Patent ID: 12258169

The drawings show some but not all embodiments. The elements depicted in the drawings are illustrative and not necessarily to scale, and the same (or similar) reference numbers denote the same (or similar) features throughout the drawings.

DETAILED DESCRIPTION

In accordance with the practice of at least one embodiment, as seen in the Figures for example, there is a tri-fold machine10to fold up compressed high expansion force material20, such as a mattress product. In order to see certain structures, vantage point A is employed inFIGS.1and2. However, for the discussion ofFIGS.3-10, vantage point B is employed to give meaning to the left and right orientation of machine parts. As should be clear to one or ordinary skill in the art, in combination with the teaching herein, the opposite orientation could be easily employed and is interchangeable therewith by flipping from the B vantage point to the A vantage point, if desired. Accordingly, from the B vantage point, there is a left-side horizontal conveyor30next to a middle conveyor50. A left longitudinal gap52is formed between the left-side horizontal conveyor30and the middle conveyor50. A right-side horizontal conveyor70is next to an opposite side54(FIG.2) of the middle conveyor with a right longitudinal gap58formed between the right-side horizontal conveyor70and the middle conveyor50. An upper surface32,72of each of the left-side horizontal conveyor and the right-side horizontal conveyor defines a horizontal plane34. Additionally, the left-side horizontal conveyor30and the right-side horizontal conveyor70, preferably, each have a movable surface36,76to locate the material20into a material folding position (as seen inFIG.3) relative to a left longitudinal bar90and a right longitudinal bar100. Surfaces36,76, and also preferably56, could be belts, rollers, forced air or other conventional mechanical transport mechanisms, as can be arranged to form a horizontal surface or horizontal-like surface. Movable surfaces36,56,76, can move in direction of travel13to receive compressed material12from a conventional upstream conveyor12. Conveyor12itself, or prior to material20arriving there, transformed a conventional compressible product, like a mattress, into the compressed high expansion force material20using conventional compression equipment and techniques. Thus, prior to folding, the material20is positionable on the left-side conveyor and the right-side conveyor, preferably with each of the left longitudinal bar and the right longitudinal bar overlying a middle portion22of the material (FIG.3).

The left longitudinal bar90is operable between (i) a raised position92where a bottom surface94is spaced from and above the horizontal plane34(FIG.3) as well as spaced from the top surface24, and (ii) a lowered position96where the bottom surface94is located closer to the horizontal plane34than in the raised position. The right longitudinal bar100is also operable between (i) a raised position102where a bottom surface104is spaced from and above the horizontal plane34(FIG.3) as well as spaced from the top surface24, and (ii) a lowered position106where the bottom surface104is located closer to the horizontal plane34than in the raised position. Preferably, the left longitudinal bar and the right longitudinal bar are coupled together, for example by a cross bar108, such that each longitudinal bar90,100is movable between the raised position and the lowered position simultaneously, i.e., in a vertical direction relative to the horizontal surfaces32,72. This can be accomplished, for example, by a bar raising linkage110that also extends below the machine folding surface and uses a conventional mechanism to move the bars90,100up and down as desired. Preferably, the bottom surface94,104of at least one of the left longitudinal bar and the right longitudinal bar is equal with to below the horizontal plane when in the lowered position (e.g.,FIGS.4to8A, inclusive), and more preferably both surfaces94,104can be so located in the lowered position simultaneously. That is, preferably, bottom surface(es)94,104is/are in contact with top surface24of the material when the longitudinal bar90,100is in the lowered position. Still more preferably in this regard, at least one of the longitudinal bars90,100press(es) the material into the respective longitudinal gaps52,58when the longitudinal bar(s)30,70is in the lowered position. Without being limited to a theory of understanding, the inventors have discovered such positioning of one or more of the surfaces94,104can be desirable to aid in holding the material in place relative to the conveyors30,50and70, and can be still more desirable to also help impart crisp and clear fold lines/areas, as discussed herein. Still more preferably, when desired for storage, left longitudinal bar90is sized to fit completely in the left longitudinal gap52, as is right longitudinal bar100sized to fit completely in the right longitudinal gap58, and this occurs when material20is not present.

In other aspects concerning the longitudinal bars90,100, they can be adjustable, in a horizontal direction98(FIGS.11and12), as well as the vertical direction (i.e., positioned between raised positions92,102and lowered positions96,106and anywhere in between). That is, preferably: (i) one of the bars90or100can be fixed relative the conveyors30,50,70and the other of the bars100or90adjustable relative to that bar, or (ii) both bars90and100can be adjustable relative to the conveyors30,50,70and each other bar100,90, respectively. In this way, and without being limited to a theory of understanding, this enables various tri-fold configuration sizes of middle portion22of the material relative to right side26and left side28, when material20is folded. For example, the middle portion width in horizontally direction98is determined by the horizontal spacing of the bars90,100, and so can make the middle be a true one-third of the overall width of material20, or something less or greater than that, as desired. Further, more preferably, the bars90,100, while adjustable as discussed, are temporarily fixed relative to one another when being used to fold the material around the bars. However, it is also contemplated that one of the bars90,100may be movable relative to the other bar100,90, even during folding, as may be desired to further assist with the folding process, especially in such a tri-fold configuration.

Further in regards to the longitudinal bars90,100, and their adjustability in horizontal direction98(FIGS.11and12), as seen inFIGS.13and14the conveyors30,50,70can also be adjustable in horizontal direction44(i.e., for conveyors30and50each individually, as well as relative to one another) and/or in horizontal direction64(i.e., for conveyors50and70each individually, as well as relative to one another). That is, preferably: (i) one of the bars90can be fixed relative the other bar100, and bar100can be positioned further to the right relative to the bar positioning in all the prior FIGs, and then in concert with this further right position so can one or both of conveyors50and70be positioned further to the right relative to the conveyor positioning in all the prior FIGs. Preferably both conveyors are so moved to the right a sufficient distance to cause the right longitudinal gap between conveyors50and70to be centered under bar100(but an off-set positioning of this gap can be used too, if desired). In this way, and without being limited to a theory of understanding, this enables even more tri-fold configuration sizes of middle portion22of the material relative to right side26and left side28, when material20is folded. For example, the middle portion width in horizontally direction98is determined by the horizontal spacing of the bars90,100, and so can make the middle be a true one-third of the overall width of material20, or something less or greater than that, as desired.

Still further in regards to the longitudinal bars90,100, as seen inFIGS.1,15and16, restriction force130can be employed coinciding with distal end62of middle conveyor50and respective ends of the bars90,100. In this way the force130acts to push the distal ends of bars90,100outward, or at least prevent the distal ends of bars90,100from being pressed inward of the span represented by the ends of the arrows representing force130. That is, the proximal end60that corresponds to bars90,100and their coupling together108acts to hold bars90,100apart as desired (or not, as described elsewhere for the spacing of bars90,100in general) during the folding process. Similarly, restriction force130can be employed at the opposite end of the bars90,100to help hold them at a desired spaced apart location (or not, as described elsewhere for the spacing of bars90,100in general) during the folding process, preferably to help form a more crisp fold along the entire length of the folded material20. For example, force130could be achieved by restriction plates132that prevent the inward toward-each-other movement of bars90,100during the folding process. Plates132can selectively move up and down to assist holding apart bars90,100before and during folding, and then move down (FIG.16) to get out of the way of the advancing folded material20when time for it to move into the roll forming stage of the packaging process. Alternatively, plates132could be a single horizontal plate (not shown) that has horizontal pins (not shown) projecting orthogonally therefrom toward the ends of bars90,100and bars90,100could have receiving holes (not shown) in the distal ends of bars90,100to receive the pins and thus hold distal ends of bars90,100apart when desired. Still alternatively, other mechanical structures could be employed to attain the restriction force130, when desired, as would be known to one of ordinary skill in the art in combination with the innovative teachings herein.

The tri-fold machine10also includes the right-side conveyor70that is movable between a horizontal home position78and a folding position80, as seen in progression ofFIGS.7to8Ainclusive, via a travel path depicted by the dotted line arrows(s) in each ofFIGS.8and8A. The folding position80is where the right-side conveyor is located above and extending over the middle conveyor with at least some overlying overlap of conveyor70over conveyor50. As seen inFIGS.8and8A, there is complete overlap of conveyor70over conveyor50. However, there need not be so much overlap and in one preferred aspect, the folding position80of the right-side conveyor can be the right-side conveyor located above and extending over the right longitudinal bar100, completely over as seen in the figures, or even just partially over though not specifically seen in the figures. Further in this regard, more preferably, the folding position80of the right-side conveyor can be the right-side conveyor located above and also extending over the left longitudinal bar90, as seen inFIGS.8and8Awith right-side conveyor70located above and extending over the left longitudinal bar90, though only over a portion of bar90. In another aspect of the travel path for conveyor70, preferably the folding position80of the right-side conveyor can be a left edge82of the right-side conveyor located above and extending over the middle conveyor50, as seen inFIG.8. Accordingly, the movement of conveyor70can be first in a purely vertical direction (as represented by the up dotted arrow inFIG.8), and then in a purely horizontal direction (as represented by the left pointing dotted arrow inFIG.8). Alternatively, the movement of conveyor70can be first in a slight vertical direction (as inFIG.7), and then in a curved vertical and horizontal direction (represented by the curved dotted arrow inFIG.8A), as first edge82pivots around itself allowing the opposite edge of conveyor70to flip over and thereby cause the right side26of the material20to be folded over, as opposed to be pushed up and over in theFIG.7toFIG.8operation.

In a similar regard, the tri-fold machine10also includes the left-side conveyor30that is movable between a horizontal home position38and a folding position40, as seen in progression ofFIGS.5to6Ainclusive, via a travel path depicted by the dotted line arrows(s) in each ofFIGS.6and6A. The folding position40is where the left-side conveyor is located above and extending over the middle conveyor with at least some overlying overlap of conveyor30over conveyor50. As seen inFIGS.6and6A, there is complete overlap of conveyor30over conveyor50. However, there need not be so much overlap and in one preferred aspect, the folding position40of the left-side conveyor can be the left-side conveyor located above and extending over the left longitudinal bar90, completely over as seen in the figures, or even just partially over though not specifically seen in the figures. Further in this regard, more preferably, the folding position40of the left-side conveyor can be the left-side conveyor located above and extending over the right longitudinal bar100, as seen inFIGS.6and6Awith left-side conveyor30located above and extending over the right longitudinal bar100, though only a portion of bar100. In another aspect of the travel path for conveyor30, preferably the folding position40of the left-side conveyor can be a right edge42of the left-side conveyor located above and extending over the middle conveyor50, as seen inFIG.6. Accordingly, the movement of conveyor30can be first in a purely vertical direction (as represented by the up dotted arrow inFIG.6), and then in a purely horizontal direction (as represented by the right pointing dotted arrow inFIG.6). Alternatively, the movement of conveyor30can be first in a slight vertical direction (as inFIG.5), and then in a curved vertical and horizontal direction (represented by the curved dotted arrow inFIG.6A), as first edge42pivots around itself allowing the opposite edge of conveyor30to flip over and thereby cause the left side28of the material20to be folded over, as opposed to be pushed up and over in theFIG.5toFIG.6operation.

Referring toFIGS.9and10, once the material is tri-folded, right side26over left side28, and both over middle portion22, preferably the pair of longitudinal bars90,100are moved up to a partially raised position93,103and located between the raised position and the lowered position to release the middle portion of the material from being in the longitudinal gaps formed on each side of the middle conveyor. Then, a pusher bar(s)120can be located adjacent proximal end60of the middle conveyor and can be operable to move longitudinally from the proximal end of the middle conveyor to distal end62of the middle conveyor. That is, bar120can push the material from proximal end60toward distal end62to advance the material to downstream conveyor14. Bar120uses a conventional mechanism to cause the tri-folded material to be pushed over conveyor50and off of bars90,100in direction15(FIG.1) by linear movement of the same. The upper surface of conveyor14aids in moving material20in direction15for further package processing. For example, this can include rolling up the tri-folded material into an even more compact package, with equipment and process taught by a conventional roll cage, or preferably, as taught by applicant's U.S. patent application Ser. No. 17/081,639, filed Oct. 27, 2020 and titled: VARIABLE ROLL CAGE MACHINE AND PROCESS.

Also disclosed here is a process for tri-folding, preferably compressed material12, and more preferably high expansion force compressed material, like a mattress. Such process can be employed by machine10, for example, and as discussed below for reference. The process comprises a variety of steps and while some steps can be performed in any order, some steps have an order dictated by their nature and the results desired, but when this is not the case the order can be varied. In reference toFIGS.3-10, for example, the process includes positioning the material20on the left-side horizontal conveyor30and the right-side horizontal conveyor70, with the middle conveyor50located between the left-side horizontal conveyor and the right-side horizontal conveyor, and longitudinal gaps52,58formed on each side of the middle conveyor. A next step is pressing the middle portion22of the material into at least one longitudinal gap52,58, and preferably both gaps52,58. Another step is folding the left side28of the material over the middle portion22of material20. And, there is the step folding the right side26of the material over the left side28of the material which is located over the middle portion22of the material. As discussed earlier, and/or depending on your point of reference, alternatively, the right side could be first folded over the middle portion and then the left side folded over the right side that is already folded over the middle portion. Additionally, if desired, the process can be where positioning is operating the surface of each of the left-side horizontal conveyor and the right-side horizontal conveyor, as well as the middle conveyor, to locate the material into the material folding position and inFIG.3, and then the balance of steps depicted inFIGS.4-10, inclusive, performed.

Other aspects of the process are directed to the orientation and operation of the conveyors. For example, the process can include folding the left side28of the material by moving the left-side conveyor30from the horizontal home position38to the folding position40. The folding position can be achieved by locating the left-side conveyor above and extending over the middle conveyor, for example, by the travel path inFIG.6or6A, as described previously. Preferably, folding of the left side28of the material includes positioning the right edge42of the left-side conveyor above and extending over the middle conveyor, as seen inFIG.6. Either way conveyor30moves, because the material20is in a dense, highly compressed state, it tends to be somewhat stiff but also flexible under its own weight when folded. That is, as the left side28moves from its position inFIG.5to that ofFIG.6or6A, the weight of material20tends to flop it over onto itself and hold it there. Preferably the left side28is folded onto the middle22before the right side26is folded on top, but it could be in reverse too.

In a similar regard as the left conveyor30, the process can then include folding the right side26of the material by moving the right-side conveyor70from the horizontal home position78to the folding position80. The folding position can be achieved by locating the right-side conveyor above and extending over the middle conveyor, for example, by the travel path inFIG.8or8A, as described previously. Preferably, folding of the right side26of the material includes positioning the left edge82of the right-side conveyor above and extending over the middle conveyor, as seen inFIG.8. Either way conveyor70moves, because material20is in a dense, highly compressed state, it tends to be somewhat stiff but also flexible under its own weight when folded. That is, as the right side26moves from its position inFIG.7to that ofFIG.8or8A, its weight tends to flop it over onto itself and hold it there.

In still other aspects of the process, it can include operating the pair of spaced apart longitudinal bars90,100between (i) the raised position92,102where the bottom surface94,104is spaced from and above horizontal plane34defined by upper surface32,72of each of the left-side horizontal conveyor and the right-side horizontal conveyor. Additionally, preferably the process as related to bars90,100, also includes (ii) a lowered position where the bottom surface is located closer to the horizontal plane than in the raised position. For example, even more preferably, the lowered position can be pressing the middle portion22by moving the pair of spaced apart longitudinal bars90,100into the fully lowered position and the bottom surfaces94,104are engaging the top surface24of the material adjacent to surfaces94,104and bars90,100thereby press the material into the longitudinal gaps52,58respectively. Still more preferably, movement of bars,90,100can be by simultaneously positioning the pair of longitudinal bars together, and particularly so relative to the middle conveyor50.

Related to and building upon one or more of these points, other aspects are directed to certain capabilities of parts of the machine and/or the process. For example, and as seen inFIGS.9-10, the process can include releasing the middle portion22of the material from being in the longitudinal gaps52,58formed on each side of the middle conveyor. In conjunction with this, and while not necessarily needed due to the weight of the sides holding themselves in place once reaching the folded configuration seen inFIGS.8/8A, preferably to best ensure crisp folding and maintenance of the same throughout the process, the process can further include holding the right side of the material over the left side of the material, for example by use of conveyor70as seen inFIG.9. Next, the process can include pushing the material20from the proximal end60of the middle conveyor toward the distal end62of the middle conveyor. And, preferably, holding and pushing occur simultaneously. Finally, and while not shown expressly it is easily understood as described here, as material20is pushed completely off of bars90,100it simultaneously moves onto the downstream conveyor14(FIG.1). Conveyor14has an upper surface which travels in direction15to help carry the folded material onto the next step in the packaging process, for example, as taught by applicant's U.S. patent application Ser. No. 17/081,639, filed Oct. 27, 2020 and titled: VARIABLE ROLL CAGE MACHINE AND PROCESS.

In yet other aspects, the process can include adjusting longitudinal bars90,100in the horizontal direction98(FIGS.11and12). Further, preferably, the process includes fixing at least one of bars90or100relative to the conveyors30,50,70and adjusting the other of the bars100or90relative to that bar. Additionally, or alternatively, preferably the process includes adjusting both bars90and100relative to the conveyors30,50,70and relative to each other bar100,90. In this way, and without being limited to a theory of understanding, this enables various tri-fold configuration sizes of middle portion22of the material relative to right side26and left side28, when material20is folded. For example, the middle portion width in horizontally direction98is determined by the horizontal spacing of the bars90,100, and so can make the middle be a true one-third of the overall width of material20, or something less or greater than that, as desired. Further, more preferably, the process includes temporarily fixing the bars90,100relative to one another when being used to fold the material around the bars. However, it is also contemplated that the process can include moving at least one of the bars90,100relative to the other bar100,90, even during folding, as may be desired to further assist with the folding process, especially in such a tri-fold configuration.

In still other aspects, the process can include adjusting one or more of horizontal conveyors30,50and70in the horizontal direction44and/or horizontal direction64(FIGS.13and14). Further, preferably, the process includes fixing at least one of bars90or100relative to the conveyors30,50,70and adjusting the other of the bars100or90relative to that bar. Additionally, or alternatively, preferably the process includes adjusting one or both of conveyors50and70be positioned a sufficient distance to cause the right longitudinal gap between conveyors50and70to be centered under bar100(but an off-set positioning of this gap can be used too, if desired). In this way, and without being limited to a theory of understanding, this enables even more tri-fold configuration sizes of middle portion22of the material relative to right side26and left side28, when material20is folded. For example, the middle portion width in horizontally direction98is determined by the horizontal spacing of the bars90,100, and so can make the middle be a true one-third of the overall width of material20, or something less or greater than that, as desired.

Additional discussion of embodiments in various scopes now follows:A. A tri-fold machine to fold up compressed high expansion force material. The machine includes a left-side horizontal conveyor next to a middle conveyor with a left longitudinal gap formed between the left-side horizontal conveyor and the middle conveyor. The machine also includes a right-side horizontal conveyor next to an opposite side of the middle conveyor with a right longitudinal gap formed between the right-side horizontal conveyor and the middle conveyor. An upper surface of each of the left-side horizontal conveyor and the right-side horizontal conveyor is defining a horizontal plane. The machine also includes a left longitudinal bar operable between (i) a raised position where a bottom surface is spaced from and above the horizontal plane and (ii) a lowered position where the bottom surface is located closer to the horizontal plane than in the raised position. Further, the machine includes a right longitudinal bar operable between (i) a raised position where a bottom surface is spaced from and above the horizontal plane and (ii) a lowered position where the bottom surface is located closer to the horizontal plane than in the raised position. The right-side conveyor is movable between a horizontal home position and a folding position. The folding position is where the right-side conveyor is located above and extending over the middle conveyor. The left-side conveyor is movable between a horizontal home position and a folding position. The folding position is where the left-side conveyor is located above and extending over the middle conveyor.B. The machine of any of the prior embodiments, wherein the folding position of the right-side conveyor comprises the right-side conveyor located above and extending over the right longitudinal bar.C. The machine of any of the prior embodiments, wherein the folding position of the right-side conveyor comprises the right-side conveyor located above and extending over the left longitudinal bar.D. The machine of any of the prior embodiments, wherein the folding position of the left-side conveyor comprises the left-side conveyor located above and extending over the left longitudinal bar.E. The machine of any of the prior embodiments, wherein the folding position of the left-side conveyor comprises the left-side conveyor located above and extending over the right longitudinal bar.F. The machine of any of the prior embodiments, wherein the left longitudinal bar and the right longitudinal bar are coupled together such that each longitudinal bar is movable between the raised position and the lowered position simultaneously.G. The machine of any of the prior embodiments, wherein the bottom surface of at least one of the left longitudinal bar and the right longitudinal bar is equal with to below the horizontal plane when in the lowered position.H. The machine of any of the prior embodiments, further including the compressed high expansion force material positionable on the left-side conveyor and the right-side conveyor with the left longitudinal bar overlying a middle portion of the material and the bottom surface of the left longitudinal bar spaced from a top surface of the material when the left longitudinal bar is in the raised position.I. The machine of any of the prior embodiments, wherein the bottom surface of the left longitudinal bar is in contact with the top surface of the material when the left longitudinal bar is in the lowered position.J. The machine of any of the prior embodiments, wherein the left longitudinal bar presses the material into the left longitudinal gap when the left longitudinal bar is in the lowered position.K. The machine of any of the prior embodiments, further including a pusher bar located adjacent a proximal end of the middle conveyor and operable to move longitudinally from the proximal end of the middle conveyor to a distal end of the middle conveyor.L. The machine of any of the prior embodiments, wherein the left-side horizontal conveyor and the right-side horizontal conveyor each have a movable surface to locate the material into a material folding position relative to the left longitudinal bar and the right longitudinal bar.M. The machine of any of the prior embodiments, wherein the folding position of the right-side conveyor comprises a left edge of the right-side conveyor located above and extending over the middle conveyor.N. The machine of any of the prior embodiments, wherein the folding position of the left-side conveyor comprises a right edge of the left-side conveyor located above and extending over the middle conveyor.O. The machine of any of the prior embodiments, wherein the left longitudinal bar is sized to fit in the left longitudinal gap.P. The machine of any of the prior embodiments, wherein the right longitudinal bar is sized to fit in the right longitudinal gap.Q. The machine of any of the prior embodiments, wherein at least one of the left longitudinal bar and the right longitudinal bar is adjustable relative to each other.R. The machine of any of the prior embodiments, wherein adjustable comprises in a horizontal direction relative to each other.S. The machine of any of the prior embodiments, wherein adjustable comprises in a vertical direction relative to each other.T. The machine of any of the prior embodiments, wherein at least one of the left-side horizontal conveyor, the right-side horizontal conveyor and the middle conveyor is adjustable relative to at least one other conveyor.U. The machine of any of the prior embodiments, wherein the conveyor(s) being adjustable comprises in a horizontal direction.V. The machine of any of the prior embodiments, further comprising a restriction force that acts on each distal end of the left horizontal bar and the right horizontal bar to hold each distal end at a spaced apart location.W. A process for tri-folding a compressed high expansion force material. The process including positioning the material on a left-side horizontal conveyor and a right-side horizontal conveyor, with a middle conveyor located between the left-side horizontal conveyor and the right-side horizontal conveyor and a longitudinal gap formed on each side of the middle conveyor. And, pressing a middle portion of the material into the longitudinal gap formed on each side of the middle conveyor. The process also including folding a left side of the material over the middle portion of material. And, folding a right side of the material over the left side of the material which is located over the middle portion of the material. These steps can, preferably, occur in this order.X. The process of any of the prior process embodiments, further including releasing the middle portion of the material from being in the longitudinal gap formed on each side of the middle conveyor.Y. The process of any of the prior process embodiments, further including holding the right side of the material over the left side of the material.Z. The process of any of the prior process embodiments, further including pushing the material from a proximal end of the middle conveyor toward a distal end of the middle conveyor.AA. The process of any of the prior process embodiments, wherein holding and pushing occur simultaneously.BB. The process of any of the prior process embodiments, wherein folding the right side of the material comprises moving the right-side conveyor from a horizontal home position to a folding position where the folding position comprises locating the right-side conveyor above and extending over the middle conveyor.CC. The process of any of the prior process embodiments, wherein folding the left side of the material comprises moving the left-side conveyor from a horizontal home position to a folding position where the folding position comprises locating the left-side conveyor above and extending over the middle conveyor.DD. The process of any of the prior process embodiments, further including operating a pair of spaced apart longitudinal bars between (i) a raised position where a bottom surface is spaced from and above a horizontal plane defined by an upper surface of each of the left-side horizontal conveyor and the right-side horizontal conveyor and (ii) a lowered position where the bottom surface is located closer to the horizontal plane than in the raised position.EE. The process of any of the prior process embodiments, wherein pressing the middle portion comprises moving the pair of spaced apart longitudinal bars into the lowered position and the bottom surface presses the material into the longitudinal gap.FF. The process of any of the prior process embodiments, further including simultaneously positioning the pair of longitudinal bars together.GG. The process of any of the prior process embodiments, wherein positioning comprises operating a surface of each of the left-side horizontal conveyor and the right-side horizontal conveyor to locate the material into a material folding position.HH. The process of any of the prior process embodiments, wherein folding of the right side of the material further comprises positioning a left edge of the right-side conveyor above and extending over the middle conveyor.II. The process of any of the prior process embodiments, wherein the folding of the left side of the material further comprises positioning a right edge of the left-side conveyor above and extending over the middle conveyor.JJ. The process of any of the prior process embodiments, further including adjusting at least one of the left longitudinal bar and the right longitudinal bar relative to each other.KK. The process of any of the prior process embodiments, wherein adjusting comprises moving in a horizontal direction relative to each other.LL. The process of any of the prior process embodiments, wherein adjusting comprises moving in a vertical direction relative to each other.MM. The process of any of the prior process embodiments, wherein adjusting comprises moving the at least one of the left longitudinal bar and the right longitudinal bar before both folding steps begin.NN. The process of any of the prior process embodiments, further comprising adjusting at least one of the left-side horizontal conveyor, the right-side horizontal conveyor and the middle conveyor relative to at least one other conveyor.OO. The process of any of the prior process embodiments, wherein adjusting the conveyor(s) comprises in a horizontal direction.PP. The process of any of the prior process embodiments, further comprising restricting each distal end of the left horizontal bar and the right horizontal bar at a spaced apart location relative to each other during the folding steps.

Each and every document cited in this present application, including any cross referenced or related patent or application, is incorporated in this present application in its entirety by this reference, unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any embodiment disclosed in this present application or that it alone, or in any combination with any other reference or references, teaches, suggests, or discloses any such embodiment. Further, to the extent that any meaning or definition of a term in this present application conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this present application governs.

The invention includes the description, examples, embodiments, and drawings disclosed; but it is not limited to such description, examples, embodiments, or drawings. As briefly described above, the reader should assume that features of one disclosed embodiment can also be applied to all other disclosed embodiments, unless expressly indicated to the contrary. Unless expressly indicated to the contrary, the numerical parameters set forth in the present application are approximations that can vary depending on the desired properties sought to be obtained by a person of ordinary skill in the art without undue experimentation using the teachings disclosed in the present application. Modifications and other embodiments will be apparent to a person of ordinary skill in the packaging arts, and all such modifications and other embodiments are intended and deemed to be within the scope of the invention.