SINGLE-FOLD INTERFOLDING MACHINE WITH ABILITY TO PRODUCE OFF-FOLDED TOWEL OR TISSUE PRODUCTS

• US 20110201486A1
• Filed: 02/16/2010
• Published: 08/18/2011
• Est. Priority Date: 02/16/2010
• Status: Active Grant

• Current Assignee: C.G. Bretting Manufacturing Co., Inc.
• Original Assignee: C.G. Bretting Manufacturing Co., Inc.
• Inventors: Cline, Curtis, Kauppila, Greg M.
• Granted Patent: US 8,696,537 B2
• Time in Patent Office: Days
• US Class Current: 493/418
• CPC Class Codes: B65H 2404/1362 vacuum
• CPC Class Codes: B65H 2404/1363 air supply or suction
• CPC Class Codes: B65H 45/162 with folding jaw cylinders
• CPC Class Codes: B65H 45/24 Interfolding sheets, e.g. cigarette or toilet papers

Abstract

A method and apparatus are provided, for forming a stack of interfolded sheets of porous material including a leading panel having a partial-panel width joined along a fold line to a trailing panel having a full-panel width, by controlling the position of leading edges of the sheets both upstream and downstream from the nip between the interfolding rolls of the folding machine with vacuum applied through corresponding vacuum ports disposed in the periphery of the folding rolls at circumferential distances equal to the partial panel length ahead of each gripper and tucker in the direction of rotation. Sufficient suction is applied to hold both the leading edge of the leading panel of a given sheet and an underlying portion of the trailing panel of the immediately preceding sheet against the periphery of one of the other of the rolls downstream from the nip.

Claims

1. A method for using an apparatus, including a pair of counter-rotating folding rolls having respective peripheries thereof defining a nip between the rolls and having cooperating grippers and tuckers alternately circumferentially spaced around peripheries of the rolls at the full panel width with the rolls being operatively connected for counter-rotation in a timed relationship to one another such that the grippers from each roll interface cooperatively with respective tuckers from the other roll at the nip, to form a stack of interfolded sheets of porous material including a trailing panel having a full panel width joined along a fold line to a leading panel having a partial panel width that is less than the full panel width, where the sheets define a trailing edge of the trailing panel and the sheet and a leading edge of the leading panel and the sheet spaced from the fold line by the full panel width and the partial panel width respectively, the method comprising:

positioning the leading edges of the sheets both upstream and downstream from the nip with vacuum applied through corresponding vacuum ports disposed in the periphery of the first and second folding rolls at a circumferential distance equal to the partial panel length ahead of each gripper and tucker in the direction of rotation.

2. The method of claim 1, further comprising, selectively applying vacuum to, and removing vacuum from, vacuum ports disposed in the periphery of the first and second folding rolls at a circumferential distance equal to the partial panel length ahead of each gripper and tucker in the direction of rotation in such a manner that the leading edge of the leading panel of each sheet is first held directly against the periphery of one or the other of the rolls by a vacuum port disposed ahead of a gripper as the leading edge of the leading panel approaches the nip and is then held by a vacuum port disposed ahead of a tucker of the other roll of the one or the other rolls against a radially outer surface of an underlying trailing panel of an immediately preceding sheet resting on the periphery of the other roll as the leading edge of the leading panel moves away from the nip.

3. The method of claim 2, further comprising, removing vacuum from the vacuum port holding both the leading edge of the leading panel of a given sheet and an underlying portion of the trailing panel of the immediately previous sheet against the periphery of the roll downstream from the nip, at a desired angular position beyond the nip in the direction of rotation of the vacuum port holding both the leading edge of the leading panel of a given sheet and an underlying portion of the trailing panel of the immediately previous sheet against the periphery of the roll downstream from the nip.

4. The method of claim 1, further comprising, positioning the leading edges of the sheets downstream from the nip by applying sufficient suction for holding both the leading edge of the leading panel of a given sheet and an underlying portion of the trailing panel of the immediately previous sheet against the periphery of one or the other of the rolls downstream from the nip.

5. The method of claim 4, further comprising, transferring the leading edge to the other roll substantially as corresponding vacuum ports in the first and second folding rolls pass through the nip in substantial juxtaposition to one another, by the process of:

(a) removing vacuum from the one or the other of the folding rolls to release the leading edge from the periphery of the one or the other of the folding rolls, substantially as corresponding vacuum ports in the first and second folding rolls pass through the nip in substantial juxtaposition to one another; and

then

(b) supplying sufficient vacuum to the vacuum port in the other of the one or the other folding rolls for holding both the leading edge of the leading panel of a given sheet and an underlying portion of the trailing panel of the immediately previous sheet against the periphery of the other of the one or the other folding rolls downstream from the nip.

6. An apparatus for forming a stack of interfolded sheets of porous material including a trailing panel having a full panel width joined along a fold line to a leading panel having a partial panel width that is less than the full panel width, where the sheets define a trailing edge of the trailing panel and a leading edge of the leading panel spaced from the fold line by the full panel width and the partial panel width respectively, the apparatus comprising:

a pair of counter-rotating folding rolls having respective peripheries thereof defining a nip between the rolls and having cooperating grippers and tuckers alternately circumferentially spaced around the peripheries of the rolls at the full panel width with the rolls being operatively connected for counter-rotation in a timed relationship to one another such that the grippers from each roll interface cooperatively with respective tuckers from the other roll at the nip; and

a control arrangement configured and operatively connected for positioning the leading edges of the sheets both upstream and downstream from the nip with vacuum applied through corresponding vacuum ports disposed in the periphery of the first and second folding rolls at a circumferential distance equal to the partial panel length ahead of each gripper and tucker in the direction of rotation.

7. The apparatus of claim 6, wherein, the control arrangement is further configured and operatively interconnected for positioning the leading edges of the sheets downstream from the nip by applying sufficient suction for holding both the leading edge of the leading panel of a given sheet and an underlying portion of the trailing panel of the immediately previous sheet against the periphery of one or the other of the rolls downstream from the nip.

8. The apparatus of claim 6, wherein, the control arrangement is further configured and operatively interconnected transferring the leading edge to the other roll substantially as corresponding vacuum ports in the first and second folding rolls pass through the nip in substantial juxtaposition to one another, by the process of:

(a) removing vacuum from the one or the other of the folding rolls to release the leading edge from the periphery of the one or the other of the folding rolls, substantially as corresponding vacuum ports in the first and second folding rolls pass through the nip in substantial juxtaposition to one another; and

then

(b) supplying sufficient vacuum to the vacuum port in the other of the one or the other folding rolls for holding both the leading edge of the leading panel of a given sheet and an underlying portion of the trailing panel of the immediately previous sheet against the periphery of the other of the one or the other folding rolls downstream from the nip.

9. An apparatus for interfolding sheets of porous material fed alternately from two sheet streams to form a stack of interfolded sheets each having a leading panel and a trailing panel joined to one another along a fold line with the sheets being folded such that the trailing panel defines a full panel width and the leading panel has a partial panel width that is less than the full panel width, the apparatus comprising:

first and second folding rolls each having vacuum ports and a control arrangement for selectively controlling application of vacuum to the vacuum ports;

the first and second folding rolls defining respective peripheries thereof and being mounted for rotation about respective substantially parallel first and second roll axes to form a nip between the rolls for passage therethrough of the sheets along a sheet path extending through the nip;

each of the first and second folding rolls having at least one gripper and at least one tucker alternately circumferentially spaced at a circumferential distance from one another substantially equal to the full panel width, with the rolls being operatively connected for counter-rotation in a timed relationship to one another such that the grippers from each roll interface cooperatively with respective tuckers from the other roll at the nip;

the vacuum ports being disposed in the periphery of the first and second folding rolls at a circumferential distance equal to the partial panel length ahead of each gripper and tucker in the direction of rotation;

the control arrangement being configured and operatively connected for selectively applying vacuum to, and removing vacuum from, the vacuum ports in such a manner that the leading edge of the leading panel of each sheet is first held directly against the periphery of one or the other of the rolls by a vacuum port disposed ahead of a gripper as the leading edge of the leading panel approaches the nip and is then held by a vacuum port disposed ahead of a tucker of the other roll of the one or the other rolls against a radially outer surface of an underlying trailing panel of an immediately preceding sheet resting on the periphery of the other roll as the leading edge of the leading panel approaches and then passes through the nip;

the control arrangement applying sufficient vacuum for holding the leading edges of the sheets directly against the periphery of one or the other of the folding rolls upstream from the nip, and then transferring the leading edge to the other of the one or the other folding rolls substantially as corresponding vacuum ports in the first and second folding rolls pass through the nip in substantial juxtaposition to one another, by the process of;

(a) removing vacuum from the one or the other of the folding rolls to release the leading edge from the periphery of the one or the other of the folding rolls, substantially as corresponding vacuum ports in the first and second folding rolls pass through the nip in substantial juxtaposition to one another; and

then

(b) supplying sufficient vacuum to the vacuum port in the other of the one or the other folding rolls for holding both the leading edge of the leading panel of a given sheet and an underlying portion of the trailing panel of the immediately previous sheet against the periphery of the other of the one or the other folding rolls downstream from the nip.

10. The apparatus of claim 9, wherein, the sheets consist of the leading and trailing panels joined at the fold line.

11. The apparatus of claim 10, wherein, the sheets further consist of a single layer of material.

12. The apparatus of claim 9, wherein, the control arrangement is further configured and operatively connected to remove vacuum from the vacuum port holding both the leading edge of the leading panel of a given sheet and an underlying portion of the trailing panel of the immediately preceding sheet against the periphery of the roll downstream from the nip, at a desired angular position beyond the nip in the direction of rotation of the vacuum port holding both the leading edge of the leading panel of a given sheet and an underlying portion of the trailing panel of the immediately previous sheet against the periphery of the roll downstream from the nip.

13. The apparatus of claim 12, wherein, the circumferential spacing of the vacuum ports from the grippers and tuckers is variable from at least a first to a second circumferential spacing to accommodate production of interfolded sheets having at least a first partial panel width and sheets having a second partial panel width.

14. The apparatus of claim 13, wherein, the vacuum ports are defined by plates which are alternatively attachable to the rolls, for changing the circumferential spacing of the vacuum ports with respect to the grippers and tuckers.

15. The apparatus of claim 12, further comprising, a sheet cutting arrangement for feeding the sheets to the interfolding rolls in such a manner that the sheets overlap one another by a distance equal to the partial panel width.

16. The apparatus of claim 15, wherein, the sheet cutting arrangement provides sheets having an overall width equal to the sum of the full panel width and the partial panel width.

17. The apparatus of claim 9, wherein, the circumferential spacing of the vacuum ports from the grippers and tuckers is variable from at least a first to a second circumferential spacing to accommodate production of interfolded sheets having at least a first partial panel width and sheets having a second partial panel width.

18. The apparatus of claim 17, wherein, the vacuum ports are defined by plates which are alternatively attachable to the rolls, for changing the circumferential spacing of the vacuum ports with respect to the grippers and tuckers.

19. The apparatus of claim 9, further comprising, a sheet cutting arrangement for feeding the sheets to the interfolding rolls in such a manner that the sheets overlap one another by a distance equal to the partial panel width.

20. The apparatus of claim 19, wherein, the sheet cutting arrangement provides sheets having an overall width equal to the sum of the full panel width and the partial panel width.

21. The apparatus of claim 20, wherein, the sheets further consist of a single layer of material.

22. The apparatus of claim 9, wherein, the grippers are configured and operatively connected for grasping the sheets only at the fold line and at a trailing edge of the trailing panel of each sheet.

23. The apparatus of claim 22, wherein, the control arrangement is further configured and operatively connected to remove vacuum from the vacuum port holding both the leading edge of the leading panel of a given sheet and an underlying portion of the trailing panel of the immediately previous sheet against the periphery of the roll downstream from the nip, at a desired angular position beyond the nip in the direction of rotation of the vacuum port holding both the leading edge of the leading panel of a given sheet and an underlying portion of the trailing panel of the immediately previous sheet against the periphery of the roll downstream from the nip.

24. The apparatus of claim 22, wherein, the circumferential spacing of the vacuum ports from the grippers and tuckers is variable from at least a first to a second circumferential spacing to accommodate production of interfolded sheets having at least a first partial panel width and sheets having a second partial panel width.

25. The apparatus of claim 24, wherein, the vacuum ports are defined by plates which are alternatively attachable to the rolls, for changing the circumferential spacing of the vacuum ports with respect to the grippers and tuckers.

26. The apparatus of claim 9, further comprising, a sheet cutting arrangement for feeding the sheets to the interfolding rolls in such a manner that the sheets overlap one another by a distance equal to the partial panel width.

27. The apparatus of claim 26, wherein, the sheet cutting arrangement provides sheets having an overall width equal to the sum of the full panel width and the partial panel width.

28. A method for using an apparatus, including a pair of counter-rotating folding rolls having respective peripheries thereof defining an nip between the rolls and having cooperating grippers and tuckers alternately circumferentially spaced around peripheries of the rolls at the full panel width with the rolls being operatively connected for counter-rotation in a timed relationship to one another such that the grippers from each roll interface cooperatively with respective tuckers from the other roll at the nip, to form a stack of interfolded sheets of porous material including a trailing panel having a full panel width joined along a fold line to a leading panel having a partial panel width that is less than the full panel width, where the sheets define a trailing edge of the trailing panel and a leading edge of the leading panel spaced from the fold line by the full panel width and the partial panel width respectively, the method comprising:

alternately feeding sheets having a total length equal to the sum of the full and partial panel widths from a first and a second sheet stream through a nip in such a manner that successive sheets overlap by the partial panel width;

grasping the sheets with the grippers only along the fold line and trailing edges of the sheets; and

selectively applying vacuum to, and removing vacuum from, vacuum ports disposed in the periphery of the first and second folding rolls at a circumferential distance equal to the partial panel length ahead of each gripper and tucker in the direction of rotation in such a manner that the leading edge of the leading panel of each sheet is first held directly against the periphery of one or the other of the rolls by a vacuum port disposed ahead of a gripper as the leading edge of the leading panel approaches the nip and is then held by a vacuum port disposed ahead of a tucker of the other roll of the one or the other rolls against a radially outer surface of an underlying trailing panel of an immediately preceding sheet resting on the periphery of the other roll as the leading edge of the leading panel moves away from the nip.

29. The method of claim 28, further comprising, removing vacuum from the vacuum port holding both the leading edge of the leading panel of the given sheet and the underlying portion of the trailing panel of the immediately preceding sheet against the periphery of the roll downstream from the nip, at a desired angular position beyond the nip in the direction of rotation of the vacuum port holding both the leading edge of the leading panel of the given sheet and the underlying portion of the trailing panel of the immediately preceding sheet against the periphery of the roll downstream from the nip.

30. The method of claim 28, further comprising, transferring the leading edge to the other roll substantially as corresponding vacuum ports in the first and second folding rolls pass through the nip in substantial juxtaposition to one another, by the process of:

(a) removing vacuum from the one or the other of the folding rolls to release the leading edge from the periphery of the one or the other of the folding rolls, substantially as corresponding vacuum ports in the first and second folding rolls pass through the nip in substantial juxtaposition to one another; and

then

(b) supplying sufficient vacuum to the vacuum port in the other of the one or the other folding rolls for holding both the leading edge of the leading panel of a given sheet and an underlying portion of the trailing panel of the immediately previous sheet against the periphery of the other of the one or the other folding rolls downstream from the nip.

31. The method of claim 30, further comprising, removing vacuum from the vacuum port holding both the leading edge of the leading panel of a given sheet and an underlying portion of the trailing panel of the immediately previous sheet against the periphery of the roll downstream from the nip, at a desired angular position beyond the nip in the direction of rotation of the vacuum port holding both the leading edge of the leading panel of a given sheet and an underlying portion of the trailing panel of the immediately previous sheet against the periphery of the roll downstream from the nip.

32. An apparatus for providing stacks of interfolded sheets having a leading panel and a trailing panel joined at a fold line with the leading and trailing panels both having a full panel width, and alternatively for providing stacks of interfolded sheets of porous material having a leading panel and a trailing panel joined at a fold line with the leading panel having a partial panel width that is less than the full panel width, the sheets further defining a leading edge of the leading panel thereof and a trailing edge of the trailing panel thereof regardless of the width of the leading and trailing panels;

the apparatus comprising;

first and second folding rolls each having vacuum ports and a control arrangement for selectively controlling application of vacuum to the vacuum ports;

the first and second folding rolls defining respective peripheries thereof and being mounted for rotation about respective substantially parallel first and second roll axes to form a nip between the rolls for passage therethrough of the sheets along a sheet path extending through the nip;

each of the first and second folding rolls having at least one gripper and at least one tucker alternately circumferentially spaced at a circumferential distance from one another substantially equal to the full panel width, with the rolls being operatively connected for counter-rotation in a timed relationship to one another such that the grippers from each roll interface cooperatively with respective tuckers from the other roll at the nip;

the vacuum ports, control arrangement and grippers being selectively configurable and operatively connectable such that when the apparatus is providing interfolded sheets having leading and trailing panels both equal to the full panel width, the control arrangement applies vacuum to vacuum ports located adjacent the tuckers for holding the leading edge of the leading panel against the periphery of the folding rolls upstream from the nip, with the grippers grasping each sheet at the fold line, the trailing edge and the leading edge thereof; and

the vacuum ports, control arrangement and grippers being further alternatively selectively configurable and operatively connectable such that when the apparatus is providing interfolded sheets having the trailing panel equal to the full panel width and the leading panel equal to the partial panel width;

(a) the grippers grasp the sheets only at the fold line and at a trailing edge of the trailing panel of each sheet; and

(b) the control arrangement selectively applies vacuum to, and removes vacuum from, vacuum ports disposed in the periphery of the first and second folding rolls at a circumferential distance equal to the partial panel length ahead of each gripper and tucker in the direction of rotation in such a manner that the leading edge of the leading panel of each sheet is first held directly against the periphery of one or the other of the rolls by a vacuum port disposed ahead of a gripper as the leading edge of the leading panel approaches the nip and is then held by a vacuum port disposed ahead of a tucker of the other roll of the one or the other rolls against a radially outer surface of an underlying trailing panel of an immediately preceding sheet resting on the periphery of the other roll as the leading edge of the leading panel moves away from the nip.

33. The apparatus of claim 32, wherein, the sheets consist of the leading and trailing panels joined at the fold line.

34. The apparatus of claim 33, wherein, the sheets further consist of a single layer of material.

35. The apparatus of claim 32, wherein, when the apparatus is providing sheets of porous material with the leading panel having a partial panel width, the control arrangement is further configured and operatively connected to remove vacuum from the vacuum port holding both the leading edge of the leading panel of a given sheet and the underlying portion of the trailing panel of the immediately preceding sheet against the periphery of the roll downstream from the nip, at a desired angular position beyond the nip in the direction of rotation of the vacuum port holding both the leading edge of the leading panel of the given sheet and the underlying portion of the trailing panel of the immediately previous sheet against the periphery of the roll downstream from the nip.

36. The apparatus of claim 32, wherein, when the apparatus is providing sheets of porous material with the leading panel having a partial panel width, the control arrangement selectively applies and removes vacuum from the vacuum ports of the folding rolls in such a manner that the leading edges of the sheets are held directly against the periphery of one or the other of the folding rolls upstream from the nip, and are then transferred to the other of the one or the other folding rolls substantially as corresponding vacuum ports in the first and second folding rolls pass through the nip in substantial juxtaposition to one another, by the process of:

(a) removing vacuum from the one or the other of the folding rolls to release the leading edge from the periphery of the one or the other of the folding rolls, substantially as corresponding vacuum ports in the first and second folding rolls pass through the nip in substantial juxtaposition to one another; and

then

(b) supplying sufficient vacuum to the vacuum port in the other of the one or the other folding rolls for holding both the leading edge of the leading panel of a given sheet and an underlying portion of the trailing panel of the immediately previous sheet against the periphery of the other of the one or the other folding rolls downstream from the nip.

37. The apparatus of claim 36, wherein, when the apparatus is providing sheets having sheets of porous material with the leading panel having a partial panel width, the control arrangement is further configured and operatively connected to remove vacuum from the vacuum port holding both the leading edge of the leading panel of a given sheet and an underlying portion of the trailing panel of the immediately previous sheet against the periphery of the roll downstream from the nip, at a desired angular position beyond the nip in the direction of rotation of the vacuum port holding both the leading edge of the leading panel of a given sheet and an underlying portion of the trailing panel of the immediately previous sheet against the periphery of the roll downstream from the nip.

38. The apparatus of claim 32, wherein, the circumferential spacing of the vacuum ports from the grippers and tuckers is variable from at least a first to a second circumferential spacing to accommodate production of interfolded sheets having at least a first partial panel width and sheets having a second partial panel width.

39. The apparatus of claim 38, wherein, the vacuum ports are defined by plates which are alternatively attachable to the rolls, for changing the circumferential spacing of the vacuum ports with respect to the grippers and tuckers.

40. The apparatus of claim 38, wherein, when the apparatus is providing sheets having sheets of porous material with the leading panel having a partial panel width, the control arrangement is further configured and operatively connected to remove vacuum from the vacuum port holding both the leading edge of the leading panel of a given sheet and an underlying portion of the trailing panel of the immediately previous sheet against the periphery of the roll downstream from the nip, at a desired angular position beyond the nip in the direction of rotation of the vacuum port holding both the leading edge of the leading panel of a given sheet and an underlying portion of the trailing panel of the immediately previous sheet against the periphery of the roll downstream from the nip.

41. The apparatus of claim 40, wherein, the control arrangement selectively controls applies and removes vacuum from the vacuum ports of the folding rolls in such a manner that the leading edges of the sheets are held directly against the periphery of one or the other of the folding rolls upstream from the nip, and are then transferred to the other of the one or the other folding rolls substantially as corresponding vacuum ports in the first and second folding rolls pass through the nip in substantial juxtaposition to one another, by the process of:

(a) removing vacuum from the one or the other of the folding rolls to release the leading edge from the periphery of the one or the other of the folding rolls, substantially as corresponding vacuum ports in the first and second folding rolls pass through the nip in substantial juxtaposition to one another; and

then

(b) supplying sufficient vacuum to the vacuum port in the other of the one or the other folding rolls for holding both the leading edge of the leading panel of a given sheet and an underlying portion of the trailing panel of the immediately previous sheet against the periphery of the other of the one or the other folding rolls downstream from the nip.