Patent Abstract:
Apparatus for producing selected color or material sequences within a stack of transversely single or doublefolded products. Product width webs are longitudinaly folded and slideably advanced at slow speed metering rolls to create alternate void spaces before a segment is cut so that unocuppied alternate repeats on each anvil roll of the plurality can accept folded segments from other units in the plurality. With programmable changes to the same plurality of cutoff units including changes in the amount of web slippage before cutoff, several smaller product segments are cut, cooperatively folded and advanced by anvil and carrier rolls to produce different sizes within the color sequence defined by machine configuration. In another embodiment, programmable commands for selection of vacuum path, phase change of fold line, speed change to web metering roll and synchronized speed control during production vary the amount of web slippage, the resultant segment size, and folded product size within a single color stack.

Full Description:
FIELD OF THE INVENTION  
         [0001]    This invention involves vacuum folding apparatus to make single or double transverse folds in articles like napkins from one, two, or more, different colored webs and delivering them as color or material mixed stacks.  
           [0002]    Other embodiments include means for making multiple sizes for single or double vacuum cross folds in single or two color stacks.  
         BACKGROUND AND SUMMARY OF THE INVENTION  
         [0003]    Co-invented U.S. Pat. No. 6,375,605 B 1 describes apparatus for combining spaced segments from each of two or more tandem mounted cutoff units to form a continuous intermixed stream of differently colored segments that are subsequently folded by air blast, etc.  
           [0004]    By using slow speed metering rolls in U.S. Pat. No. 6,375,605 B 1, each incoming web is slidably advanced to alternate repeat surfaces of an anvil roll before cutting. One cutoff unit feeds spaced segments to even repeats, a second cutoff unit feeds spaced segments to odd repeats. The two streams of spaced segments are transferred to, and combined on a carrier for subsequent air folding as a continuos series of intermixed colors or materials for subsequent packout and delivery into stacks.  
           [0005]    In the instant invention, segments are vacuum held against the anvil roll and advanced until vacuum is applied to carrier ports along a pre-selected fold line.  
           [0006]    This extended timing of anvil roll vcuum results in the fold being made by interaction between the anvil and carrier roll vacuum before and as it is transferred to the carrier surface.  
           [0007]    Apparatus for vacuum folding is described in prior art teachings U.S. Pat. No.  3 , 689 , 061  of Nyatrand, U.S. Pat. No. 3,870,292 of Bradley, and U.S. Pat. No. 4,329,185 of Small, all of which produce single color stacks of one size.  
           [0008]    The instant invention utilizes the same slow speed infeed and cutoff and further describes details for vacuum ports arrangements and timing needed to produce color mixed stacks, but also the use of slow speed feed rolls in combination with multiple ports on multiple fold lines to produce products of various sizes for single or multiple color stacks.  
           [0009]    It is an object of this invention to describe means to complete an overfold using vacuum in anvil and carrier roll ports rather than air blast and a stationary plate.  
           [0010]    Another object is to define folding apparatus using various combinations of vacuum port placement and timing to describe apparatus for multiple sizes, including independent drives for selected components and changes in phase relationships between anvil and carrier rolls as a function of product size.  
           [0011]    These and other advantages and objects of the invention may be seen in the ensuing specifications:  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]    [0012]FIG. 1 is a side elevation schematic illustrating a prior art single napkin folder for packout of napkins from a series of napkins to produce a one color stack.  
         [0013]    [0013]FIG. 2 is a side elevation schematic illustrating a prior art doublefold napkin folder for packout of napkins from a series of napkins to produce a one color stack.  
         [0014]    [0014]FIG. 3 is a side elevation schematic of the inventive folder illustrating placement and timing of two cutoff units to produce a stream of single folded napkins with alternating colors or materials for packout into stacks.  
         [0015]    [0015]FIG. 4 is an enlarged side elevation of the anvil/knife roll pair illustrating typical components to control and cut segments from a web.  
         [0016]    [0016]FIG. 5 is an enlarged side elevation of the two cutoff units in FIG. 3 illustratnig phase relationships and folding cooperation between the anvil and carrier rolls.  
         [0017]    FIGS.  6 A through FIG. 6H are side elevation schematics illustrating advancement of segments at anvil surface speed and slipping advancement of the incoming web to create an open repeat surface on the anvil roll in order to receive alternate segments from the second cutoff unit.  
         [0018]    [0018]FIG. 7A and FIG. 7B are plan view schematic diagram illustrating vacuum timing, force, and duration to achieve advancement and slipping advancement of segments (shown unfolded) along a path from each of two cutoff units.  
         [0019]    [0019]FIG. 7C is a plan view schematic illustrating placement of the combined folded segments on the carrier surface to produce a stream of alternately colored napkins.  
         [0020]    [0020]FIG. 8 is a side elevation schematic illustrating placement of three cutoff units mounted in tandem along a common carrier roll path.  
         [0021]    [0021]FIG. 9 is a side elevation schematic illustrating location of two cutoff units along a common carrier roll path, each including a first anvil/folding roll and second folding roll coacting with a carrier to produce a two color stack of doublefolded products.  
         [0022]    [0022]FIG. 10 is a plan view schematic of one repeat surface of the carrier roll arranged with air apertures to complete a second cross fold on a consecutive series of single folded segments.  
         [0023]    [0023]FIG. 11 is a front elevation view schematic of longitudinal folding plates viewed along line  11 - 11  of FIG. 3 illustrating the arrangement of folding plates, draw rolls, and turning bars for a plurality of product webs from a multi-width web.  
         [0024]    [0024]FIG. 12 is a top view schematic viewed from line  12 - 12  of FIG. 11 illustrating one of two full width webs being slit into a plurality of product width webs and advanced over V-fold plates into the nip of pull rolls before advancement over turning bars and subsequent slow speed draw rolls.  
         [0025]    [0025]FIG. 13 is a plan view schematic viewed from line  13 - 13  of FIG. 11 illustrating superposed product webs being separated and turned 90 degrees for advancement to the slow speed and cutoff section.  
         [0026]    [0026]FIG. 14 is a a simplified side elevation schematic of FIG. 8 illustrating the three color being advanced for packout.  
         [0027]    [0027]FIG. 15 is a simplified side elevation schematic illustrating two folders of FIG. 8 arranged face-to-face and the resultant color sequence produced for packout.  
         [0028]    [0028]FIG. 16 is a side elevation schematic view of an anvil roll illustrating means for selecting a vacuum conduit for a selected product length.  
         [0029]    [0029]FIG. 17A is a plan view schematic of anvil repeat surfaces illustrating vacuum port arrangment for a segment length equal to a repeat surface.  
         [0030]    [0030]FIG. 17B is a plan view schematic of anvil repeat surfaces on a second unit illustrating vacuum port arrangement for a segment length equal to about ⅔ of a repeat surface.  
         [0031]    [0031]FIG. 17C is a plan view schematic of anvil roll repeat surfaces illustrating vacuum port arrangement for a segment length equal to about ½ of a repeat surface.  
         [0032]    FIGS.  18 A- 18 C are simplified side elevation schematics of the FIG. 3 apparatus illustrating changes in phase relationships between anvil and carrier for three different segment sizes.  
         [0033]    [0033]FIG. 18A is a side elevation schematic illustrating roll phase relationships for a product length that equals length of a repeat surface.  
         [0034]    [0034]FIG. 18B is a side elevation schematic illustrating phase relationships for a product length equal to about ⅔ of a repeat surface.  
         [0035]    [0035]FIG. 18C is a side elevation schematic illustrating phase relationships for a product length equal to about ½ of a repeat surface.  
         [0036]    [0036]FIG. 19 is a simplified side elevation schematic illustrating apparatus with only one cutoff unit and separate stepping motor drives for phase change between anvil—carrier, selected slow speed for metering roll and synchronous roll rotation.  
         [0037]    [0037]FIG. 20A is a plan view schematic illustrating vacuum ports along the leading margin for three different segment lengths on an anvil surface.  
         [0038]    [0038]FIG. 20B is a plan view schematic illustrating vacuum ports arranged along fold lines for three different segment lengths on a carrier surface.  
         [0039]    [0039]FIG. 20C is a side elevation schematic illustrating two longest segments L  1  folded, placed. and advancing on 2 consecutive carrier repeats.  
         [0040]    [0040]FIG. 20D is a side elevation schematic illustrating two folded segments L  2  folded, placed and advancing on 2 consecutive carrier repeats.  
         [0041]    [0041]FIG. 20E is a side elevation schematic illustrating two folded segments L  3  folded, placed and advancing on 2 consecutive carrier repeats.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0042]    In prior art folders of FIGS.  1 - 2 , rolls having the same function have the same reference numbers.  
         [0043]    In FIG. 1, vacuum folding apparatus  1  produces a singlefolded product and is comprised of draw rolls  2 , knife roll  3 , anvil roll  4 , and carrier  5 .  
         [0044]    In FIG. 1, longitudinally folded web  6  (folding plates not shown) is advanced by draw rolls  2  and held on the surface of anvil roll  4  by vacuum ports that communicate with conduits drilled into the solid roll blank parallel to the axis of rotation.  
         [0045]    After a segment is cut by knife roll  3 , anvil roll  4  grips the leading edge of the front half panel until it reaches release position  7 . Similar vacuum ports in carrier  5  located midway between segment ends  8  advance the trailing portion until the lead panel portion is released from anvil roll  4  to complete the fold.  
         [0046]    In folding apparatus  9  of FIG. 2, a first transverse fold is completed by folding co-action between anvil roll  4  and a subdequent vacuumized roll  5 ′.  
         [0047]    In FIG. 2, roll  5 ′ includes a transverse line of vacuum ports along a second fold line FD-FD′ (see FIG. 10) between first fold line FS-FS′ and the cut end  8 ′ of a segment S to create a double cross folded product like a dinner napkin by second folding co-action between rolls  5 ′ and roll  5 .  
         [0048]    In FIG. 3, cutoff units  16  and  21  are spaced one repeat R apart along the periphery of the carrier  22 . Cutoff units can be spaced differently and the anvil/carrier roll phasing of each advanced or retarded as required.  
         [0049]    In FIG. 3, lower cutoff unit  16  and related components are described below. Upper cutoff unit  21  operates the same and similar elements have the same reference numbers with a prime mark (′).  
         [0050]    In FIG. 3, cutoff unit  16  creates a series of spaced apart segments S  1 , S  3 , S  5 , etc. (see FIG. 7A), for cooperative folding with anvil vacuum V  1  (see FIGS. 5,7) and carrier vacuum V  4  for transfer to spaced carrier roll repeats R  1 , R  3 , R  5 , etc., and for subsequent combining with folded segments from a second unit  21 .  
         [0051]    Surface speed of anvil rolls  19  and carrier  22  are the same carrier.  
         [0052]    In FIG. 3, cutoff unit  21  simultaneously processes web W  2  into a series if spaced segments S  2 , S  4 , S  6 , etc. (see FIG. 7B) held on alternate repeats of the anvil for cooperative folding with anvil vacuum V  1 ′ and carrier V 5 , and transfer to spaced unoccupied repeat surfaces R  2 , R  4 , R  6 , etc. on the carrier to create a series of segments S 1 , S  2 , S  3 , S  4 , etc on consecutive repeats of the carrier (see FIG. 7C) and advancment to removal position  23  and packout by reciprocating fingers  24 .  
         [0053]    Prior to the above functions in FIG. 3, web W  1  advances through constant tension device  10 , and slitters  11  to slit a full width web into two or more product webs (slitting not required for 1-wide parent rolls), over longitudinal folding plate  12 , through pull rolls  13 , over turning bar  14 , through draw roll 5   15 , S-wrap roll  17 , and over variable speed metering roll  18  at a pre-selected speed less than anvil roll surface speed.  
         [0054]    Details for each cutoff unit  16 ,  21  are similar and FIGS. 5, 6,  7  below describe slow speed web feed by metering rolls  18 ,  18 ′ relative to slippage and advancement to create the above-mentioned space between consecutive segments on each anvil roll.  
         [0055]    One embodiment for a second fold involves air blast through apertures  53  in the carrier surface (see FIG. 10) to lift the front portion of the already folded product, and stationary plate  25  creates the second cross foldover (see also FIG. 9 for another doublefold embodiment).  
         [0056]    In FIG. 4, machined slot  26  contains anvil holder  27  fastented by bolt  28  to roll  19 . Vacuum passages  29  communicates with vacuum conduits drilled parallel with the axis of rotation. Vacuum is applied from circular grooves in a stationary valve communicating with a vacuum source (both known means not shown).  
         [0057]    In FIG. 4, co-acting knife roll  20  includes an adjustable knife holder  30  containing knife  31 . Ports  32  adjacent anvil  33  normally hold the web taut during cutoff.  
         [0058]    In well known practice, vacuum to grip the leading edge of a segment is applied before the cut. The gripping vacuum applies tension to the web from the cut edge to the incoming web portion approaching the cutting position. Other means to hold the web at cutoff can include instantaneous vacuum on the web when cut (on-off of ports  32 ), or smaller and fewer ports adjacent the anvil since the web must slip immediately after the cut.  
         [0059]    In FIG. 5, a lower 2-time anvil roll  19  having one anvil  33  contacts the surface of carrier  22  at radial line RL 2  and is arranged one repeat distance R  1  apart from second anvil roll  19 ′.  
         [0060]    Both cutoff systems  16 ,  21  are the same. For brevity, function of only the first unit is described noting that folded segments FS 1  from cutoff unit  16  and FS 2  from unit  21  (both shown dashed) are placed on consecutive repeats R 1 , R  2 ′ of the carrier surface as described above.  
         [0061]    In FIG. 5, anvil  33  underlies a cut common to the trailing edge  38  of a cut segment and the leading edge  37 ″ of the incoming slow speed web.  
         [0062]    In FIG. 5, the leading edge of segment S  3  is cut on the same line as the trailing edge  38  of segment S  1 . In FIGS. 6A to  6 H, segment S  3  is progressively slipped over one repeat surface of the anvil roll to create a blank space between S  1 , S  3 . etc.  
         [0063]    In FIGS.  5 ,  6 A- 6 J, the anvil roll is marked in 22 ½ degree segments as a common reference for anvil roll rotation versus the lead edge of the next to be cut segment, noting that the knife/anvil rolls make one cut each revolution of 24″ versus 12″ web feed during the same time.  
         [0064]    In a typical example, the surface speed of the anvil roll is 450 fpm for transferring folded 12″ segments to the carrier (also at 450 fpm), while the webs from each cutoff unit are advancing at 225 fpm and combined to deliver 450 products/min to the carrier roll.  
         [0065]    For larger repeat lengths and larger roll diameters requiring more space than 1 repeat between two successive cutoff units, phasing of anvils relative to carrier roll fold lines change along with timing of carrier folding vacuum.  
         [0066]    In FIG. 5, the leading edge  37  of segment S  1  is gripped by vacuum V  1  in ports  32  at position  39  and advanced to position  40  where the lead panel is overfolded, vacuum V  1  stops, and the folded segment FS 1  is transferred to the carrier  22  by vacuum in ports  36 .  
         [0067]    In FIG. 6A (like FIG. 5), anvil  33  and knife  31  cut web W land at the same time as vacuum V  1  is applied at position  39  to advance the leading edge of the first cut degment S  1  to position  40 .  
         [0068]    Carrier  22  (not shown) coacts with roll  19  to complete he fold by applying vacuum V  4  to ports  36  (dashed) at the mid-point fold line FS-FS′ of segment S  1  (see FIG. 10).  
         [0069]    In FIG. 6B, cut segment S  1  advances two 22 ½ degree arcuate portions whille web W  1  advances one portion at half speed. Vacuum V  1  in path  42  grips and advances the segment.  
         [0070]    In FIG. 6C, similar S  1  and W  1  advances occur. Reduced vacuum path  43  terminates at  40  when the leading edge of S  1  is ready to be overfolded as shown dashed in FIG. 6D.  
         [0071]    Upon further anvil rotation in FIGS. 6E through 6H, the slow speed web is slideably advanced until reaching the position shown as S  3 .  
         [0072]    In FIG. 6J, the absence of a segment on 180 degrees of anvil surface  44  results in a blank space on alternate repeats of the carrier roll  22 . FIGS. 6J, 8A, and FIG. 5 are similar and comparable.  
         [0073]    In FIG. 5, similar means and operation place folded segments S  2 , S  4 , etc. from cutoff unit  21  on the alternate blank repeats of the carrier.  
         [0074]    In FIG. 7A, segment S  1  on lower roll  19  (See FIGS. 3, 5) is severed from web W  1  at cut line  19 C  
         [0075]    In FIG. 7A (left side), vacuum ports  32  under leading edge  37  of segment S  1  grip and advance it to position  40  of the anvil roll without slippage (see FIGS. 5, 6C)  
         [0076]    In FIG. 7A, ports  47 ′ under web W  1  apply restricted vacuum to allow slipping advancement. In one anvil roll revolution, the web slips 180 degrees to be deposited as S  3  when the next cut occurs.  
         [0077]    In FIG. 7A, the same slipping advancement occurs to cut another segment shown as S  5 . Vector  45  represents full speed advancement of S  1 . Vector  46  represents resultant half speed of the sliding web.  
         [0078]    In FIGS. 7A and 7B, vacuum V  1  is applied to ports  32 ′ on the lead edge  37 ,  37 ′ of segment S  1 , S  2  respectively. V  2  restricted vacuum is applied to ports  47  (circles) which grip a cut segment S and V  3  (solid) to allow slippage of the uncut slow speed web as described.  
         [0079]    In FIG. 7B, space D is segment displacement due to a repeat space between the carrier contact point with two spaced cutoff units  16 ,  21 .  
         [0080]    In FIG. 7B, segments S  2 , S  4 , S  6 , etc are cut, slipped, and advanced by the upper cutoff unit  21 .  
         [0081]    In FIG. 7C, both streams of spaced folded segments are combined to form a consecutive series of products advancing on the carrier at speed vector  45 .  
         [0082]    In FIG. 7C, full vacuum V  4  (shown in FIG. 3) is applied to carrier ports for segments S 1 , S 3 , S 5 , etc and full vacuum V  5  (see FIG. 3) is applied to carrier ports for S  2 , S  4 , etc.  
         [0083]    In each instance, vacuum starts just before the carrier reaches the midpoint segment fold line FS-FS′. (see FIG. 10).  
         [0084]    In FIG. 8, three cutoff units  16 ,  21 , and  48  are arranged one repeat R apart on the periphery of carrier  22  to advance, cut, fold and transfer segments S A, S B, S C etc, to consecutive repeat surfaces of the carrier for packout in the same sequence at position  23 .  
         [0085]    The apparatus of FIG. 8 produces a 3-color (or 3 different materials) sequence from 3 webs each advancing at ⅓ the surface speed of the anvil  19  and carrier  22  rolls, etc.  
         [0086]    In FIG. 8, each of three webs run at a speed equal to one-third of the carrier surface, and with one web stopped, each web in a two color sequence runs at ½ carrier surface speed.  
         [0087]    In FIG. 9 double folding apparatus, each cutoff unit  49 ,  50 , includes a second folding roll  51  to make the second fold.  
         [0088]    In FIG. 9, roll  51  grips the leading folded edge, and in cooperation with carrier ports  52 , completes a second cross fold on line FD-FD′ for advancement on spaced repeat surfaces of the carrier.  
         [0089]    In FIG. 9, roll  51 ′ of upper cutoff unit  50  coacts with ports  52 ′ on carrier  22  to fold and deposit doublefolded segments on alternate blank repeat surfaces left blank by first unit  49 .  
         [0090]    In FIG. 10 when making a single fold product (as in FIGS. 3, 5,  6 ,  7 ), ports  32  on leading edge  8  of segment S advance with anvil roll  19  until ports  36  in carrier roll grip the segment along FS-FS′ to complete the first fold.  
         [0091]    In FIG. 10 when making a doublefold, ports  36 B (same location as  36 , but on second roll  51 ) complete the first fold and ports  52  on the carrier roll  22  complete the second fold along line FD-FD′.  
         [0092]    Referring back to FIGS.  3 , another embodiment for double folding involves two cutoff units (each with one anvil/folding roll) that complete the first fold with vacuumized anvil ports  32  and carrier ports  36  for the first fold along FS-FS′ (see FIG. 10), and air blast A through carrier apertures  53  (see FIG. 10) to uplift the leading portion and complete the second fold along line FD-FD′ with a stationary plate (see  52 ,  53 , and  25  on left side of FIG. 3).  
         [0093]    In FIG. 11, incoming web W  1  is supported by slitter bedroll  54  as it is slit into a plurality of product width webs P. For single width parent rolls slitters  11  are not required.  
         [0094]    With one or more producrt width webs P, each web is drawn over folding plates  12  by draw rolls  13 , threaded around turning bars  14  and pulled toward web metering rolls  18  by pull rolls  15 . (see right side of FIG. 3). In lieu of turning bars, parent rolls can be fed from the side.  
         [0095]    In FIG. 12, after individual webbs P are longitudinally folded by plates  12 , they are superposed for a short distance (as at  55 ) before each web is turned 90 degrees as at  57  for entry into the metering and cutoff units  16 ,  21 , etc.  
         [0096]    .FIG. 13 turning bars  14 , superposed webs  55  and individual webs  57  are shown in plan view for clarity.  
         [0097]    [0097]FIG. 14 (like FIG. 8 above) is a complete (single) folding apparatus that includes three cutoff units referenced a for W  1 , b for W  2  and c for W  3  to produce a color sequence. If three webs are used, unit a will deposit the first folded segment a (see Sa in FIG. 8) and in turn, b, then c, to define a series of sequences A-B-C . . . A-B-C . . . etc.  
         [0098]    In FIG. 15, two duplicate folding apparatus are arranged face-to-face to deliver superposed folded segments  60  between delivery belt pair  59  for packout by reciprocating packers  24  to define a series of sequences CF-BE-AD . . . CF-BF-AD . . . etc.  
         [0099]    Generally, the arrangement of FIG. 14 ( 1 - 4  wide webs) is used to produce coin edge embossed napkins from 2 or 3 ply stock, while the arrangement of FIG. 15 would use multiple width parent rolls of 1-ply stock for commercial or consumer napkin products.  
         [0100]    In FIG. 16 cross section adjacent an end of roll  19 , bored holes (not referenced for clarity) each contain rotatable inserts  61 ,  61 ′,  61 ″ with passage holes  62 ,  62 ′,  62 ″.  
         [0101]    Hole  62  is shown open for vacuum V  1  to communicate with a matching conduit drilled transversely in the roll body. Drilled holes (shown dashed) connect vacuum in the conduits to ports  32 .  32 ′,  32 ″ on the surface of roll  19 .  
         [0102]    Insert  61  is shown activated for product L  1  while inserts  61 ′,  61 ″ are turned 90 degrees and are inactive.  
         [0103]    One selected insert is rotated to activate a selected conduit and line of vacuum ports while others are turned off. Electronic valve means can be used for programmable activation or shutoff.  
         [0104]    In FIG. 16, roll  19  has one anvil  33 . The incoming web W  1  advances at a selected speed to make the anvil/knife cut at position  33 ′ (shown phantom) when the proper length L  1 , L  2  etc. is fed beyond cutting position at  33 ′.  
         [0105]    In FIG. 16, vacuum V  1  on leading edge  37  of segment L  1  (see left side of anvil roll) ends when fold line FS-FS′ reaches line  63  (zero reference line) when product length equals repeat length.  
         [0106]    For shorter lengths L  2 , L 3 , folded length and fold lines change, and retarding carrier  22  compensates to keep the segment trailing edge at the nip between anvil and carrier rolls  
         [0107]    Means and steps to change sizes are detailed below.  
         [0108]    In FIGS. 16,17, segment lengths L  1 , L  2 , L  3 , are generated on the surface of anvil roll  19  and in this instance product lengths of 12″, 8″, and 6″ are described as a typical example.  
         [0109]    In FIG. 17A, slippage of 12″ (S 12 ) is required to keep every other repeat open for segments L  1 ′ from another unit—as in FIG. 5.  
         [0110]    In FIG. 17A, leading edge  37  of W  1  advances at slow speed toward position  33  during one anvil roll revolution of 2 repeat surfaces. Slippage S  12  represents retarding the lead edge (of web L 1 ) 12″ until it reaches the position of anvil  33  (shown solid) and thereafter is cut and folded by coaction of anvil and ports  36  on the carrier roll.  
         [0111]    In FIG. 17B for shorter product L  2  (8″), the amount of web slip S  16  on the anvil roll is one repeat plus 4″ with the phase angle correction made by retarding the carrier to fold line position  64 .  
         [0112]    In FIG. 17C, for product L  3  (6″ length), the amount of web slip (S  18 ) is one repeat plus 6″, with phase correction made by retarding the carrier to fold line position  66 .  
         [0113]    In FIG. 18A, carrier ports  36  on fold line  63  (base reference) is in phase for L 1 .  
         [0114]    In FIG. 18B, due to shorter folded length 2, the fold line is retarded by rotating carrier  22  to position  64  by retarding the carrier an amount shown as  65 .  
         [0115]    In FIG. 18C, shorter product L 3  and shorter folded length FL  3  require rotation of carrier  22  to fold line  66  by retarding it an amount shown as  67 .  
         [0116]    In FIGS.  18 A- 18 C, separate, digitally controlled variable speed programmable stepping motors M rotate metering roll  18  for a pre-determined web speed and drive the anvil/knife roll pair in synchronous surface speed with the carrier, after the steps of; selection of the active anvil roll vacuum conduit  61 ,  61 ′ etc., phasing of carrier fold line to the anvil roll, adjust for proper web speed required by L 1 . L 2 , etc and energizing drives to maintain the set relationships in synchronism.  
         [0117]    In the apparatus of FIGS.  3  to  15  with one or two curoff units, web feed speeds of ½ or ⅓ of the anvil surface speed are required to slip the incoming web to create blank repeat space (s) for full length segments from other units.  
         [0118]    Apparatus described in FIGS.  16 - 18  are also capable of making a range of product sizes in a color mixed sequence and require ½ web speed times the ratio of segment sengths. For example, ½×8″/12″ or 0.333 of anvil surface speed.  
         [0119]    [0119]FIGS. 19 and 20 describe the use of only one of the described cutoff units for a range of sizes in only one color.  
         [0120]    In the embodiment of FIG. 19, similar elements including drives, cutoff and carrier components etc., are located and operated in similar manner using a 2-time anvil roll and 2-time knife roll to cut and advance a segment on each consecutive repeat surface for folding transfer to the carrier.  
         [0121]    In FIG. 19, segments FL 1 , FL 1 ′ advance on consecutive repeat surfaces R  1 , R  2  respectively and web speed is increased equal to anvil and carrier roll surface speed times the ratio of product size.  
         [0122]    Apparatus in the embodiment of FIG. 19 produces multiple sizes without intermediate blank repeat spaces at pre-selected uniform web speed for slippage of shorter products. For example, for the 3 sizes compared above, zero slip for 12″, 4″ slippage for L 2 , and 6″ slippage for L 3  using the approporate web speeds.  
         [0123]    In FIG. 20A, anvil roll ports  32 ,  32 ′,  32 ″ are positioned for the leading edge of three product lengths for two consecutive repeat surfaces R  1 , R  2 . etc.  
         [0124]    In FIG. 20B, carrier fold line ports  36 . 36 ′ etc. are positioned along fold lines  63 ,  64 ,  66  for products L 1 , L 2 , L 3  respectively.  
         [0125]    In FIG. 20C, folded segments SF 1 , FS 1 ′ are deposted on repeats R  1 , R 2 , respectively to result in folded lengths FL  1 , Fl  2 , FL  3 .  
         [0126]    In FIGS.  20 C- 20 E, folded lenght is ½ of segment length, but can be changed to other ratios.  
         [0127]    It is furthermore to be understood that the present invention may be embodied in other specific forms without departing from the spirit or special attributes, and it is therefore desired that the present embodiments be considered in all respects as illustrative, and therefore not restrictive, reference being made to the claims rather than the foregoing description to indicate the scope of the invention.  
         [0128]    Having thus described the invention, what is desired to protect by Letters Patent are the following claims:  
       Reference Numbers  
       [0129]    FIG Ref No Description  
         [0130]    [0130] 1  singlefold apparatus  
         [0131]    [0131] 2  draw rolls  
         [0132]    [0132] 3  knife roll  
         [0133]    [0133] 4  anvil roll  
         [0134]    [0134] 5  carrier roll  
         [0135]    [0135] 6  longitudinally folded web  
         [0136]    [0136] 7  release position of leading edge from anvil roll  
         [0137]    [0137] 8  vacuum ports at miidway folding position  
         [0138]    [0138] 9  doublefold apparatus  
         [0139]    [0139] 5 ′ doublefold vacuum folding roll  
         [0140]    W 1  bottom first web  
         [0141]    W 2  top second web  
         [0142]    [0142] 10   3 -roll constant tnesion system  
         [0143]    [0143] 11  product width web slitter  
         [0144]    [0144] 12  plates for longitudinal fold  
         [0145]    [0145] 13  pull rolls  
         [0146]    [0146] 14  turning bars  
         [0147]    [0147] 15  pull rolls  
         [0148]    [0148] 16  first web cutoff unit  
         [0149]    [0149] 17  s-wrap roll pair  
         [0150]    [0150] 18  variable speed metering roll  
         [0151]    [0151] 19  anvil roll  
         [0152]    [0152] 20  knife roil  
         [0153]    [0153] 21  second web cutoff unit  
         [0154]    [0154] 22  carrier roll (or cyllinder)  
         [0155]    [0155] 23  product removal position  
         [0156]    [0156] 24  reciprocating packer fingers  
         [0157]    [0157] 25  stationary plate to complete a doublefold (air blast apertures not shown in carrier)  
         [0158]    R 1  first repeat surface on carrier  
         [0159]    R 2  . . . subsequent repeat surfaces on carrier  
         [0160]    S 1  . . . folded segments S  1 , S  3 , S  5  from cutoff  16   
         [0161]    V 4  vacuum for fold line ports on segments from 16 (unit  19 )  
         [0162]    S 2 ′ . . . folded segment S  2 , S  4 , S  6 , from cutoff  21   
         [0163]    V 5  vacuum for fold line ports on segments from cutoff  21   
         [0164]    [0164] 26  machined slot for anvil holder  
         [0165]    [0165] 27  anvil holder in roll  19   
         [0166]    [0166] 28  bolt for holder  
         [0167]    [0167] 29  vacuum passage in anvil  
         [0168]    [0168] 30  knife holder in roll  20   
         [0169]    [0169] 31  knife blade  
         [0170]    FS 1  first segment from cutoff unit  16   
         [0171]    FS 2  first segment from c.o. unit  21   
         [0172]    S 3  slow speed web for next spaced segment  
         [0173]    [0173] 33  anvil in roll  19   
         [0174]    [0174] 34  vacuum conduit in carrier  22   
         [0175]    [0175] 35  vacuum channel to carrier ports  36   
         [0176]    [0176] 36  carrier vacuum ports  
         [0177]    [0177] 37  leading edge of first segment  
         [0178]    [0178] 37 ′ leading cut edge of incoming web  
         [0179]    [0179] 38  trailing edge of segment  
         [0180]    [0180] 39  leading margin when anvil vacuum V I starts  
         [0181]    [0181] 40  leading margin when anvil vacuum V  1  stops  
         [0182]    V 1  anvil roll vacuum applied to lead edge  37   
         [0183]    V 2  anvil roll restricted vacuum (circle) (no slip)  
         [0184]    V 3  anvil roll restricted vacuum (solid)-web slippage  
         [0185]    RL 2  carrier radial line of contact w/anvil roll  
         [0186]    V 5  anvil roll vacuum applied to lead edge  37 ″  
         [0187]    [0187] 41  22 ½ degree arcuate portion of rotation  
         [0188]    [0188] 42  vacuum path in FIG. 6 b    
         [0189]    [0189] 43  vacuum path in FIG. 6 c    
         [0190]    [0190] 44  blank repeat (no segment)  
         [0191]    [0191] 45  full speed forward vector  
         [0192]    [0192] 46  resultant half speed forward vector  
         [0193]    [0193] 47  restricted vacuum carrier ports for gripping  
         [0194]    [0194] 47 ′ restricted vac. carrier ports for slip(ping advancement  
         [0195]    D spacing on carrier between cutoff units  
         [0196]    [0196] 19 C cut line, lower cutoff unit  
         [0197]    [0197] 19 ′C cut line, upper c.o. unit  
         [0198]    [0198] 48  third cutoff unit  
         [0199]    S A segment from # 1  cutoff  
         [0200]    S B segment from #  2  cutoff  
         [0201]    S C segment from #  3  cutoff  
         [0202]    [0202] 49  lower double fold cutoff unit  
         [0203]    [0203] 50  upper double fold cutoff unit  
         [0204]    [0204] 51  second fold roll-lower unit  
         [0205]    [0205] 51 ′ second fold roll-upper unit  
         [0206]    [0206] 52  vacuum ports for doublefold line FD-FD′  
         [0207]    [0207] 53  air blast apertures  
         [0208]    FS-FS′ fold line for first fold  
         [0209]    FD-FD′ fold line for second (double) fold  
         [0210]    [0210] 54  slitter bedroll  
         [0211]    [0211] 55  superposed webs  
         [0212]    [0212] 56  intermediate frame  
         [0213]    P product width web  
         [0214]    [0214] 57  longitudinally folded product web  
         [0215]    [0215] 58  singlefold apparatus for 3-color mix  
         [0216]    [0216] 22 ′ duplicate folder-face-to-face  
         [0217]    CDE cutoff units on dual folder  
         [0218]    [0218] 59  delivery belt pair  
         [0219]    [0219] 60  pair of superposed napkins  
         [0220]    L 1  length of product =repeat surface length  
         [0221]    [0221] 32  leading edge ports on anvil roll for L 1   
         [0222]    L 2  length of segment L 2   
         [0223]    [0223] 32 ′ leading edge ports on anvil roll for L 2   
         [0224]    L 3  length of segment L 3   
         [0225]    [0225] 32 ″ leading edge ports on anvil roll for L 3   
         [0226]    [0226] 61  rotatable insert  
         [0227]    [0227] 62  hole in insert for path to roll conduit  
         [0228]    S  1  slippage to alternate space—L 1   
         [0229]    S  2  slippage to alternate space—L 2   
         [0230]    S  3  slippage to alternate space—L 3   
         [0231]    V  3  restricted vacuum for slipping  
         [0232]    L  1  segment length (example 12″)  
         [0233]    [0233] 63  reference line for phasing carrier to anvil  
         [0234]    S 12  slippage of L 1  web ( 12 ′)  
         [0235]    L  2  segment length (example 8″)  
         [0236]    [0236] 64  fold line for phasing to  12   
         [0237]    S 16  slippage for L 2  web ( 8 ″)  
         [0238]    [0238] 65  phase angle for L  2  fold line  
         [0239]    L 3  segment length (example 6″)  
         [0240]    [0240] 66  fold line for phasing to L 3   
         [0241]    S  18  slippage for L 3  web ( 6 ″)  
         [0242]    [0242] 67  phase angle for L 3  fold line  
         [0243]    FL 1  folded segment on R  1  repeat  
         [0244]    FL 1 ′ folded segment on R  2  repeat

Technology Classification (CPC): 1