Manufacturing container or tube from paper; or other manufacturi – Bending – Folding
Reexamination Certificate
1999-10-25
2001-05-29
Kim, Eugene (Department: 3721)
Manufacturing container or tube from paper; or other manufacturi
Bending
Folding
C493S443000, C493S379000
Reexamination Certificate
active
06238328
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates generally to a folded sheet material web and assembly, and in particular, to a specific arrangement of a starter sheet material web for a stack of folded webs. The invention also relates to a method and apparatus for folding the starter web.
It is well known in the field of facial tissue for an uppermost or starter web of a stack of longitudinally folded webs to be folded back on itself so as to provide a centrally located longitudinally folded edge on a top of the stack as described, for example, in U.S. Pat. No. 3,401,927, issued Sep. 17, 1968 to Frick, and assigned to Kimberly-Clark Corporation, the same assignee of the present application. The folded edge, and overlying folds of the starter web, are provided so as to allow a user to easily grasp and withdraw the uppermost web from the stack, which is typically retained within a carton or similar packaging. It is also well known in the art to provide a next lower web interfolded with the uppermost web so that a portion of the next lower web is withdrawn from the stack as the uppermost web is withdrawn. In this way, the next lower web is exposed to the user for successive removal from the stack.
Typically, the overlying folds of the starter web are arranged so that a single uppermost fold extends away from the centrally located longitudinally folded edge and terminates in a free edge proximate the side edge of the stack as shown in Frick U.S. Pat. No. 3,401,927. When arranged in such a configuration, a clip of webs, made from a stack of webs cut to a specified length, experiences what is commonly referred to as a “flying sheets” problem, wherein the top few sheets of the clip fly off the top of the clip as it is transported at high speeds from a saw, where the stack of webs is cut to form the clips, to a cartoner, where the clips are packaged in cartons and the like. Another problem typically encountered with a stack having a web with an uppermost fold terminating in a free edge, whether it be at the side of the stack or at a midpoint, is that the uppermost fold has a tendency to adhere both to a top pull-belt, which is used to urge the stack of webs from a folding board toward the saw, and to hold-down chains, which engage the top of the stack as it passes through the saw. In addition, because the uppermost fold presents two exposed edges, i.e., the centrally located longitudinally folded edge and the outer free edge, the folding process must be closely monitored so as to ensure that the free edge is proximate to the side edge of the stack. If the free edge extends past the side edge, it can be caught on the machinery and the like as the stack is conveyed from the folding board to the saw, and then as the clip is conveyed to the cartoner. Conversely, if the free edge is not aligned with, or falls short of, the side edge, it can present an aesthetically displeasing appearance to the user.
To combat the problem of “flying sheets” and adhesion, facial tissue manufacturers commonly are forced to reduce line speeds and/or incorporate additional manufacturing steps, such as spraying liquids on the top sheets, employing weights to hold the top sheets down, applying antistatic products to reduce static, cleaning surfaces to reduce static, and/or controlling the humidity/temperature in the relevant operating areas. Alternatively, additional folds or webs can be introduced in the top sheets, but with the adverse impact of requiring extra sheets to be dispensed on the initial withdrawal by the user. Therefore, the above-mentioned efforts can result in lower productivity, increased manufacturing costs or waste by the user.
Another problem encountered with a stack having only a single uppermost web is that the web is susceptible to tearing and the like upon removal by a user. This problem is especially acute when the uppermost web is interfolded with a next lower web, as the next lower web applies forces to the uppermost web as it is being withdrawn.
SUMMARY OF THE INVENTION
Briefly stated, the invention is directed to a sheet material assembly comprising a stack of longitudinally folded sheet material webs including a first web and second web. The first web includes a first fold, a second fold overlying a portion of the first fold, and a third fold lying between the first and second folds. The second web includes a first fold underlying the first fold of the first web, a second fold overlying the second fold of the first web, and a third fold lying between the first folds and the second folds of the first and second web.
In a preferred embodiment, the first and second folds of each of the first and second webs form a first longitudinally folded edge at a side of the stack, and the second and third folds form a second longitudinally folded edge intermediate the sides of the stack, and preferably at an approximate midpoint of the stack. Each of the third folds includes a longitudinal free edge lying between the first and second folds.
In one aspect of the invention, the longitudinal free edge of the third fold is proximate to the first longitudinal folded edge such that the first fold underlies substantially the entirety of the second fold.
In a preferred embodiment, the second and third folds of the first web are in contact, and the first, second and third folds of the first and second webs are in contact respectively.
In another aspect of the invention, a next lower web is interfolded with the first web, or the first and second webs, by providing a fold lying between the first and third folds of the webs. In a similar fashion, a plurality of next lower webs is progressively interfolded with the next lower web and each other.
In another aspect of the invention, a folding device is provided for folding a web of sheet material as described above. The folding device has a first, second and third folding edge formed in a first plane and extending from a first junction, with the third folding edge extending between the first and second folding edges. A fourth folding edge also extends from the first junction, but out of the first plane. The folding device also has a fifth and sixth folding edge formed in a second plane and extending from a second junction. The second junction is formed adjacent an end of the first edge opposite the first junction. The second plane is parallel to and positioned above the first plane. The fifth folding edge crosses over the third folding edge in a spaced apart relationship. Finally, the folding device includes a seventh folding edge that extends from the second junction, but out of the second plane.
In another aspect of the invention, the first, fourth and seventh folding edges form the edges of a first panel, the second and third folding edges form the edges of a second panel and the fifth and sixth folding edges form the edges of a third panel. In a preferred embodiment, the panels are formed out of a single piece of material, with a fourth panel interconnecting the first and second panels, and a fifth panel interconnecting the first and third panels.
In yet another aspect of the invention, a method is provided for forming the sheet material web described above. In particular, the first longitudinal fold is formed by drawing the web over the second, third and fourth folding edges of the folding device. The second longitudinal fold is formed in an overlying relationship with the first fold by drawing the web over the first folding edge of the folding device. Finally, the third longitudinal fold is formed in an overlying relationship with the first fold, and in an underlying relationship with the second fold, by drawing the web over the fifth, sixth and seventh folding edges of the folding device. In a preferred embodiment, a second web is applied to and aligned with the first web prior to the above-described forming process such that the two webs are folded together.
The present invention provides significant advantages over other longitudinally folded sheet material webs and assemblies. In particular, by folding the third fold between the first and s
Keating Brian E.
Loppnow Jay
Traugott David K.
Brinks Hofer Gilson & Lione
Kim Eugene
Kimberly--Clark Worldwide, Inc.
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