Patent ID: 7223223

Claim:
A method of folding sheets into a selected configuration comprising the steps of: a. loading a predetermined number of unfolded sheets at an in-feed station; b. propelling the unfolded sheets one at a time in a downstream direction to a folder station; c. folding the unfolded sheets one at a time into respective folded sheets each having a selected configuration; d. discharging the folded sheets from the folder station onto an output conveyor; and e. holding on a telescoping stacker a number of folded sheets equal to at least the predetermined number of unfolded sheets, wherein the step of holding on a telescoping stacker comprises the further steps of: i. propelling the folded sheets by the output conveyor to the telescoping stacker; ii. providing a deck that supports a shaft of the output conveyor; iii. sliding a first tray from a retracted location whereat the first tray is nested substantially inside the deck to an extended location whereat the first tray is extended from the deck; iv. sliding a second tray from a first location whereat the second tray is nested substantially within the first tray to an extended location whereat the second tray extends from the first tray; and v. discharging the folded sheets from the folder station to the first tray and from the first tray to the second tray.