Patent ID: 7351190

Claim:
A method of constructing a folder system for folding a continuous web of material, the method comprising: coupling a system frame with a spiral folder assembly having a first set of rotatable spirals and a second set of rotatable spirals; coupling the system frame with a deflection means that alternates between a first position and a second position, the deflection means configured to guide the continuous web toward the first set of spirals when in the first position and toward the second set of spirals when in the second position; coupling the system frame with a beater assembly having a first beater configured to urge the continuous web against the first set of spirals to form a first fold in the web, and a second beater configured to urge the continuous web against the second set of spirals to form a second fold in the web; coupling the system frame with a first stop bar configured to restrain movement of the continuous web when the web is urged against the first set of spirals, and coupling the system frame with a second stop bar configured to restrain movement of the continuous web when the web is urged against the second set of spirals; and coupling the system frame with a conveyor assembly configured to receive and transport the folded continuous web as it exits the spiral folder assembly, the conveyor assembly providing a support disposed between a first vertical plane defined by the first set of spirals and a second vertical plane defined by the second set of spirals, the support adapted to modulate an amount of sagging in the continuous web as the web is suspended between the first set of spirals and the second set of spirals.