Embodiments of the present invention provide new and improved folding apparatuses and methods for interfolding a continuous stream of sheets into a single-fold interfolded pattern of sheets while passing all of the sheets substantially along a single sheet path. More particularly, all sheets in the continuous stream of sheets pass through the nips between adjacent components.

Embodiments of the present invention provide new and improved folding apparatuses and methods for interfolding a continuous stream of sheets into a single-fold interfolded pattern of sheets while passing all of the sheets substantially along a single sheet path. More particularly, all sheets in the continuous stream of sheets pass through the nips between adjacent components.

A web processing system is provided. The web processing system supplies a processed continuous web of material to a cutting arrangement. The cutting arrangement forms sheets from the continuous web of material. The sheets are then supplied to multiple folding arrangements such that a single web of material is used to supply sheets to multiple folding arrangements.

A web processing system is provided. The web processing system supplies a processed continuous web of material to a cutting arrangement. The cutting arrangement forms sheets from the continuous web of material. The sheets are then supplied to multiple folding arrangements such that a single web of material is used to supply sheets to multiple folding arrangements.

An interleaving unit, comprising a pair of rolls (1, 2) set alongside one another and counter-rotating and provided with respective first and second folding tools (3, 4; 5, 6) set at a distance from one another along the circumferential development of the respective peripheral surfaces so as to operate in a common point of tangency (Z) on a succession of sheets (7a, 7b) fed between the two rolls, said tools (3, 4; 5, 6) being set on respective mobile cylinder sectors (8, 9, 10, 11) to enable positioning thereof at an adjustable distance apart along the circumferential development of a corresponding roll (1, 2), said interleaving unit comprising means (M1, M2, U) for independently adjusting the speed of rotation of one or more of said sectors according to their angular position in order to reduce or increase the peripheral speed of said sectors with respect to a speed of feed (Vm) of said sheets.

An interleaving unit, comprising a pair of rolls (1, 2) set alongside one another and counter-rotating and provided with respective first and second folding tools (3, 4; 5, 6) set at a distance from one another along the circumferential development of the respective peripheral surfaces so as to operate in a common point of tangency (Z) on a succession of sheets (7a, 7b) fed between the two rolls, said tools (3, 4; 5, 6) being set on respective mobile cylinder sectors (8, 9, 10, 11) to enable positioning thereof at an adjustable distance apart along the circumferential development of a corresponding roll (1, 2), said interleaving unit comprising means (M1, M2, U) for independently adjusting the speed of rotation of one or more of said sectors according to their angular position in order to reduce or increase the peripheral speed of said sectors with respect to a speed of feed (Vm) of said sheets.

An interfolding machine (1) is described, including folding rollers (3). Such a roller has a cylindrical sleeve (3C) having a rotation axis (3A), an outer surface (3X) and an inner surface (3Y) defining an inner axial cavity (23) of the cylindrical sleeve (3C). The cylindrical sleeve includes, furthermore, a plurality of suction holes (41, 43) which extend from the outer surface (3X) to the inner surface (3Y) of the cylindrical sleeve (3C). The suction holes are arranged depending on longitudinal alignments (42, 44), parallel to the rotation axis (3A) of the cylindrical sleeve (3C) and angularly staggered in relation to one another. Inside a suction chamber (23A) in the cylindrical sleeve (3C), shutters are stationarily arranged having closing surfaces (37A) cooperating with the inner surface (3Y) of the cylindrical sleeve (3C) to selectively close the suction holes.

An interfolding machine (1) is described, including folding rollers (3). Such a roller has a cylindrical sleeve (3C) having a rotation axis (3A), an outer surface (3X) and an inner surface (3Y) defining an inner axial cavity (23) of the cylindrical sleeve (3C). The cylindrical sleeve includes, furthermore, a plurality of suction holes (41, 43) which extend from the outer surface (3X) to the inner surface (3Y) of the cylindrical sleeve (3C). The suction holes are arranged depending on longitudinal alignments (42, 44), parallel to the rotation axis (3A) of the cylindrical sleeve (3C) and angularly staggered in relation to one another. Inside a suction chamber (23A) in the cylindrical sleeve (3C), shutters are stationarily arranged having closing surfaces (37A) cooperating with the inner surface (3Y) of the cylindrical sleeve (3C) to selectively close the suction holes.

A method in which, while an article is carried with a main portion in contact with a carrying surface and a to-be-folded portion in contact with a folder plate, includes: a first guiding step, wherein a first guide surface guides the to-be-folded portion of the unfolded article, on a side of the carrying surface, in parallel to the carrying surface; a second guiding step, following the first guiding step, wherein a second guide surface, while being in contact with the to-be-folded portion, gradually raises the to-be-folded portion while moving downstream; and a third guiding step, following the second guiding step, wherein a third guide surface guides the to-be-folded portion so that the to-be-folded portion is folded onto the main portion.

Apparatuses and methods of forming sheets having different lengths are provided. The apparatuses and methods may also be used to form panel lengths of different values using a same processing roll. In some embodiments, the diameter of the roll need not change. In some embodiments, the spacing between adjacent rolls need not be changed when transitioning from one sheet length to another sheet length. In some embodiments, the processing roll includes an excess material receiving component that can be active or deactivated to switch between different sheet sizes.