the width folder (100) according to claim 1; b) adjusting only the first male member (38) width to a desired article width according to user input or sensory input; c) Pulling the article on top of the first male member (38) in the motion direction (MD) while the extremities of the article hang respectively over the first folding edges (44), until a two double-folds are created, one on each side of the article.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0060] For a better understanding of the subject matter of the present application and to show how the same may be carried out in practice, reference will now be made to the accompanying drawings, in which:

[0061] FIG. 1 is an isometric view of an active width folder with retractable or adjustable folding members;

[0062] FIG. 2 is a front view of the width folder of FIG. 1;

[0063] FIG. 3 is a top plan view of the width folder of FIG. 1;

[0064] FIG. 4 is a side view of the folder of FIG. 1.

[0065] FIG. 5 is an isometric bottom view of the folding members of FIG. 1, each having a lifting surface—one in a retracted position and the other in an extended position, each lifting surface having a linear actuator connected to extension bars;

[0066] FIG. 6 is a front view of the folding members of FIG. 5;

[0067] FIG. 7 is an isometric view of a first holding member embodiment of the folding mechanism;

[0068] FIG. 8 is an isometric view of a second holding member embodiment of the folding mechanism;

[0069] FIG. 9 is an isometric view of a third holding member embodiment of the folding mechanism;

[0070] FIG. 10 is an isometric view of a fourth holding member embodiment of the folding mechanism showing sliding members attached beneath each holding panel;

[0071] FIG. 11 is a side view of a sliding member of FIG. 10;

[0072] FIG. 12 is an illustrative side view showing an additional hinge arrangement of a holding member;

[0073] FIG. 13 is an isometric view of a passive width folder with three stacked folding members;

[0074] FIG. 14 is a bottom plan view of the passive width folder of FIG. 13;

[0075] FIG. 15 is a front view of the passive width folder of FIG. 13; and

[0076] FIG. 16 is a plan view of an article in an unfolded flat position and designated locations of fold lines which are going to be formed in the article by the passive width folder; and

[0077] FIG. 17 is a front view of the passive width folder of FIG. 13 which illustrates two pairs of width folds created in the article by the passive width folder of FIG. 13;

[0078] FIG. 18 is a front isometric bottom view of an alternative embodiment of the width folder of FIG. 1, having an alternative actuation mechanism which includes an actuator connected directly to a mobile portion; and

[0079] FIG. 19 is a rear isometric bottom view of the width folder embodiment of FIG. 18.

DETAILED DESCRIPTION OF THE INVENTION

[0080] In the following description, various aspects of the subject matter of the present application will be described. For purposes of explanation, specific configurations and details are set forth in sufficient detail to provide a thorough understanding of the subject matter of the present application. However, it will also be apparent to one skilled in the art that the subject matter of the present application can be practiced without some specific configurations and details presented herein.

[0081] Reference is made to FIGS. 1 and 2. An article width folder 10 has a holding member 12 (or fold-line defining member) and can have at least two opposite motorized folding members 14, each located on opposite side of the holding member 12. The width folder 10 is located directly above a conveyor 16, which is configured to convey articles 17 to be width-folded by the width folder 10. The conveyor 16 defines a conveyance direction, or an article motion direction MD which is parallel to the conveyor belts 34 motion direction. A width direction WD is defined perpendicular to the motion direction MD. A vertical direction VD is defined perpendicular to the motion direction MD and perpendicular to the width direction WD. The article 17 rests on, and is conveyed by, the conveyor 16 under the holding member 12.

[0082] A width adjustable holding member 12 can include exactly two elongated elements preferably ski-shaped, holding panels 18, or holding sub-members, which extend in the motion direction MD longitudinally thereabout. Each holding panel 18 can be slender and planar, and have a thin cross section relative to its length. Each holding panel 18 needs to be rigid to be able to hold the fabric and counter folding forces exerted by the folding members 14 in the width direction WD. Each holding panel 18 has an outwardly facing holding edge 20. Each holding edge 20 defines a fold line, or crease, as will be further explained below. Each holding panel 18, and consequently each holding edge 20 extends, or is oriented, in the motion direction MD.

[0083] The holding panels 18 are configured to hold the fabric to allow the folding members 14 to fold only the necessary portion of the fabric. The holding panels 18 are configured to locate, create, or define two folds, or fold lines in each article 17. Each holding panel 18 is secured to the width folder 10 at one end thereof, and free to move according, e.g., to a hinged parallelogram support assembly 22.

[0084] The holding member 12 preferably has a width adjustment mechanism. According to some embodiments, both holding panels 18 can be connected, e.g., to a right-left screw. Depending on the direction, when the screw is turned, the two holding panels 18 are either distanced from each other, or come together. This adjustment therefore affects the distance between the two width fold lines created by the holding member 12.

[0085] Attention is drawn to FIG. 7, showing a first holding member embodiment. According to the first holding member embodiment, the holding panels 118 of the holding member 112 can be located between two holding surfaces 119, and can extend, or protrude outwardly in the width direction WD.

[0086] Attention is drawn to FIG. 8. According to a second holding member embodiment, the holding member 212 includes a receiving plate 221 which extends across the entire machine width in the width direction WD. The receiving plate 221 is configured to lead the article 17 in between the holding member 212 and the conveyor 16 underneath.

[0087] Attention is drawn to FIG. 9. According to a third holding member embodiment, the holding panels 318 can be supported, or suspended over the conveyor 16 via a parallelogram leveling mechanism 322. The leveling mechanism support assembly 322 keeps the holding panels 318 parallel with respect to the conveyor 16, and accommodates various article thicknesses, folded or unfolded. The leveling mechanism allows a single degree of freedom of movement along a curved path for the holding panels 318.

[0088] Attention is drawn to FIGS. 10 and 11. According to a fourth holding member embodiment, each holding panel 418 can include a sliding member 423 which can be secured thereto with screws. In some cases where the holding panels 418 contact the conveyor 16, the sliding members 423 are configured to allow smooth motion of the holding panels 418 when moving in the width direction WD across the conveyor belts 34. The sliding members 423 are also advantageous since a mass thereof shifts the center of gravity of each holding panel 418 towards a front end of the holding panel 418 to assist in keeping the holding panel 418 in its place, e.g., in a scenario where lifting the fabric may result in lifting or otherwise compromising the fold-lines created by the holding member 412. Finally, the sliding members 423 are configured to allow smooth motion of the folded articles 17.

[0089] Attention is drawn to FIG. 11. Each sliding member has a smoothed, or low-friction surface 427 to enable safe and reliable passage for the articles and prevent tangling with the conveyor belts. Each sliding member 423 can be broader than the holding panel (extending in the width direction WD)

[0090] Attention is drawn to FIG. 12, a double hinge support assembly 22 is one example that allows the holding member at least two degrees of freedom of movement. The right-hand portion of FIG. 12 illustrates the displacement of the holding member or panel 12, 18 after an article 17 has been conveyed between the holding member or panel 12, 18 and the conveyor 16.

[0091] Each folding member 14 is configured to lift, throw and fold at least a portion of the article across a respective adjacent holding edge 20 in the width direction WD perpendicular to the motion direction MD.

[0092] Each folding member 14 is retractable, or adjustable, at least in a dimension in the width direction WD. Each folding member 14 includes a lifting surface 24. Each lifting surface 24 can be generally planar and configured to engage the article and preferably always faces upwards, away from the conveyor 16 in the vertical direction VD. According to some embodiments, each lifting surface 24 is attached to a lifting arm 26 which can pivot, and can move the lifting surface 24 in a semi-circular path, in which path the lifting surface 24 passes, while carrying, and preferably throwing, a portion of the article, across and above the respective holding edge 20 thus creating the fold in the article.

[0093] Each lifting surface 24 is retractable to adapt to various article sizes to be folded. In other words, each lifting surface 24 has a variable length in the width direction WD. Each lifting surface 24 can have parallel (and preferably generally co-planar) base and mobile portions 28, 30, at least one of which is movable, or retractable with respect to the other. According to the present embodiments, the mobile portion 30 is actuated and movable with respect to the base portion 28 which is connected to the lifting arm 26. The total length (in the width direction, including both the base and mobile portions 28, 30) of each lifting surface 24 is adjusted before the article reaches/contacts the width folder 10.

[0094] The lifting surfaces 24 can have various actuation mechanisms for extending or retracting at least one of the base and mobile portions 28, 30, and preferably, the mobile portion 30 with respect to the base portion 28. Attention is drawn to FIGS. 18 and 19. For example, the mobile portion 30 can be connected to the base portion 28 via a linear actuator 29 that is screw threaded into a female thread of at least one of the base and mobile portions 28, 30. Alternatively, according to another example which is best illustrated in FIG. 5, the lifting surfaces 24 can include extension bars 31 which extend from the mobile portion 30 and connected to a linear actuator 29, located at the base portion 28. The linear actuator 29 was chosen, partially due to an advantageous high locating accuracy. It was mainly chosen since it was a lighter mechanism than others considered. Reducing the total mass of the folding member 14 is advantageous since in addition to being retractable, the lifting surface 24 has to move quickly, to throw and fold the fabric. A faster movement of the lifting surface 24 increases the fold's accuracy and the general reliability.

[0095] Each folding member 14 has operational and non-operational positions. In the non-operational position, the lifting surface 24 is located slightly below, or at the same level as, a conveyor top surface 32 of the conveyor 16 which is oriented perpendicular to the vertical direction VD. In other words, a fabric conveyed by the conveyor 16 is conveyed on top of the lifting surfaces 24. In the operational position, the lifting surface 24 is located above the holding member 12 in the vertical direction VD and is configured to move across the respective holding edge 20 as seen at the bottom of FIG. 3. Each lifting surface 24 has retracted and extended positions. In a retracted position, the lifting surface 24 has a minimal length in the width direction WD (In FIGS. 5 and 6, the right hand lifting surface 24 is in the retracted position). In an extended position, the mobile portion 30 is located with respect to the base portion 28 anywhere between the minimal length and a maximum length (In FIGS. 5 and 6, the left hand lifting surface 24 is in the extended position). The folding members 14 can be synchronized, at least in a sense that the folding members 14 do not engage each other in the extended position, and configured for fast, and efficient consecutive motion and lifting of the article across the holding edge 20. In other words, each folding member 14 can be in the extended position when the other isn't. This is advantageous, to save room in the width direction, which keeps the folding mechanism ‘slender’. Alternatively, the folding member can simultaneously move into the extended position, provided that there is sufficient space in the width direction WD. According to the current example, the folding members 14 are operated by a single motor 25. According to the present embodiments, the folding members 14 move into the operational position simultaneously, i.e., extend and fold the article at the same time. Specifically, even in a fully extended position, the lifting surfaces 24 cannot engage each other.

[0096] Attention is drawn to FIGS. 3 and 4. Each lifting arm 26 is located on opposite sides of the conveyor 16. Therefore, the conveyor 16 becomes narrower (e.g., seven belts 34 become five belts 34—as seen in FIGS. 1-3) in the width direction WD, right before entering the width folder 10. Specifically, the conveyor 16 can include seven belts 34 connected to a first roller (left hand side of FIG. 3), five belts 34 connected to a second roller (right hand side of FIG. 3), and a third roller which connects the two sets of belts 34 which is located between said first and second rollers located at opposite ends of the conveyor 16. A swing lever 35 can connect the single motor 25 to both of the lifting arms 26, which lowers costs and improves production efficiency, and power savings as compared to two motors and/or solenoids. According to the subject matter of the present application, the lifting arms 26 can work in the width direction WD while the article is simultaneously being conveyed in the motion direction MD.

[0097] The width folder 100 can automatically (e.g.—input received from the user prior to loading the article) and/or autonomously (i.e.—sensory input) adjust in the width direction WD to accommodate different article widths. The width folder 100 can change a distance (in the width direction WD) between each pair of male and female extensions 42 using, e.g., a rail mechanism.

[0098] Articles can be conveyed into the width folder 10 via the conveyor 16. The holding member 12 and folding members 14 adjust their width/extension magnitude, to adapt to the incoming article width. The article is conveyed between the holding member 12 and the conveyor 16. As the article proceeds in the motion direction MD, extremities thereof climb on top of the folding members 14 which are in a respective, desired retracted or extended position, according to user or sensory input/s. As the article is being conveyed, the single motor 25 turns, causing the lifting arms 26 to move synchronously while lifting the article extremities in the width direction and across the holding edges 20 respectfully. Once the extremities of the article are folded on top of the article itself, the folding members 14 can repeat the folding action as required, e.g., according to remaining, unfolded portions of the article along its length/motion direction MD.

[0099] According to the subject matter of the present application, a method of width folding articles via the width folder 10 includes the following steps: [0100] a. Providing the width folder 10; [0101] b. Adjusting a holding width HW between the holding panels 18 to adapt to certain article dimension according to user input or sensory input; [0102] c. Pulling or conveying the article between the holding member 12 and the conveyor 16; [0103] d. Lifting article extremities in the width direction via the folding members 14 and moving them across the holding edges 20; and [0104] e. Repeating steps b and c until the article includes two complete fold lines, or creases.

[0105] According to the subject matter of the present application, a method of width folding articles via the width folder 10 includes the following steps: [0106] a. providing the width folder; [0107] b. adjusting the holding width HW to adapt the holding member to a desired article width according to user input or sensory input; [0108] c. adjusting the retractable lifting surface 24 to a desired article width according to user input or sensory input; [0109] d. conveying the article under the holding member 12 and above the retractable lifting surface 24; [0110] e. lifting article extremities in the width direction WD via the folding members 14 and throwing them across the holding edges 20; [0111] f. repeating steps d and e until the article includes two fold-lines throughout, in the motion direction MD.

[0112] Attention is drawn to FIGS. 13-17. A passive width folder 100 is configured to perform, or create, two width-folds on each side of an article centerline AC which extends in the motion direction MD. The width folder 100 is passive, or semi-passive mechanism, in the sense that it is stationary, and does not actively move by itself, or the fabric, to fold it, but rather the fabric is being pulled thereacross (or therethrough) in the motion direction MD, to create the two pairs of folds. According to the present embodiment, the width folder 100 includes three members 36, 38, 40 stacked in the vertical direction VD—a first male member 38 located above a female member 36, which is located above a second male member 40.

[0113] The first male member 38 can include two width-adjustable first male extensions 39, each of which includes a first folding edge 44. According to a preferred embodiment, only the first male member 38 is width-adjustable. Alternatively, the first male member 38 can be non-adjustable, and have a unitary, one-piece construction. Both first folding edges 44 are preferably parallel, or generally parallel, within tolerances (deviations of about 2 degrees), and define the first fold lines in the article. The first male member 38 preferably includes a bend (forming a downwards-facing concavity in the male member) such that after the bend it extends downwards in the vertical direction, towards the second male member 40.

[0114] In the width direction WD, the female member 36 includes two opposite female extensions 42 and an opening therebetween. Each of the two female extensions 42 includes an internal second folding edge 46 which faces a second folding edge 46 of the opposite female extension 42. The two second folding edges 46 are located opposite of each other and converge inwards, in the motion direction MD.

[0115] The second male member 40 includes second male extensions 50. Each of the second male extensions 50 includes an external third folding edge 48. The two third folding edges 48 are located opposite of each other and diverge inwards, in the motion direction MD.

[0116] In a bottom view of the width folder 100, each third folding edge 48 can be at least partially curved, and when progressing therealong, at each point thereof, a tangent line to the third folding edge 48 progressively changes direction, and forms an acute third angle (a2) which respectively and progressively ranges between 0 and 90 degrees.

[0117] The two second folding edges 46 are located between the two first folding edges 44 (transversely thereto) such that when an article is pulled across the first male member 38 in the motion direction MD, a mid-portion of the article climbs onto the first male member 38 and any excess fabric at its sides is urged, or folded (folds are therefore created both at, and by, the first folding edges 44 and, at the third folding edges 48), beneath the first male member 38 and beneath the female member 36.

[0118] According to the subject matter of the present application, a method of width folding articles via the width folder 100 includes the following steps: [0119] a. providing the width folder 100; [0120] b. adjusting a female member 36 width to a desired article width according to user input or sensory input; [0121] c. adjusting the second male member (40) width to a desired article width according to user input or sensory input; and [0122] d. Pulling the article on top of the first male member (38) in the motion direction (MD) while the extremities of the article hang respectively over the first folding edges (44), until a two double-folds are created, one on each side of the article.

[0123] According to the subject matter of the present application, a method of width folding articles via the width folder 100 includes the following steps: [0124] a. providing the width folder 100; [0125] b. adjusting only the first male member 38 width to a desired article width according to user input or sensory input; and [0126] c. Pulling the article on top of the first male member 38 in the motion direction MD while the extremities of the article hang respectively over the first folding edges 44, until a two double-folds are created, one on each side of the article.