Dispensing fold improvement for a clip separator

Method and apparatus for forming a dispensing fold for a clip or predetermined number of interfolded sheets from a continuously building interfolding process having first and second opposed dispensing fold fingers operable between actuated and deactutated positions to engage a mediate portion of a depending layer of the bottommost sheet from the interfolding process stack to form a dispensing fold.

FIELD OF THE INVENTION 
This invention relates to an improvement for an automatic separator for 
separating predetermined quantities of items such as paper napkins, 
towels, or similar items into a stack or clip wherein the first sheet is 
folded over to aid withdrawal of the first sheet from a carton or package 
containing the clip.

DETAILED DESCRIPTION OF THE DRAWINGS 
FIG. 1 shows a clip 10 formed from a stack of interfolded laminar products 
or items 11 such as paper napkins, towels, or facial tissues. A carton or 
package 110 for clip 10 is shown in phantom. Carton 110 has an opening 112 
to permit a consumer to reach inside, grasp and withdraw a tissue 114 from 
carton 110. It may be observed that without a seam or crease 116 
accessible to the consumer, withdrawing the first tissue 114 will be more 
difficult. This invention is an apparatus and method for forming a 
dispensing fold or crease 116 in tissue 114 as an improvement to the clip 
separator of U.S. Pat. No. 4,770,402, application Ser. No. 040,546 filed 
Apr. 17, 1987. 
In a preferred practice of this invention, the bottom sheet is folded over 
and inverted cartons are loaded with the dispensing fold on the bottom of 
the clip. The carton bottom panel is closed and sealed, and the carton 
turned upright for purchase and use by a consumer. 
FIG. 1a shows a simplified view of the machine environment of this 
dispensing fold improvement. Machine 62 receives two continuous webs or 
sheets 64, 66 and processes them by slitting longitudinally, cutting 
transversely, interfolding the cut-web sheets and stacking them in a 
continuous fashion. 
Webs 64, 66 pass over spreader rolls 68, 70 which may be conventional Mount 
Hope-type rolls. Web 64 then passes over idler roll 72. Webs 64, 66 then 
pass through slitter roll pairs 74, 76 and folder feed roll pairs 78, 80. 
After passing over idler roll 82, web 64, passes between cutoff roll 84 
and cutoff bedroll 86 where it is severed transversely (indicated by gaps 
88 in web 64). Similarly web 66 passes over rolls 90-94. Webs 64, 66 are 
then transferred respectively to folding rolls 22, 20. 
Folding rolls 22, 20 interfold severed webs 64, 66 and release the 
interfolded severed webs or cut sheets 11 to be built into a stack 8 on a 
table 26 by a pair of packer fingers 40, 38. 
An automatic separator 12 is located in the lower portion of machine 62 and 
periodically separates a clip 10 of a predetermined number of sheets 11 
from the continuously building stack 8 on an interfolding table 26 
carrying clip 10 to a separator outlet position 98 adjacent a reject gate 
96. 
Automatic separator 12 is shown in more detail in FIGS. 2a-2b and in 
various positions during a clip separation cycle in FIGS. 5-11. A stack 
principal axis 5 represents the direction along which stack 8 is built. 
Separator 12 has three moveable carriages 14, 16, 18. The center carriage 
is the first count finger/interfolding table carriage 14 and is located 
directly below the folding rolls 20, 22 at a package building station 95 
and is movable along the stack principal axis 5. As will be later 
described in greater detail, carriages 14-18 operate to separate 
interfolded sheets 11 into a succession of clips 10 each having a 
predetermined number of sheets 11 with the bottom sheet 114 formed with a 
dispensing fold. As a part of this process, carriage 14 moves the 
separated clip 10 from the folding rolls 20, 22 to the separator outlet 
position 98 for further processing. Such further processing may include 
orienting and shaping clip 10 prior to inserting clip 10 into a carton 110 
or other package. A first count finger assembly or retention means 24 and 
interfolding or elevator table 26 are mounted on carriage 14. Carriages 
14, 16 and 18 are movable by positive drive belts 15 and motors (not 
shown) or other drive means which allow controlled positioning. 
As may be seen in FIGS. 3, 4 and 5, a plurality of first or initial count 
fingers 28 are transversely aligned with radial grooves 30 in folding roll 
20 which itself is mounted for rotation in machine frame 21. First count 
fingers 28 are mounted to a pivoting shaft 32 to which a torque is applied 
by an actuator 36 which may be a mechanical spring or pre loaded air 
cylinder. Shaft 32 is prevented from moving in response to the applied 
torque by mechanical latch 34. 
A plurality of first and second packer fingers 38, 40 are mounted on first 
and second packer finger shafts 42, 44 respectively and operate in a 
conventional manner to build stack 8 as may be seen in FIGS. 3-7. A 
plurality of stationary guides 61, 63 serve to align successive layers 11 
as they are built into stack 8 along stack principal axis 5. 
Referring now also to FIG. 2c, at a desired time (after a predetermined 
number of sheets 11 have been interfolded into stack 8 and between folds 
when first packer fingers 38 are actuated as in FIG. 5) hook 35 of latch 
34 is released and the actuator 36 operates through clevis 37 and link 39 
to move count fingers 28 toward table 26 in a pivoting motion which ends 
in a controlled deceleration to avoid shock or impact loading of fingers 
28. The controlled deceleration is accomplished by hydraulic shock 
absorbers 45, 46 operating mechanically in parallel with actuator 36 at 
the end of pivoting motion of fingers 28 as they come to rest in an 
actuated position 58 so as to retain clip 10 (as shown in FIG. 5). 
Carriage 16 includes a plurality of pivoting second or platform count 
fingers 48 controlled by a latch and actuator mechanism 59 similar to that 
which operates first count fingers 28. 
Carriage 18 carries a plurality of package build fingers 50, each of which 
has a relatively flat end portion 52. 
Each of carriages 14, 16, 18 is capable of controlled movement in the "Y" 
or package build direction 54 Direction 54 is parallel to the stack 
principal axis 5. In addition, carriages 16 and 18 are also capable of 
controlled movement in the "X" direction 56 for clearance purposes as will 
be described in more detail. Although direction 54 is shown to be vertical 
and direction 56 is shown to be horizontal, it is to be considered within 
the scope of this invention that these directions are not limited to 
vertical and horizontal, respectively, and are utilized merely to aid in 
understanding the operation of this invention. As a further aid in 
describing this invention, upward movement along direction 54 and 
rightward movement along direction 56 will be considered positive, while 
downward and leftward movement will be considered negative. 
The operation of separator 12 is as follows. Cut web interfolding is 
performed continuously by folding rolls 20, 22 cooperating with first and 
second packer fingers 38, 40 forming or building stack 8 on table 26. In 
FIG. 5, stack 8 which will be become separated as clip 10 is shown at the 
beginning of a separation cycle. Once a predetermined number of sheets 11 
have been built into stack 8 by folding rolls 20, 22 and packer fingers 
38, 40 between guides 61, 63 on table 26, latch 34 releases first count 
fingers 28. First count fingers 28 then come to rest in an actuated 
position 58. Clip 10 is now held between count fingers 28 in position 58 
and table 26. It is to be understood that folding rolls 20, 22 and packer 
fingers 38, 40 continue uninterrupted operation throughout the clip 
separation cycle. 
Referring now to FIG. 6, second or platform count fingers 48 are actuated 
from a ready position away from the stack principal axis one fold after 
actuation of the first count fingers, when second packer fingers are 
actuated. Second count fingers move transversely (in an arc) toward the 
stack principal axis 5 and come to rest in an actuated position 60. 
As may be seen most clearly in FIG. 7, second count fingers 48 in actuated 
position 60 provide a platform count finger or stack supporting means to 
support continued building of succeeding sheets or laminar products 11' 
into stack 8 at a package building station or position 95. Platform count 
fingers 48 are thus selectively interposable above table 26, preferably 
after a fixed or predetermined number of sheets or laminar products 11' 
have been interfolded into stack 8. 
As successive sheets 11' are building, separated clip 10 is rapidly moved 
away from the folding rolls 20, 22 by carriage 14 moving in the -Y 
direction. It is to be understood that the rate of this motion is 
preferably substantially greater than the stack build rate motion. At this 
time, second count finger carriage 16 is continuously moved downward at a 
gradual rate corresponding to the build rate of successive clip 10' such 
that each successive top sheet 11' of stack 8 is properly positioned by 
packer fingers 38, 40. Carriage 14 moves clip 10 from the package build 
station or position 95 to the separator outlet station or position 98 (as 
shown in FIG. 8. Carriage 14 is shown at station 95 in FIG. 2a and at 
station 98 in FIG. 2b. Retention fingers 28 hold clip 10 to table 26 as 
carriage 14 moves from position 95 (shown in FIG. 7) to position 98 (shown 
in FIG. 8). 
After clip 10 is moved away from the package build station 95, loose end 
sheet portion or depending layer 9 is hanging or depending freely from the 
bottom of the stack below the second count fingers or stack supporting 
means 48. At this time, first and second dispensing fold fingers 118, 120 
are in their retracted or deactuated positions 122, 124, clear of the 
interfolding process stack 8 and depending layer 9 as shown in FIG. 7a. 
Fingers 118, 120 are respectively supported on finger mounts 126, 128 for 
sliding movement relative to first and second cross members 130, 132. 
Fingers 118, 120 are thus each movable perpendicularly to the stack 
principal axis 5. It is to be understood that the first and second 
dispensing fold fingers 118, 120 are longitudinally offset from each other 
along the stack principal axis 5. As may be seen in FIG. 7c, first 
dispensing fold finger 118 is intermediate the horizontal portion of stack 
supporting means 48 and the second dispensing fold finger 120 when fingers 
118, 120 are in their respective actuated positions 164, 170. 
Referring now also to FIG. 7a, if the side of the stack from which layer 9 
depends is the "first" side of the stack, finger 118 projects toward 
principal axis 5 from the first side of the stack and finger 120 projects 
toward principal axis 5 from the other or "second" side of the stack 8. 
When fingers 118, 120 are actuated, they will contact, respectively, first 
and second sides of mediate region 168 of layer 9. Referring now also to 
FIG. 7b, the first and second dispensing fold fingers 118, 120 preferably 
have a relatively flat tip portion 134, 136. Tip portions 134, 136 are 
mounted to supports 126, 128 by extension portions 138, 140. Finger mounts 
126, 128 each have a rack gear 142, 144 and may have a linear bearing (not 
shown) between finger mounts 126, 128 and cross members 130, 132. Rack 
gears 142, 144 are driven by pinion gears 146, 148. Pinion gears 146, 148 
are preferably driven by rotary air cylinders 150, 152, of the type as 
manufactured by Rota-Cyl Corp. at P.O. Box 98, 97 Main Street, 
Schwenksville, Pa. 19473. Cylinders 150, 152 are supported by U-clamps 
154, secured to transverse tubes 156, 158. It is to be understood that 
cylinders 150, 152 may alternatively be linear air cylinders to drive 
finger mounts 126, 128 with respect to cross members 130, 132. Pinion gear 
146 is connected by a rigid shaft 160 to a follower pinion gear 162. It is 
to be understood that gears 146 and 162 are preferably spaced to 
approximately trifurcate the transverse dimension of machine 62. Follower 
gear 162 is to be understood as engaging a rack gear (not shown) to avoid 
misalignment of finger mount 126 and fingers 118. More specifically, gears 
146, 162 cooperating with their respective rack gears will maintain finger 
mount 126 parallel to the transverse dimension of machine 62 as mount 126 
moves with respect to member 130. 
Referring now more particularly to FIGS. 7c and 7d, actuator 150 moves 
first dispensing fold fingers 118 to an actuated position 164 to begin to 
form tail 9 into a dispensing fold. At this time, the leading edge 166 of 
tip portion 134 is in contact with a mediate portion or region 168 of the 
depending layer 9. By "mediate portion or region" is meant any position or 
portion between: (i) the line of contact 3 between layer 9 and the 
adjacent layer on stack support 48 and (ii) the free end or edge 7 of 
layer 9. 
Next, second dispensing fold fingers 120 are advanced to an actuated 
position 170, as shown in FIGS. 7c and 7d. Actuated position 170 is 
subjacent or below the first dispensing fold fingers 118 in actuated 
position 164, overlapping to fold the depending layer against the first 
dispensing fold fingers 118 as shown in FIG. 7c. 
As may be seen in FIG. 8, while carriage 14 holds clip 10 in position 98, 
ejector 100 moves clip 10 to reject gate 96. Normally gate 96 remains 
stationary. In the event a defective clip is formed, it may be rejected 
immediately after separation from the package building stack by pivoting 
gate 96 to position 106. By locating reject gate at the separate outlet 
station 98, further processing of defective clips is eliminated, thus 
improving machine efficiency. Actuator 100 may be a bi-directional air 
cylinder or other conventional actuator. Retention or initial count 
fingers 28 are then retracted to a deactuated position 101 (as shown in 
FIG. 8). 
Referring now to FIGS. 9 and 10, the stack 8 continues to build from 
folding rolls 20, 22 and packer fingers 38, 40. As stack or package 
building continues, second count fingers 48 continue to move relatively 
slowly downward in the -Y direction such that the topmost layer of stack 8 
is properly positioned with respect to packer fingers 38, 40. During this 
process, carriages 16 and 18 move together. Table 26 is preferably held 
stationary with package building advancing towards it. Alternatively table 
26 may be positioned to the package building station 95, moving relatively 
slowly in the -Y direction as stack building continues. 
Referring now more particularly to FIG. 9, first dispensing fold fingers 
118 are retracted, and tail 9 having a dispensing fold formed therein is 
supported by second dispensing fold fingers 120. Referring now also to 
FIG. 10, the package build fingers 50 are advanced in the +X direction 
lateral to principal axis 5 of stack 8 to support tail 9 (which is now a 
folded depending layer) and second dispensing fold fingers 120 are 
retracted to position 124 clear of the interfolding process stack 8. 
Referring now to FIG. 11, package building fingers 50 assume support of 
stack 8 including the depending layer after a dispensing fold is formed 
therein at portion 52, when second count fingers 48 are retracted from 
position 60 to position 102. After count fingers 48 are clear of stack 8, 
they are reset to a deactuated position 104, ready to be actuated for a 
successive clip separation cycle. Meanwhile, package build fingers 50 are 
advanced in the -Y direction parallel to the stack principal axis 5 as 
package building continues. 
Referring now to FIG. 12, once table 26 has returned to the package 
building station 95, package build fingers 50 are retracted in the -X 
direction and translated in the +Y direction stopping at a deactuated or 
ready position 108. Once package build fingers 50 are retracted, stack 8 
is supported by table 26. Guides 61 prevent movement of stack 8 in the -X 
direction while fingers 50 are retracted. It is to be understood that 
table 26 may be positioned at the lowermost region of package building 
station 95 or may be moved slowly downward at a rate equal to the build 
rate of the stack in the -Y direction (along the stack principal axis 5) 
in a manner similar to that described for platform 48 during continued 
stack building. After a predetermined number of layers have been 
interfolded into stack 8, the clip separation cycle is repeated starting 
with the unlatching of the first count fingers 28. The separated clip with 
a dispensing fold formed in an end sheet thereof is subsequently inserted 
into an inverted carton such that when the carton and clip are returned to 
an upright position, the dispensing fold is accessible to a person seeking 
to withdraw the first sheet from the carton, as shown in FIG. 1. 
The invention is not to be taken as to be limited to all of the details of 
the specification hereof as variations and modifications may be made 
without departing from the spirit or scope of the invention.