Napkin folding apparatus

Abstract

Provided is napkin folding apparatus for folding a napkin around at least one piece of flatware forming a flatware bundle. The apparatus includes a napkin cartridge for receiving a plurality of napkins, at least one flatware cartridge for receiving a plurality of pieces of flatware, a folding assembly having a deck assembly for receiving one of the plurality of napkins and at least one of the plurality of pieces of flatware, and a rolling assembly for rolling the one of the plurality of napkins and the at least one of the plurality of pieces of flatware into the flatware bundle, a transport assembly including an actuator and a gripper assembly movable by the actuator for transporting the flatware and the flatware bundle, a taping assembly, a first lifting assembly, and at least one second lifting assembly.

What is claimed is: 
     
         1 . A napkin folding apparatus for folding a napkin around at least one piece of flatware to form a flatware bundle, the apparatus comprising:
 a napkin cartridge for receiving a plurality of napkins;   at least one flatware cartridge for receiving a plurality of pieces of flatware;   a folding assembly having a deck assembly for receiving one of the plurality of napkins and at least one of the plurality of pieces of flatware, and a rolling assembly for rolling the one of the plurality of napkins and the at least one of the plurality of pieces of flatware into the flatware bundle; and   a transport assembly including an actuator and a gripper assembly movable by the actuator for transporting the flatware and the flatware bundle.   
     
     
         2 . The napkin folding apparatus according to  claim 1 , wherein the deck assembly includes a deck and a motor configured to rotate the deck such that a top of the deck is proximate a napkin in the napkin cartridge. 
     
     
         3 . The napkin folding apparatus according to  claim 2 , wherein the deck includes a receiving area for receiving the napkin and at least one piece of flatware, and one or more vacuum openings for grabbing the napkin. 
     
     
         4 . The napkin folding apparatus according to  claim 1 , wherein the deck assembly includes a base and a napkin pickup assembly rotatable relative to the base. 
     
     
         5 . The napkin folding apparatus according to  claim 4 , wherein the base has a receiving area for receiving the napkin and at least one piece of flatware, and the napkin pickup assembly has a vacuum for grabbing the napkin. 
     
     
         6 . The napkin folding apparatus according to  claim 1 , wherein the rolling assembly includes a grip assembly that engages an end of the at least one of the plurality of pieces of flatware to rotate the flatware to form the flatware bundle. 
     
     
         7 . The napkin folding apparatus according to  claim 1 , further including a taping assembly including a roll holder for receiving a roll of tape, a guide rail for guiding the roll of tape, a cutting mechanism for cutting the tape, and a transport mechanism for transporting the tape once cut to the deck assembly. 
     
     
         8 . The napkin folding apparatus according to  claim 7 , wherein the taping assembly further includes a feed mechanism including one or more drive wheels that are driven by a motor to drive the tape towards the cutting mechanism. 
     
     
         9 . The napkin folding apparatus according to  claim 7 , wherein the transport mechanism includes one or more drive wheels that are driven by a motor to drive the tape towards the deck assembly. 
     
     
         10 . The napkin folding apparatus according to  claim 1 , further including a first lifting assembly having a first lever arm for lifting the plurality of napkins, and at least one second lifting assembly having a second lever arm for lifting the plurality of pieces of flatware. 
     
     
         11 . The napkin folding apparatus according to  claim 10 , further including a housing, wherein the napkin cartridge, at least one flatware cartridge, the folding assembly, the transport assembly, the first lifting assembly, and the at least one second lifting assembly are disposed in the housing. 
     
     
         12 . The napkin folding apparatus according to  claim 1 , wherein the at least one flatware cartridge includes a first flatware cartridge, a second flatware cartridge, and a third flatware cartridge. 
     
     
         13 . A napkin folding apparatus for folding a napkin around at least one piece of flatware to form a flatware bundle, the apparatus comprising:
 a napkin cartridge for receiving a plurality of napkins;   at least one flatware cartridge for receiving a plurality of pieces of flatware;   a folding assembly having a deck assembly for receiving one of the plurality of napkins and at least one of the plurality of pieces of flatware, and a rolling assembly for rolling the one of the plurality of napkins and the at least one of the plurality of pieces of flatware into the flatware bundle;   a transport assembly including an actuator and a gripper assembly movable by the actuator for transporting the flatware and the flatware bundle;   a taping assembly including a roll holder for receiving a roll of tape, a cutting mechanism for cutting the tape, and a transport mechanism for transporting the tape once cut to the deck assembly;   a first lifting assembly having a first lever arm for lifting the plurality of napkins; and   at least one second lifting assembly having a second lever arm for lifting the plurality of pieces of flatware.   
     
     
         14 . The napkin folding apparatus according to  claim 13 , wherein the deck assembly includes a base and a napkin pickup assembly rotatable relative to the base. 
     
     
         15 . The napkin folding apparatus according to  claim 14 , wherein the base has a receiving area for receiving the napkin and at least one piece of flatware, and the napkin pickup assembly has a vacuum for grabbing the napkin. 
     
     
         16 . The napkin folding apparatus according to  claim 13 , wherein the rolling assembly includes a grip assembly that engages an end of the at least one of the plurality of pieces of flatware to rotate the flatware to form the flatware bundle. 
     
     
         17 . The napkin folding apparatus according to  claim 13 , wherein the taping assembly further includes a feed mechanism including one or more drive wheels that are driven by a motor to drive the tape towards the cutting mechanism. 
     
     
         18 . The napkin folding apparatus according to  claim 13 , wherein the at least one flatware cartridge includes a first flatware cartridge, a second flatware cartridge, and a third flatware cartridge, and the at least one second lifting assembly includes one lifting assembly for each of the first, second, and third flatware cartridges. 
     
     
         19 . The napkin folding apparatus according to  claim 13 , further including a housing, wherein the napkin cartridge, at least one flatware cartridge, the folding assembly, the transport assembly, the first lifting assembly, and the at least one second lifting assembly are disposed in the housing. 
     
     
         20 . A method of creating a flatware bundle, the method including:
 rotating a napkin pickup assembly from a first position to a second position to pick up a napkin;   rotating the napkin pickup assembly from the second position to the first position;   transporting at least one piece of flatware via a transport assembly from a flatware cartridge to a receiving position over the napkin; and   rotating the napkin and at least one piece of flatware via a grip assembly to create the flatware bundle.