COMPACT DOMESTIC ARTICLE FOLDING MACHINE WITH AN IMPROVED DRIVING MECHANISM

Abstract

A compact domestic article folding machine configured for autonomous article folding and has machine top and bottom portions and a front and rear portions which extend therebetween. The folding machine includes a hanger rack located at the front portion and configured for receiving articles from a user at a rack external portion and move them inside the folding machine. The folding machine further includes a folding device located between the front and rear portions, and a robot configured for moving each article from a rack internal portion onto the folding device.

Claims

1. A compact domestic article folding machine (200) configured for autonomous article folding and having machine top and bottom portions (208, 210) and a uniform body extending therebetween and comprising machine front, rear and side portions (212, 214, 216), the folding machine (200) comprising: a hanger rack (222) located at the front portion (212) and configured for receiving articles from a user at a rack external portion (226) and moving them inside the folding machine (200); a folding device (202) located between the front and rear portions (212, 214); and a robot (224) configured for moving each article from a rack internal portion (228) to the folding device (202) to be folded.

2. The folding machine (200) according to claim 1, wherein the hanger rack (222) comprises top and bottom bars (238, 240) connected by two chains (236) onto which multiple hangers (242) are clamped, and wherein the top bar (238) is located farther away from the machine rear portion (214) than the bottom bar (240).

3. (canceled)

4. The folding machine (200) according to claim 1, wherein the folding device (202) is configured for creating a fold in a fabric article and comprises: a table (256) for supporting the fabric article; a holding member (45) which has an elongated holding axis and adjustable between a retracted position and an extended position; a folding member (44) which has an elongated folding axis and movable in a direction perpendicular to the holding axis, the folding member (44) is configured to create a fold in the fabric article along the holding member (45) by carrying at least a portion of the fabric article over the holding member (45); a motor operatively connected to at least one of the holding member (45) and the folding member (44); and a movement means configured to adjust a distance between the holding member (45) and the fabric article; characterized in that the holding member (45) is configured to retract and leave the fold.

5-6. (canceled)

7. The folding machine (200) according to claim 4, wherein the folding member (44) includes fluid or gas conveying channels, and is configured for fabric treatment via said channels.

8. The folding machine (200) according to claim 4, wherein the holding member (45) is a concave-convex tape.

9. The folding machine (200) according to claim 4, wherein the folding member (44) is a cylindrical rod configured to rotate about the folding axis.

10. (canceled)

11. The folding machine (200) according to claim 4, wherein the folding member (44) is configured to vibrate to overcome entanglement or snags in the fabric.

12. (canceled)

13. The folding machine (200) according to claim 4, wherein the folding member (44) is not retractable.

14. The folding machine (200) according to claim 4, wherein the folding device (202) comprises: first and second holding members (45) and first and second folding members (44) arranged in pairs, each pair comprises one holding member (45) and one folding member (44), wherein the first pair is oriented perpendicular to the second pair.

15. The folding machine (200) according to claim 1, wherein the total folding time is less than 1 minute per article being folded.

16-17. (canceled)

18. A driving mechanism (258) configured for driving and bending a semi-rigid holding member (45) of a folding machine (200), the driving mechanism (258) comprising a driving portion (260) which only contacts the holding member (45) along a longitudinally extending strip-portion (282) which is located midway between two longitudinal side edges (280) of the holding member (45).

19. The driving mechanism (258) according to claim 18, wherein the driving portion (260) contacts the holding member (45) only before or after a bend apex (284) generated by a bending portion (262).

20. The driving mechanism (258) according to claim 18, wherein the driving mechanism (258) comprises a support member (276) which only contacts the holding member (45) along a longitudinally extending strip-portion (282), which is located midway between two longitudinal side edges (280) of the holding member (45).

21. The driving mechanism (258) according to claim 18, wherein the support member (276) contacts the holding member (45) only before or after a bend apex (284) generated by a bending portion (262).

22. The driving mechanism (258) according to claim 18, wherein the driving mechanism (258) comprises an output opening (268) which has a relief concave portion (286).

23-24. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0093] 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:

[0094] FIGS. 1A, 1B, 1C, and 1D show the sequence of steps in one embodiment of a shirt being folded;

[0095] FIG. 2A shows one rod and a motor for spinning the rod;

[0096] FIG. 2B shows a tape partially retracted;

[0097] FIG. 2C shows one embodiment of a tape end;

[0098] FIG. 3 shows a rod and a tape, along with their respective directions of motion relative to a fabric article to be folded;

[0099] FIG. 4 shows an embodiment with two rod-tape pairs in one axis and a third rod-tape pair in another axis;

[0100] FIG. 5A shows a fabric article placed on a curved support platform;

[0101] FIGS. 5B and 5C show outlines used to assist operators in placing articles on a support platform;

[0102] FIG. 6 shows an overhead view of one embodiment;

[0103] FIG. 7 shows a side view of one embodiment;

[0104] FIG. 8 shows an enclosure for one embodiment and a shroud;

[0105] FIGS. 9A and 9B show two snapshots in an exemplary folding sequence;

[0106] FIG. 10 is an isometric view of a folding machine;

[0107] FIG. 11 is a front plan view of a machine front portion of the folding machine of FIG. 1;

[0108] FIG. 12 is a side plan view of a machine side portion of the folding machine of FIG. 1;

[0109] FIG. 13 is a top plan view of a machine top portion of the folding machine of FIG. 1;

[0110] FIG. 14 is an isometric internal view of the folding machine of FIG. 1;

[0111] FIG. 15 is an isometric view of a holding member driving mechanism;

[0112] FIG. 16 is a cross-sectional view of the driving mechanism of FIG. 15 taken along line XV-XV of FIG. 15; and

[0113] FIG. 17 is a top, or plan, view of a holding member about to enter a holding member anchor.

[0114] Where considered appropriate, reference numerals may be repeated among the figures to indicate corresponding or analogous elements.

DETAILED DESCRIPTION OF THE INVENTION

[0115] 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 the specific configurations and details presented herein.

[0116] FIG. 1A shows a fabric article, here a long-sleeve shirt, in a position to be folded. 1 is the shirt prior the start of folding. It is helpful to consider the shirt sitting roughly horizontally on a platform or table, with a Y-axis through the collar along the primary axis of the shirt; an orthogonal horizontal X-Axis, and vertical Z-axis normal to the X-Y plane on which the shirt lies. The views in FIGS. 1A through 1D are overhead views, looking down. 2 is the first fold line, which is parallel to the Y-axis. A tape (not shown in this Figure) moves over the shirt and then contacts from the shirt the shirt from above so that it's distal edge is aligned with the shown fold line 2. Contact with the shirt may be achieved in three ways. First, the tape may lower to touch the shirt. Second, the platform supporting the shirt may rise to meet the tape. Third, the tape may already be at the correct height (above or on the fabric); as the tape is extended it glides over the surface.

[0117] Refer now to FIG. 1B. Described elsewhere is the precise sequence of steps to accomplish one fold or a pair of folds. Here a rod (not shown in this Figure) is under the left side of the shirt (where left is as the viewer looks at this Figure), under the fabric, lifting up the fabric distal to the fold line 2, then moving to the right over the top of the tape, to the second fold line 6. This operation creates two folds: a first fold at 4, comprising the body of the shirt, and a second fold at 5, in the left sleeve. The partially folded shirt is 3. The tape, which defined the first fold at 4, now retracts.

[0118] FIG. 1C shows the shirt, 7, after the second set of two folds. These are accomplished similar to and symmetrically to the first two folds on the left side of the shirt, as shown in FIG. 1B, but are now on the right side of the shirt. In one embodiment, a second rod-tape pair is used to accomplish these two folds. 8, a fold in the body of the shirt is the third fold position. 9, in the right sleeve, is the fourth fold. Dotted line 10, parallel to the X-axis, shows the position of the fifth fold. In one embodiment the fifth and six folds are accomplished by a third rod-tape pair.

[0119] FIG. 1D shows the shirt 11 fully folded, after the fifth and sixth folds. 12 shows the fifth fold position while 13 shows the sixth fold position. The fifth and sixth folds are orthogonal to the first through the fourth folds, in this example.

[0120] The final shirt, 11, is in the form of a rectangle. The locations of the first and second fold positions (4 and 5, respectively), and the fifth and sixth (12 and 13, respectively) fold positions are generally selectable to create a desirable final size and shape of the folded article. Generally, the first and forth fold positions are similar, as viewed against the X-Y plane, as are the second and third fold positions. However, this is not necessary.

[0121] FIG. 2A shows an exemplary rod with an exemplary motor to spin the rod. The rod is 21. Rods may be solid or hollow. The rod should be reasonably rigid so that it need be supported at only one end. It should be a low-cost, non-corrosive material that will not damage the fabric articles. A suitable rod material is diameter solid aluminum. Smooth polypropylene is another suitable material. The length of the rod should be long enough, in most embodiments, to reach across the article to be folded. The end of the rod should be blunt, 22, so as to not damage the article. Here, three holes, 23, are shown in a hollow rod. A rod fluid, such as air, steam, fragrance, or many other fluids, may be moved through the rod and then onto or through the fabric. A motor, 24, may be an electric motor, here shown with electric leads, 25. It is advantageous to be able to reverse the motor direction. Here, the motor shown is a DC motor; direction may be reversed by changing the direction of current through the leads 25. Alternatively, motors may be hydraulic, wind up, or remotely connected to the rod through a mechanical or magnetic coupling.

[0122] FIG. 2B shows a partially retracted tape, 28. The concave-convex tape is bi-stable in that it has one cross-sectional shape when extended and a different cross-sectional shape when coiled in the receptacle 26. The tape may be efficiently coiled inside the receptacle, 26. The basic mechanical design of the tape and receptacle is similar to a common tape measure. Note, however, that no measurement markings are required on the tape, and that the end of the tape must be smooth so as to not catch or damage the fabric during either extension or retraction. Note also that the extension and retraction of the tape are powered, as the extension and retraction are key steps in the automatic operation of this folding device 202. Extension and retraction may be achieved by rotating the spool around which the tape is wound, 27. Alternatively, the tape may be extended and retracted by the use of one or rollers or capstans (not shown), such as a rubber pinch roller. A device, such as a motor, for these purposes, is not shown. The end of the tape is shown, 29. However, the end of the tape 29 should not be square or sharp, but should be rounded, as will be discussed below, so as to glide smoothly over the fabric during both extension and retraction. 30 shows the point at which the tape 28 enters the receptacle 26.

[0123] A key feature of one embodiment is that the concave-convex tape is concave downward, when extended. This is upside down compared to the general use of most tape measures. For a tape measure, the tape is concave upward when extended to provide strength against gravity collapsing the extended tape. For this embodiment, the tape is concave downward to permit pressure to be applied between the article to be folded and the tape. From the view of the tape, this pressure is upwards. Note that the tape must be rigid enough to be self-supporting against gravity when extended, even though it is upside down. In some embodiments the tape receptacle may be placed conveniently out of the way, such as below the support platform. One or more rollers may then be used to direct the tape between its receptacle and its extended position above or on the fabric article. A suitable tape material and dimensions are similar to, although in some embodiments stronger, than a common, heavy-duty, measuring tape. For example, coated or painted spring steel, inch wide, 20 thousands of an inch thick, about the same length as the rod in the rod-tape pair.

[0124] FIG. 2C shows an exemplary rounded tape end, 31. This tape end may be smooth, molded plastic such as a polyamide. The rounded tape end may be secured to the tape with a press fit or an adhesive. Here is shown the blunt, final end, 33, and an opening, 32 into which the end of the metal tape (shown as 29 in FIG. 2B) is inserted.

[0125] FIG. 3 shows an exemplary arrangement of a rod-tape pair positioned over an exemplary article to be folded, here a shirt, 43. In this embodiment, there are two rails, a right rail 41 and a lower rail 42. These rails support the rods and tapes, and provide the mechanical mechanisms to provide the motions of the rods and tapes. Not shown in this Figure is a platform to support the fabric article. Not shown in this Figure is a mechanism to raise and lower the platform. One rod is shown, 44, and one tape, 45. The tape, 45, is its extended position. Note, again, that we often refer to rod-tape pairs for convenience, however, the rods and tapes may be operated completely independently, and an embodiment does not need an equal number of rods and tapes. For the embodiment shown in this Figure, consider that the shirt shown, 43, is flat and horizontal. The primary axis of the shirt will be known as the Y-axis. Orthogonal to the Y-axis, but still horizontal is the X-axis. The Z-axis is vertical in this embodiment. The rod 44 is parallel to the X-axis. It has three motions: First, horizontal motion along the Y-axis, 46. Second, rotation, 47, including the ability to reverse rotation. Third, vertical motion along the Z-axis, 48. This vertical motion 48 may be implemented by raising or lowering the platform (not shown) on which the article is sitting. The tape 45 is generally parallel to the rod, 44. However, in some embodiments the tape and rod are not parallel. The tape 45 has three motions. First, horizontal motion along the Y-axis, 49. Second, extension and retraction, 50. When retracted, the end of the tape is clear of the article, 43. Third, vertical motion along the Z-axis, 48. This vertical motion 48 may be implemented by raising or lowering the platform (not shown) on which the article is sitting. Tapes may be mounted on the platform.

[0126] FIG. 4 shows an embodiment with three rod-tape pairs. The right frame 41 supports and provide motions for two rod-tape pairs, while the lower frame supports and provides motions for the third rod-tape pair. The first rod tape pair is 61 and 62, respectively. The second rod tape pair is 63 and 64, respectively. The third rod tape pair is 65 and 66, respectively. All three tapes, 62, 64 and 66, are shown in their extended position. Motions of the various rods and tapes must be coordinated to avoid interference. In this embodiment, there are two rails, a right rail 41 and a lower rail 42.

[0127] FIG. 5A shows an article support platform 71 with an article placed on it 72. In this embodiment, the article support platform is circular and curved, with the center higher in a smooth, convex shape. This shape helps assists the user in centering and aligning an article 73 for folding. The concave surface allows the outer portions of the garment or article to drape slightly, due to gravity, spreading the article. Many other platform shapes are possible, including rectangular and flat. Here, a circle at the center of the platform, 72, assists a user in centering the article.

[0128] In one embodiment, a portion of the platform may lower between the time that a user places an article and the time the folding operation begins. This allows a user to place an article on a smooth, easily accessible platform, possibly raised for convenience. Then, the article is lowered into the folding device 202 in an area where the folding steps occur. In FIG. 5A, the center portion 72 may move separately from the outer portion 71. Note that the shown dimensions are not to scale. In one embodiment the article to be folded is sucked into the folding portion of the machine. A vacuum table or portion of a vacuum table may be used. In other embodiments the platform changes shape, elevation or form in order to provide both a convenient table on which a user may place an article and also provide a suitable work surface for the folding steps.

[0129] In some embodiments the article to be folded in placed directly on the platform or table used for the folding steps. In other embodiments, the article is first placed on a shroud, or other surface, and then transferred to the folding platform. The surface in FIG. 5A may be either a shroud or the folding support platform.

[0130] FIGS. 5B and 5C show exemplary outlines of articles to be folded. In one embodiment, one or more of these outlines are visible to users. Such outlines assist the user in proper or optimum placement of articles to be folded. Of particular importance is that the article is centered left-to-right so that the folding is symmetric, and that the article's axis is aligned with the primary folding axis, so that the fold lines are parallel to the articles primary axis. These outlines may be painted on the platform or shroud, or molded, or otherwise visible. In some embodiments, the outline is dynamically alterable. For example, the user may select a long-sleeve shirt to folded, rather than trousers. The folding device 202 then provides the outline 74 shown in FIG. 5B rather than the outline 75 shown in FIG. 5C. Such an outline may be projected from above, projected from below, or lit internally. For example, the outline may be translucent plastic embedded in an opaque platform. More than one such outline is embedded, however only one such outline is illuminated at a time. Note that the rear tag and the front fly is visible on outline 75 in FIG. 5C. These indicate an orientation that is face-up. Visible buttons or a zipper are examples of such face up v. face-down orientation on an article outline. Alternatively, and image of a tors, mannequin or face may be included to provide such face-up v. face-down orientation. Such orientation symbols are helpful in some embodiments to produce a set of desirable final folds.

[0131] A variation of FIGS. 5B and 5C is the use of a torso or partial torso outline, symbol or representation. An outline or partial outline of a mannequin may be used. For example, a user may then place the article to be folded on this outline as if dressing the torso, partial torso, or outline.

[0132] FIG. 6 shows an overhead view of one embodiment. The platform or table is 101. As shown, the table is generally horizontal (although it may be tilted) and defines and X-Y plane. Normal to the table is the Z-axis, where up is towards the viewer in this Figure. Two orthogonal rails, long side 102, and short side 103, are shown. These rails typically support and provide motion for the rods. This embodiment uses four rod-tape pairs. The four rod motors are 104, 105, 106, and 107. The rod motors spin four rods, 113, 114, 115, and 116, respectively. Ideally, these motors are reversible. Ideally, these motors have a mechanical, electric, electronic, or hydraulic clutch that provides a maximum rotational torque to avoid damaging the article in the event of a snag or contamination. The form of this clutch may be electronic or partially implemented in software using either the measurement of the motor current or measurement or the rotational speed, or both, to determine the effective resistance against the rotating rod. Four tapes are shown, 108, 109, 110 and 111, which may be considered part of four rod-tape pairs: 104-108, 105-109, 106-110, and 107-111. However, rods and tapes may be fully independent. In this exemplary embodiment, the four tapes are mounted on the table, 101. The four rod motors spin in either direction. The two rod motors 104 and 105 move along rail 102 in the X-axis. The two rod motors 106 and 107 move along rail 103 in the Y-axis. The rods and the rod motors may not move together. For example, a rod motor might spin a pulley, which then indirectly spins its rod. The tapes extend and retract. The tapes move in the Z-axis up and down. In some embodiments, the tapes also move in the X-Y plane. The table moves up and down. In practice, consideration must be given to mechanical interference of all components.

[0133] FIG. 7 shows a side view of one embodiment. The enclosure and most supporting frame elements are not shown. The long side rail 102 is shown, along with an end view of short side rail 103. Here the table 101 in a high position. The table may be raised and lowered by a variety of mechanisms, here a driven screw, 122. Mounted on the table, 101, are four tapes. Three of these tapes are visible, 108, 109 and 111. Tapes 108 and 109 are shown in end-view. Tape 111 is shown in side view, with its tape, 121, extended over the table, 101. After an article to be folded is placed on the table, 101, the table moves to a first elevation position. Generally, the first folds are long folds, folding the sides of the garment inward. Rod 116 driven by motor 107 would be used, along with tape 111, for this purpose. The first elevation position for the table is just below rod 116. When the folds at the first elevation are completed, the table 101 lowers to a second elevation. At this second elevation the top and bottom of the garment are folded. This second elevation is just below rods 104 and 105, shown in the Figure in end view. Folds at this second elevation typically use rods 104 and 105, and tapes 108 and 109. Typically, the table, 101, then moves to an appropriate elevation to discharge the completely folded article, or have it manually removed.

[0134] FIG. 8 shows an enclosure for the mechanical elements of the folding device 202, in one embodiment. The enclosure is 91. Either the table rises to the top of the enclosure 91 to accept an article to be folded, or a shroud is used, 92, to accept the article, which is then transferred to the folding table. An outline of the article may be visible, 93, to assist the user in placing the article. This outline may be painted, projected, or backlit, as examples. More than one outline may be available, dynamically selected, based on the type of article to be folded. After the article is placed, the user indicates that folding should start, for example, by pressing a FOLD button, 94. For safety reasons, the machine should stop if a hand or other foreign object is placed within the enclosure, 91. For this reason a protection zone, 95, is provided. This zone may also comprise mechanical clearance between the table or shroud, 92, and the sides of the enclosure, 91.

[0135] FIGS. 9A and 9B show two snapshots of an exemplary folding sequence. Prior to the snapshot of FIG. 9A, the sweater 131 is placed; the tape 132 extends over the sweater 131 and lowers onto the sweater to hold it. As described elsewhere, note that the edges of tape 132 face the sweater 131. The sweater 131 is over the rod 134, rotated by the rod motor 135. 133 shows the tape spool and spool enclosure, as described elsewhere. Thus, we see in FIG. 9A the point at which folding is about to begin. The rod 134 will move close to the tape 132; then slightly upward such that the sweater material is between the tape 132 and the rod 134, then the rod 134 will move horizontally in the direction of the arrow 139 over the top of the tape 132, pulling some of the sweater 131, including the left (as facing the sweater in this Figure) sleeve to the right, as shown by the arrow 139. The pressure of the tape 132 against the sweater 131 holds the fabric between the tape 132 and the platform (not shown) securely such that it is not pulled laterally by the rod 134.

[0136] In FIG. 9B we see the result of the motion described above. The tape 132 is in the same location as in FIG. 9A. The rod 134 has moved to the right, creating two folds: a first fold 136 defined by the distal edge of the tape 132; and a second fold 137 defined by the distal edge of the rod 134. Again we note the rod rotation motor 135 and the tape spool and enclosure 133. A this point in the folding sequence, the rod's 134 direction of rotation may reverse, as driven by the rod motor 135, then the rod may move out from under a portion of the sweater by moving in the opposite horizontal direction; that is, opposite to arrow 139. Also the tape 132 retracts into the spool 133. This latter rod motion and tape retraction steps may occur in either order, or at the same time. As a result of these folding steps, the sweater's left sleeve 138, has been neatly folded on top of the body of the sweater, 131.

[0137] Note that the sweater 131, the tape 132, and the rod 134 are not to scale in FIGS. 9A and 9B. Neither are these two Figures perspective-accurate.

[0138] In one embodiment a second rod-tape pair, with the rod starting under the sweater, then makes a second pair of folds, parallel to the two folds described above.

[0139] In one embodiment, a third, and possibly a fourth rod-tape pair, orthogonal in orientation to the first two rod-tape pairs, create one, two or more folds orthogonal to the folds 136 and 137 shown in FIG. 9B.

[0140] In some embodiments, a single sensor may provide more than one function. In some embodiments, a physical stop may be used in place of a limit sensor. In general, limit sensors and safety sensors provide a binary output. In general position sensors provide a numerical output, which may be either analog or quantized (i.e. digital). In some embodiments, it is advantageous to know the thickness of the article, both prior to folding and during folding. Similarly, it is often advantageous to know when a tape has come in contact with the article. As those trained in the art appreciate, sensors may be mechanical, optical, use reflected IR, machine vision, electrical conductivity, encoder disks, tilt switches, and numerous other sensor technologies. As one example, a single machine vision sensor could provide the necessary information to implement. Additional sensors are used in some embodiments.

[0141] Operation of the machine may be guided by machine vision. A camera and machine vision software may be used to determine the centerline of an article, its outline, the type of article, rotation of the article, and foreign objects. The machine may be directed based on this information, or a warning to the user may be provided. A weight scale may be used to determine if the article is reasonably centered by the user prior to the start of folding.

[0142] Mechanisms to move the rods, tape and fabric support platform include but are not limited to: a motor, including electric, wind-up, or pneumatic; a motor attached to a screw drive or wheel; a cable on a driven wheel; with the cable attached to the moving element; air or pneumatic powered, such as by means of a piston. Return motions may be similarly powered, or may be via a spring, pneumatic pressure, or gravity. Such mechanisms may involve use of tracks, gears, levers or belts. It is not necessary that the tape coil in its retracted position.

Definitions

[0143] ArticleA foldable article of fabric, such as foldable clothing, napkins, towels, pillow cases, sheets, blankets, tarps, flags, table cloths, and the like.

[0144] Concave-convex tapeA tape that when viewed from the end is curved. When the tape is extended in a straight line its preferred bend is concave. When the tape is rolled the curve flattens or reverses. Such bi-stable tapes are commonly used in tape measures. Note that the use of the holding member 45 in this folding device 202 is upside down from the most common orientation of such measuring tapes.

[0145] DistalMore distant from the center of the article.

[0146] FabricIncludes woven material, cloth, and non-woven material.

[0147] Foldable clothingFoldable clothing comprises a large number of name articles, without limitation, including shirts, blouses, pants, trousers, leggings, sweaters, jackets, dresses, skirts, gowns, ties, scarfs, tights, nylons, socks, under garments, and many more.

[0148] Primary axis of wearable clothingFor clothing for the torso, through the center of the neck. For pants, through the center of the waist.

[0149] Attention is drawn to FIGS. 10 and 14. A folding machine 200 includes the abovementioned folding device 202, mechanisms and methods, and can include a stacking mechanism 204 for folded articles and/or a loading mechanism 206.

[0150] Attention is drawn to FIGS. 10-13. The folding machine 200 has machine top and bottom portions 208, 210 and machine front and rear portions 212, 214 which extend between the machine top and base portions 208, 210. The folding machine 200 has side portions 216 which extend between the top and base portions 208, 210. The folding machine 200 can have a trapezoidal shape in a plan view of the machine side portions 216. The folding machine 200 has virtual opposite machine top and bottom planes 218, 220 which are perpendicular to the machine side portions 216 and respectively pass through the front and rear portions 212, 214. The folding machine 200 can include, at the machine top, bottom, side, front or rear portions slanted surfaces which are configured to enable smooth movement of the articles inside the folding machine 200.

[0151] Attention is drawn to FIG. 14. According to some embodiments, the folding machine 200 includes a loading mechanism 206 which has a hanger rack 222 and a robot 224. The hanger rack 222 is located at the machine front portion 212 and the robot 224 is located inside the folding machine 200, behind the Hanger rack 222, and between the Hanger rack 222 and the machine rear portion. As will be further disclosed below, the Hanger rack 222 has hanger rack external and internal portions 226, 228. The Hanger rack 222 is configured to receive articles from the user at the hanger rack external portion 226, and move/transfer those inwards, inside the folding machine 200 to the internal portion 228.

[0152] The robot 224 is configured to pick up articles, or grab them from the hanger rack internal portion 228 and align and release them onto the folding device 202 for folding. The function of grabbing the article by the robot 224 from the Hanger rack 222 will be referred to herein as a handshake. In some embodiments, the robot 224 is configured to move in a virtual midplane P which is perpendicular to the top and bottom planes and located midway between the machine side portions 216. The robot 224 includes a robot clamping mechanism which can include, e.g., two motorized clips 230. The motorized clips 230 can move independently along a robot rail 232 with respect to each other, at least for the purpose of enabling stretching or the articles.

[0153] The folding machine 200 can have a control console 234 (touch-screen, buttons, or other physical input means) located in the machine front portion 212. The control console 234 can be located at, or adjacent, a meeting between the machine front and top portion 212, 208. The control console 234 can be located midway between the machine side portions 216. The folding machine 200 can include wired/wireless communication modules, enabling remote operation.

[0154] Under normal use of the folding machine 200, the only physical contact between a user and the folding machine 200 is when the user places, or hands-over, the article to the hanger rack external portion 226, or when entering a command via the control console 234.

[0155] The Hanger rack 222 can have a carousel structure. According to some embodiments, the Hanger rack 222 has two opposite chains 236, each located at a meeting between a respective machine side portion 216 and the machine front portion 212. Each chain 236 is spread across/between, and revolves around, extremities of top and bottom bars 238, 240. The top and bottom bars 238, 240 are oriented perpendicularly to the machine side portions 216. The Hanger rack 222 has driving meanspreferably an electric motor which can drive one or both the top and bottom bars 238, 240. The top bar 238 is located farther away from the machine rear portion 214 than the bottom bar 240. The top bar 238 is located adjacent the machine top portion 208 and the bottom bar 240 is located adjacent the machine bottom portion 210. In a side cross section of the folding machine 200, which is taken midway between the two machine side portions 216, an imaginary line which intersects the top and bottom bars 238, 240 can form an acute front portion inner angle with the machine base plane 220. The front portion angle can receive, e.g., a range of between 60 and 75 degrees, and is preferably 70 degrees.

[0156] The Hanger rack 222 has multiple hangers 242 which extend between, and are connected to, both chains 236 on each of the machine side portions 216. Each hanger 242 is preferably located further outwardly than the next hanger 242 under it. Each hanger 242 can have a smooth hanger rail 244 that can hold at least two clamping members 246, or hanger clips 246. Each hanger clip 246 is configured to releasably hold articles. In order to fit different article-sizes, and/or straightening the articles, the hanger clips 246 can be moved closer to or farther away from each other on each rail 244, in a lateral direction between the machine side portions 216. The hanger clips 246 can be configured to rotate about the hanger rail 244 simultaneously. In other words, each hanger clip 246 can have two degrees of freedom of movement with respect to the rail, but only one degree of movement with respect to each other.

[0157] According to other embodiments, the Hanger rack 222 includes two stationary, opposite, rigid and closed tracks. Multiple hangers circulate around the tracks, attached to inner chains. Each chain can bend in accordance with the shape of the track.

[0158] In order for the folding machine 200 to perform the handshake, each hanger clip 246 can be either passive, e.g., it can alternate between a clamping position and an open position, via an actuating spring, or, it can be active, e.g., actuated by an electric motor. Each hanger clip 246 is configured to receive and hold fabrics, and to release the fabric when, e.g., the article is removed from the hanger 242 by the user, or a handshake is occurring within the folding machine 200. For example, each hanger clip 246 can include a base jaw 248 and a clamping jaw 250 connected therewith via a pivot axle 252 (the pivot axle 252, can be, e.g., the hanger rail 252). The clamping jaw 250 can be connected to a spring and can move about the pivot axle 252. In the clamping position, i.e., closed and possibly holding fabric, the spring is tensed and a tip of the clamping jaw 250 is pressed onto the base jaw 248. In an open position, the clamping jaw 250 is spaced apart from the base jaw 248 and the spring can be tensed further relative to the tension in the clamping position.

[0159] The Hanger rack 222 and robot 224 can include an array of different types of sensors aimed to detect various scenarios such, e.g., when a fabric has been inserted into a hanger clip 246; when a hanger 242 has reached a predetermined handshake position; when a fabric has been clamped/moved from the Hanger rack 222 to the robot 224 etc.

[0160] Once the folding device 202 has completed folding the article, it can be moved to a stacking mechanism 204 preferably located beneath the folding device 202. Moving the articles to the stacking mechanism 204 can be done via a split trap door 254 which opens towards the machine bottom portion 210, or a similar mechanism, which simply drops the folded article to the stacking mechanism 204 thereunder. The stacking mechanism 204 can include a movable tray which can extend outwards to the machine front portion 212 to enable easy collecting of the articles.

[0161] The table 256, or article supporting surface, on which the robot 224 places the article is preferably tilted and forms an acute table angle with the machine bottom plane 220. The table angle can receive a range of between 15 and 50 degrees and is preferably 30 degrees. This is advantageous, since it contributes to minimizing the depth of the folding machine 200 in a front-to-rear direction.

[0162] The table 256 is therefore preferably unsmooth, i.e., it is configured to form friction with respect to the articles. This is advantageous to prevent the article from falling off, and also to assist the robot 224 with stretching the article, if necessary, in the front-to-rear direction. According to some embodiments, at least a portion of the table 256 can include a trap-door style opening 254, or doors, through which the articles can fall once the article has been folded.

[0163] According to some embodiments, the machine can offer customizable folding methods/styles.

[0164] Via the rotating rod, or folding member 44, the folding machine 200 can treat the fabric while folding it (Steam, Reduce wrinkles, Capsules, Perfume, softening, sanitization).

[0165] The folding machine 200, which includes a built-in loading and stacking mechanisms 204, 206 can be very compact, in terms of outer dimensionsfor example, the folding machine 200 can be the size/volume of an average household dryer/washer machine, or even smaller than most. This is made possible due to the small volume which the holding member driving mechanism 258 takes up when the holding member 45 is contracted, while at the same time accomplishing a large holding member 45 length with an extended reach within the folding machine 200 when the holding member 45 is extracted.

[0166] A long felt need exists amongst households which relates to time and resources needed for folding laundry, at the expense of other family activities. Especially with large families, where a larger number of clothing articles are folded every day. Time is therefore an important factor when any domestic solution is considered. The folding machine is therefore only for domestic use, i.e., non-industrial. The current folding device 202 achieves the goal of saving time, space and with minimal relative monetary investment. Specifically, the driving mechanisms and methods disclosed herein minimize the total folding time to a minimum, never seen before in a compact, affordable folding machine 200. This technology enables total folding times of less than 10 minutes per article, and preferably less than 1 minute per article. In some embodiments of the machine, single article folding can take less than 10 seconds.

[0167] The holding member 45, can be made of metal, glass fibers, laminated metal, plastic etc. The holding member 45 has an elastic state, in which it is foldable/bendable in a longitudinal direction, and extends in more than a single direction. The holding member 45 has a rigid, or a relaxed state, in which it is considerably more rigid relative to the elastic state, and elongated in a single direction, in the longitudinal direction. In the relaxed state, the holding member 45 has a built-in, or preexisting, bend in a width direction, which gives it its rigidity in the longitudinal direction when extendedsimilarly to a measuring tape. In the rigid state, the holding member 45 can withstand relatively large bending moment without elastically changing direction/bending in the longitudinal direction, which allows the holding member 45 to force/press and hold articles in their place, or creating the folding line/crease.

[0168] In the longitudinal direction, the holding member 45 has a length axis X, located midway between elongated side edges (280) of the holding member 45.

[0169] In the width direction, perpendicular to the length axis X, the holding member 45 has a width axis Y.

[0170] The holding member 45 has a depth axis Z which extends perpendicularly to the length and width axes X, Y.

[0171] In the rigid state the holding member 45 can still slightly bend in the longitudinal direction, while the natural bend in the width direction is maintained. This, only for very large (relative to its width) bend radiuses.

[0172] Attention is drawn to FIGS. 15-17. According to a first aspect, the driving mechanism 258 is made of two portions, or enclosures through which the holding member 45 passes. A driving portion 260 and, a separate, bending portion 262. The bending portion 262 can be connected to the driving portion 260 via a rail 264 (on which it can move) and according to the current aspect, the distance between the driving and bending portions 260, 262 can be actively altered.

[0173] The bending portion 262 has a bending portion body 264 and input and output openings 266, 268 located at two ends thereof. The holding member 45 enters the bending portion 262 via the input opening 266 (in a rigid state), and exits therefrom via the output opening 268 (also in a rigid state). The bending portion 262 is configured to bend the holding member 45 by forming an angle, or bend, in the longitudinal direction between a first holding member portion 270 (in a rigid state) which enters the bending portion 262 and a second holding member portion 272 (also in a rigid state) exiting the bending portion 262. At least a portion of the holding member 45 located between the first and second holding member portions 270, 272 is in a bent state. In the bent state, at a bend apex 284 in the longitudinal direction, the holding member 45 is substantially flattened, i.e., has a profile, cross-section (taken perpendicular to the length axis, or the longitudinal direction), which appears as a straight, or almost straight, line.

[0174] According to a second aspect (FIGS. 15-18), the holding member driving mechanism 258 has a unitary structure, i.e., includes a single structure, or enclosure (as depicted in the drawings) in which the holding member 45 is both driven, and bent in the desired direction. According to the second aspect, the input opening 266 is located at a fixed distance from the output opening 268. In an assembled position, the article is always located between the input and output openings 266, 268 in a longitudinal direction of the driving mechanism 258. The driving mechanism 258 and the table 256 on which the article is located, are configured to move with respect to one another (in all desired directions), within said distance between the input and output openings 266, 268 (to release or hold the article).

[0175] In both abovementioned aspects, the driving mechanism 258 has a driving motor. In some aspects, the driving motor is located within the driving portion 260, and in others, externally to the unitary driving mechanism 258.

[0176] In both abovementioned aspects, the bending and/or driving portions 260, 262 are movable in any desired direction relative to the folding table 256. In other words, the driving mechanism 258 and folding table 256 can move in any direction or angle with respect to one another.

[0177] The driving mechanism 258 can advantageously mechanically manipulate the holding member 45 in order to achieve more rigidity when it is exerted outwardly and applies forces on the article. There are several constructional aspects which can improve said rigidity, while at the same time, retaining the required flexibility to bend the holding member 45 in order to change its direction, or fold it to save space in the folding machine 200.

[0178] The shape of the input and output openings 266, 268 is not a parallelogram. Specifically, the shape can have a shape with a bend in its middle. The shape can correspond to a cross section of the holding member 45, i.e., it can have a first portion with concave profile and an opposite second portion with a convex profile.

[0179] Aspects of improvements, which are combinable with each other, and with any of the aspects mentioned above: [0180] 1. Support members 276, and driving members 278, preferably contacting the holding member 45 at its middle. Specifically, along a line, or a strip-portion 282, passing midway between the two, substantially parallel side edges (280) of the holding member 45. In other words, the driving and support members 278, 276 contact the holding member 45 at a middle of a natural, built-in bend of the holding member 45 in a relaxed position, when no other external force is applied. [0181] 2. Any contact with the holding member 45 (driving, locating, leading, winding or folding) is preferable only before or after a bend in the direction of the length axis X, or the longitudinal direction. For example, the holding member 45 can be driven before the holding member 45 enters the bending portion 262, and/or after the holding member 45 exits therefrom. [0182] 3. In order to drive the holding member 45, to locate it, to support it, or to carry it, it is preferable that it is done at a portion of the tape which is in the relaxed position (not bent in the direction of the length axis X). [0183] 4. The upper portion of the output opening 268 is not straight, since it would serve as a counter force and bend the holding member 45 at the natural bend in the direction of the width axis Y. As known in the field of measuring tapes, straightening the natural bend between the side edges (280) will most likely cause a bend in the longitudinal direction in the length axis X (with the apex 284). [0184] 5. The upper portion of the output opening 268 can include a relief concave portion 286, which forces the holding member 45 into the concave portion to further increase the built in bend in the width axis Y direction. [0185] 6. The output opening 268 can be aligned (located opposite of, at the same horizontal and lateral location) with an optional holding member anchor 290 (FIG. 14), which includes a recess with a matching shape which corresponds to the shape of the holding member 45. The holding member anchor 290 is configured to catch, or support the holding member 45 when it is at its maximum extension, and improve rigidity of the holding member 45, thus improving the clamping forces the holding member 45 applies on the article.

[0186] These abovementioned characteristics enable the driving mechanism 258 to extract and retract the holding member 45, very quickly, in matter of few seconds, and in some cases less than a second. This is crucial for ultimately achieving article folding, where a quick, smooth, and non-intrusive force-applying mechanism is required