System and method for folding and handling stacks of continuous web

• US 7,402,130 B1
• Filed: 09/29/2006
• Issued: 07/22/2008
• Est. Priority Date: 09/29/2006
• Status: Expired due to Fees

• Current Assignee: Roll Systems, Inc. (Demco SRL)
• Original Assignee: Roll Systems, Inc. (Demco SRL)
• Inventors: Lewalski, Steven P., Fiske, John M., Taylor, Bruce J., Sjostedt, Richard A.
• Primary Examiner(s): DESAI, HEMANT
• Application Number:
  US11/541,120
• Time in Patent Office: 662 Days
• Field of Search: 493411-415, 493/356, 493/357, 493/448, 270/5.01, 270/32, 270/39.01, 270/39.02, 270/40, 270/39.05
• US Class Current: 493/413
• CPC Class Codes: B65H 2220/01 indicating an entity as a function of which control, adjustment or change is performed, i.e. input
• CPC Class Codes: B65H 2301/33224 180°
• CPC Class Codes: B65H 2301/4216 of web folded in zig-zag form
• CPC Class Codes: B65H 2301/4223 Pressing piles
• CPC Class Codes: B65H 2301/42252 Vehicles, e.g. carriage, truck
• CPC Class Codes: B65H 2511/12 Width
• CPC Class Codes: B65H 31/10 and applied at the top of the pile
• CPC Class Codes: B65H 31/20 adjustable for different article sizes
• CPC Class Codes: B65H 31/3054 by moving the surface supporting the lowermost article of the pile, e.g. by using belts or rollers
• CPC Class Codes: B65H 31/3063 by special supports like carriages, containers, trays, compartments, plates or bars, e.g. moved in a closed loop
• CPC Class Codes: B65H 31/32 Auxiliary devices for receiving articles during removal of a completed pile
• CPC Class Codes: B65H 45/1015 Folding webs provided with predefined fold lines; Refolding prefolded webs, e.g. fanfolded continuous forms
• CPC Class Codes: B65H 45/107 by means of swinging or reciprocating guide bars

Abstract

This invention provides a system and method for separating, folding, stacking and transporting a continuous web that allows stacks of web that are relatively large (four-feet-high or more) to be generated at high speed directly beneath the folding mechanism and to be transferred as complete, discrete stacks to downstream locations and stack utilization devices without interrupting the ongoing, upstream stack-folding and stack-formation process. A zigzag folded web passes by a pair of opposing front and rear compression plate assemblies, with fingers that are extended to selectively project into the folding area, onto a stack supported by a vertically moving supporting mechanism. The supporting mechanism cycles between an ever-lower position in which upper, loose pages of the folded web pass by plate fingers (when retracted) and an upper position in which the stack engages and presses upwardly against the now-extended plate fingers to compress the stack. After the web is separated above the chute, the supporting mechanism eventually travels to the base where the now-completed stack is conveyed to a downstream location. While the supporting mechanism is occupied transferring the completed, old stack, new folded web is deposited on a deployed temporary support that allows a new stack to form thereon until the supporting mechanism has completed the transfer of the old stack, and is ready to receive the new stack from the temporary support.

Claims

1. An apparatus for folding and stacking a continuous web comprising:

a folding and stacking mechanism that outputs folded continuous web defining a plurality of zigzag folded pages to a folding area;

a compression plate assembly that projects into a portion of the folding area at predetermined times to interfere with movement of edges of the folded pages past the compression plate assembly;

a supporting mechanism that moves cyclically away from the compression plate assembly and toward the compression plate assembly to cause the edges of the folded pages in a stack supported between the compression plate assembly and the supporting mechanism to pressurably engage and be compressed by the compression plate assembly;

a temporary support assembly that extends into the folding area when the continuous web is separated so as to support the folded pages of a leading end of the separated web while the folded pages of the trailing end of the separated web are directed away by the supporting mechanism in the stack to a stack transfer location; and

wherein the compression plate assembly includes spring-loaded compression plates that move upwardly against a bias force of springs in response to pressurable engagement with the stack so as to compress the stack.

2. The apparatus as set forth in claim 1 further comprising an infeed ramp that directs the continuous web to a location over a director chute, the location being sufficient in height above a base of the apparatus so that the stack of the folded pages has a height of at least 3 feet.

3. The apparatus as set forth in claim 1 wherein the supporting mechanism comprises a conveyor belt assembly that directs the stack out of a frame of the apparatus when the conveyor is located at the stack transfer location.

4. The apparatus as set forth in claim 3 further comprising a docking area at the stack transfer location for a downstream stack-handling support surface that receives the stack from the supporting mechanism.

5. The apparatus as set forth in claim 4 therein the docking area includes a stack-handling conveyor belt assembly that selectively moves into and out of the path of travel of the stack so as to selectively assist the stack in moving downstream onto the stack-handling support surface from the supporting mechanism.

6. The apparatus as set forth in claim 5 wherein the stack-handling support surface comprises a wheeled cart and the stack-handling conveyor belt assembly is constructed and arranged to move from a lowered position wherein the wheeled cart can move thereover to be positioned adjacent to the supporting mechanism and a raised position wherein belts of the stack-handling conveyor belt assembly reside between each of a plurality of ribs of the wheeled cart that receive the stack thereon.

7. The apparatus as set forth in claim 1 wherein the folding and stacking mechanism comprises a reciprocating swinging director chute, a plurality of beater assemblies and a plurality of spiral assemblies and wherein the swinging director chute is interconnected with a lever arm, the lever arm being interconnected to a connecting rod having a first pivot end and a second picot end, the first pivot end being adjustably movable along the level arm to set a swing arc and the second pivot end being connected to a drive arm, the drive arm being connected to a central drive that is operatively connected to the beaters and the spirals, the drive arm including a lead screw that is connected to, and rotates to radially adjust a position of the second pivot, the lead screw being operatively connected to an index wheel, the index wheel having a plurality of radially directed posts, and a movable pawl that advances the index wheel when moved to an engaging position with the posts each time the drive arm rotates past the pawl.

8. The apparatus as set forth in claim 1 further comprising a wheeled stack inverter that receives the stack from a wheeled cart, adapted to receive the stack from the supporting mechanism, the inverter including a framework that receives the wheeled cart therein and an overlying, movable belt assembly that selectively engages a top of the stack, opposite the wheeled cart, the framework being attached to an inverter base through a pivot assembly, the framework and the pivot assembly being constructed and arranged to invert the stack with the cart received in the framework and the belt assembly being engaged to the top of the stack.

9. A system for creating and handling stacks of continuous zigzag folded web comprising:

a continuous web source that directs continuous web to an infeed location;

a folding and stacking mechanism that folds the continuous web into zigzag folded pages and directs the zigzag folded pages to a folding area;

a compression plate assembly including spring-loaded compression plates that project into a portion of the folding area and move upwardly against a bias force of springs in response to pressurable engagement with the stack so as to compress the stack;

a supporting mechanism that cyclically moves away from the folding area to draw folded pages through the folding area and onto a stack that moves toward the folding area to compress the stack;

a continuous web cutter that separates the continuous web into a leading end and a trailing end;

a temporary support that allows the leading end to rest thereon as upstream folded pages are formed by the folding and stacking mechanism while the trailing end is drawn away on the stack to a stack transfer location by the supporting mechanism; and

a downstream stack-handling support surface that receives the stack from the supporting mechanism.

10. The system as set forth in claim 9 wherein the supporting mechanism comprises a conveyor located on a vertical lifter assembly within a framework.

11. The system as set forth in claim 10 wherein the temporary support comprises a plurality of rods that move between an extended position that interferes with passage of folded pages through the folding area and a retracted position remote from interference with the folding area.

12. The system as set forth in claim 9 wherein the folding area is defines by a plurality of front stack guides, rear stack guides and side stack guides that are located around a perimeter dimension of the folded pages.

13. The system as set forth in claim 12 wherein the compression plates each include a retractable finger assembly, each finger assembly moving selectively between a retracted position that is free of interference with edges of the folded pages and an extended position that engages and interferes with the edges.

14. The system as set forth in claim 9 wherein the supporting mechanism comprises a conveyor located on a vertical lifter assembly within a framework and wherein the compression plates are each mounted on a shaft assembly that is spring-loaded with respect to a frame of the apparatus so as to apply movable pressure in response to engagement by edges of the folded pages, and further comprising a sensor operatively connected with at least one of the compression plates so that a limit of movement of the vertical lifter assembly toward the folding area is controlled in response to the sensor.

15. The system as set forth in claim 14 wherein the temporary support is mounted on one of the compression plates and wherein the shaft assembly is slidably mounted with respect to the frame and further comprising a motor assembly that moves the shaft assembly interconnected with the one of the compression plates upon which the temporary support assembly is mounted away from the folding and stacking mechanism at a predetermined rate when the temporary support is extended.

16. The system as set forth in claim 15 wherein the shaft assembly is operatively interconnected with the supporting mechanism so that presumably movement of the shaft assembly causes the supporting mechanism to reverse cyclical movement toward the compression plates and thereby move away from the compression plates for a predetermined distance.

17. The system as set forth in claim 9 wherein the frame includes an adjustment mechanism constructed and arranged so that a spacing between the front stack guides and the rear stack guides can be changed and a distance between the compression plates can be changed.

18. The system as set forth in claim 9 wherein the folding and stacking mechanism comprises a reciprocating swinging chute, a plurality of beater assemblies and a plurality of spiral assemblies.

19. The system as set forth in claim 18 wherein each of the plurality of spiral assemblies are mounted on the frame so as to be adjustable by the adjustment mechanism.

20. The system as set forth in claim 9 further comprising an urge roller assembly and a cutter located upstream of the chute.

21. The system as set forth in claim 20 further comprising an infeed ramp that directs the continuous web to a location over the chute, the location being sufficient in height above a base of the apparatus so that the stack of the folded pages has a height of at least 3 feet.

22. The system as set forth in claim 9 wherein the supporting mechanism comprises a conveyor that directs the stack out of a frame of the apparatus when the conveyor is located at the stack transfer location.

23. The system as set forth in claim 22 further comprising a docking area at the stack transfer location for receiving the stack-handling supporting surface so that the stack-handling support surface can receive the stack from the supporting mechanism.

24. The system as set forth in claim 23 wherein the docking area includes a transport conveyor that selectively moves into and out of the path of travel of the stack out of the supporting mechanism so as to selectively assist the stack in moving downstream onto the stack-handling support surface.

25. The system as set forth in claim 24 further comprising a removably attachable outfeed unit having a plurality of rollers in a frame constructed and arranged to receive the stack from the transport conveyor and to admit an underlying cart, the rollers being further constructed and arranged to allow the stack to be biased onto the cart as the cart is withdrawn while the stack is biased onto the cart.

26. The system as set forth in claim 9 wherein the supporting mechanism comprises a conveyor belt assembly that directs the stack out of a frame of the apparatus when the conveyor is located at the stack transfer location.

27. The system as set forth in claim 26 further comprising a docking area at the stack transfer location for a downstream stack-handling support surface that receives the stack from the supporting mechanism.

28. The system as set forth in claim 27 wherein the docking area includes a stack-handling conveyor belt assembly that selectively moves into and out of the path of travel of the stack so as to selectively assist the stack in moving downstream onto the stack-handling support surface from the supporting mechanism.

29. The system as set forth in claim 28 wherein the stack-handling support surface comprises a wheeled cart and the stack-handling conveyor belt assembly is constructed and arranged to move from a lowered position wherein the wheeled cart can move thereover to be positioned adjacent to the supporting mechanism and a raised position wherein belts of the stack-handling conveyor belt assembly reside between each of a plurality of ribs of the wheeled cart that receive the stack thereon.

30. The system set forth in claim 9 wherein the folding and stacking mechanism comprises a reciprocating swinging director chute, a plurality of beater assemblies and a plurality of spiral assemblies and wherein the swinging director chute is interconnected with a lever arm, the lever arm being interconnected to a connecting rod having a first pivot end and a second pivot end, the first pivot end being adjustably movable along the lever arm to set a swing arc and the second pivot end being connected to a drive arm, the drive arm being connected to a central drive that is operatively connected to the beaters and the spirals, the drive arm including a lead screw that is connected to, and rotates to radially adjust a position of the second pivot, the lead screw being operatively connected to an index wheel, the index wheel having a plurality of radially directed posts, and a movable pawl that advances the index wheel when moved to an engaging position with the posts each time the drive arm rotates past the pawl.

31. The system as set forth in claim 9 further comprising a stack inverter that receives the stack from a first wheeled cart, the first wheeled cart being adapted to receive the stack from the supporting mechanism, the inverter including a framework that receives the first wheeled cart therein and an overlying removable second wheeled cart, the framework being attached to an inverter base through a pivot assembly, the framework being constructed and arranged to cause the first wheeled cart and the second wheeled cart to move toward and away from each other so as to selectively compress the stack therebetween and, when compressed, the pivot assembly being constructed and arranged to rotate the stack 180 degrees.

32. The system as set forth in claim 9 further comprising a plurality of perforator units located upstream of the folding and stacking members, the perforator units forming perforations along opposing widthwise edges of the web.

33. A method for creating and handling stacks of continuous zigzag folded web comprising the steps of:

directing a continuous web from a web processor to an infeed;

folding and stacking the continuous web into zigzag folded pages and directing the zigzag folded pages to a folding area;

cyclically moving a supporting mechanism (a) away from the folding area to draw folded pages through the folding area and onto a stack and (b) toward the folding area to compress the stack;

compressing the stack with spring-loaded compression plates that move upwardly against a bias force of springs in response to pressurable engagement with the stack;

separating the continuous web into a leading end and a trailing end;

extending a temporary support that allows the leading end to rest thereon as upstream folded pages are formed by the folding and stacking mechanism while drawing away, by the supporting mechanism, the trailing end on the stack to a stack transfer location; and

receiving, at a downstream stack-handling support surface, the stack from the supporting mechanism.

34. The method as set forth in claim 33 further comprising:

returning the supporting mechanism to the folding area after the stack has been received by the stack-handling support surface, and

retracting the temporary support to direct the upstream folded pages onto the supporting mechanism.

35. The method as set forth in claim 34 further comprising continually increasing a spacing between the temporary support when extended and a folding and stacking mechanism that generates the upstream folded pages in the folding area to accommodate a growing group of upstream folded pages supported on the temporary support.