Stack of folded hygiene products and method and apparatus for producing same

Abstract

A method for producing stacks of individual web sections involves: (a) directing the continuous web to a perforating station; (b) perforating the continuous web at predetermined intervals and forming sheets of web material between consecutive perforation lines extending laterally across the continuous web, the perforating being carried out via at least one perforation element arranged at the circumference of a perforation roller; (c) directing the continuous web to a cutting station; (d) cutting at second predetermined intervals the continuous web into web sections via a cutting element acting against an anvil element, to generate a clear cut or a tab-bond; (e) folding the web sections via a folding roll; and (f) stacking the folded web section to generate a stack of folded sheets.

Claims

1. A method for producing stacks of individual web sections from a continuous web of material, comprising the steps of: (a) directing the continuous web to a perforating station; (b) perforating the continuous web at predetermined intervals and forming sheets of web material between consecutive perforation lines extending laterally across the continuous web, the perforating being carried out via at least one perforation element arranged at the circumference of a perforation roller; (c) directing the continuous web to a cutting station; (d) cutting at second predetermined intervals the continuous web into web sections via a cutting element acting against an anvil element, to generate a clear cut or a tab-bond; (e) folding the web sections via a folding roll; and (f) stacking the folded web sections to generate a stack of folded sheets; wherein in step (b) the continuous web is frictionally held and transported at a controlled speed via a web tensioning device arranged upstream and downstream of the perforating station, wherein the web tensioning device comprises two rollers upstream of the perforating station, with a gap between the rollers and the continuous web such that the continuous web is not pinched between the rollers.

2. The method according to claim 1, comprising, after step (e) and before step (f): (e2) adding adhesive properties to the folded web sections.

3. The method according to claim 2, wherein in step (e2) adhesive is selectively ejected onto the folded web sections.

4. The method according to claim 2, wherein in step (e2) an adhesive strip or a hook and loop fastener element is applied onto the folded web sections.

5. The method according to claim 1, wherein in steps (a) and (c), the continuous web is brought to a controlled speed.

6. The method according to claim 5, wherein a first speed in step (a) and a second speed in step (c) are different.

7. The method according to claim 6, wherein the second speed is higher than the first speed.

8. The method according to claim 1, wherein in step (b) a circumferential speed V1 of the perforation roller is adjusted to be different to a transport speed V2 of the continuous web at a position at which the continuous web is perforated, the circumferential speed Viand the transport speed V2 being controlled to fixed values satisfying the equation: 0.4× V2≤V1≤1.4× V2.

9. The method according to claim 1, wherein steps (a) to (d) are carried out in parallel for two separate continuous webs; and in step (e) the web sections formed from the two separate continuous webs are interfolded to form a stack of interfolded sheets.

10. The method according to claim 1, wherein the continuous web of material is a hygiene or wiping material.

11. The method according to claim 1, wherein the continuous web of material is selected from the group of paper towels, facial tissue, cosmetic tissue, napkins, kitchen towels, and toilet paper.

12. The method according to claim 1, wherein the web tensioning device further comprises two rollers downstream of the perforating station, with a gap between the rollers and the continuous web such that the continuous web is not pinched between the rollers.

13. The method according to claim 1, wherein the web tensioning device is designed to frictionally hold and transport the web at a controlled speed, the web tensioning device being an S-wrap around two rollers.

14. An apparatus for producing stacks of sheets from a continuous web of material, comprising: a perforating station with a rotatable perforation roller comprising at least one perforation element arranged at the circumference of the perforation roller, wherein the at least one perforation element is adapted to generate a perforation line; a cutting station comprising a cutting element and an anvil element, wherein the cutting element is adapted to generate a clear cut or a tab-bond; a folding station with a folding roll; a stacking station to form a stack of sheets; and a web tensioning device arranged upstream and downstream of the perforating station, wherein the web tensioning device comprises two rollers upstream of the perforating station, with a gap between the rollers and the continuous web such that the continuous web is not pinched between the rollers.

15. The apparatus according to claim 14, wherein the anvil element is a rotating anvil roller.

16. The apparatus according to claim 14, wherein the cutting element is a reciprocating cutting knife operable via a cam mechanism to which the cutting knife is coupled.

17. The apparatus according to claim 14, wherein the cutting element is an electrically operated reciprocating cutting knife.

18. The apparatus according to claim 14, the perforation roller having several perforation knives distributed over the peripheral surface of the perforation roller, wherein at least one of the perforation knives is adapted to be selectively activated or to be put in an idle state.

19. The apparatus according to claim 14, wherein the at least one perforation element is helically arranged on the circumferential surface of the perforation roller.

20. The apparatus according to claim 14, wherein the web tensioning device is designed to frictionally hold and transport the web at a controlled speed, the web tensioning device being an S-wrap around two rollers.

21. The apparatus according to claim 14, wherein the cutting element is adapted to generate a tab-bond; and the stacking station comprises a separating element to separate the web material at the tab bond.

22. The apparatus according to claim 21, wherein the separating element is a separating finger.

23. The apparatus according to claim 21, the stacking station further comprising a counting device adapted to determine a length of a web section.

24. The apparatus according to claim 14, wherein the folding roll is operatively coupled to a source of sub-atmospheric pressure.

25. The apparatus according to claim 14, wherein the continuous web of material is a hygiene or wiping material.

26. The apparatus according to claim 14, wherein the continuous web of material is selected from the group of paper towels, facial tissue, cosmetic tissue, napkins, kitchen towels, and toilet paper.

27. The apparatus according to claim 14, wherein the web tensioning device further comprises two rollers downstream of the perforating station, with a gap between the rollers and the continuous web such that the continuous web is not pinched between the rollers.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In the following, examples will be described by means of a specific preferred embodiment of the present disclosure. In the drawings,

(2) FIG. 1 shows a cross-sectional view of a stack of hygiene sheet products comprising first and second webs that are interfolded with each other;

(3) FIG. 2 schematically shows a stack of hygiene sheet products, either consisting of one web section or two web sections with an adherence layer provided on the top side of the stack;

(4) FIGS. 3a and 3b schematically show another stack of hygiene sheet products consisting of two interfolded web sections;

(5) FIGS. 4 and 5 schematically show the method and apparatus for producing interfolded sheets of hygiene products.

DETAILED DESCRIPTION

(6) In the following description, the same or similar elements will be denoted by the same reference numerals throughout the individual drawings.

(7) FIG. 1 shows a stack 1 of interfolded webs, namely the (first) web section 2 and the second web section 3. the first and second web sections 2, 3 are divided into separable hygiene sheet products (e.g. paper hygiene product, paper towel products, tissue products, or the like) by perforation lines 4 extending laterally across the elongate webs 2, 3. The perforation lines 4 are illustrated in FIG. 1 with filled-in circles for clarity. Although the term “perforation line” is used, the above-given definition applies that this term is supposed to define intermittent or continuous weakenings, where the remaining strength of the web ranges between 4% and 50% and preferably between 4% and 15%.

(8) The perforation lines 4 for the first web section 2 are positioned offset from the perforation lines 4 for the second web sections 3 along the longitudinal direction of the web sections 2, 3 so that, if the first web section 2 is pulled through a dispensing opening, the second web section 3 will be pulled through the dispensing opening with it. The first web section 2 will thus brake at the first perforation line 4 in the dispensing order to leave a pull tab portion of the second web portion 3 protruding beyond the end of the first web section 2 for convenience of grasping at the dispensing opening. This process will alternate during dispensing of the stack 1 so that a separable sheet product of the second web section 3 is presented more forwardly than a product of the first web section 2 relative to the dispensing opening, which will then be the product that is dispensed by a user and then a product of the first web section will be more forwardly presented at the dispensing opening for the dispensing by a user, as a result of the offset perforation lines of the first web section 2 and the second web section 3. Such a stack ensures one at a time dispensing of hygiene sheet products, while also ensuring that the first and second web sections 2, 3 move together along a dispensing path as a result of face-to-face interaction of the webs 2, 3.

(9) The perforation lines 4 of the first web section 2 and the second web section 3 define separable sheets of the stack 1. The interfolding pattern for the stack 1 shown in FIG. 1 is such that each separable sheet 5 is folded at a fold line 6 to form first and second panels 7, 8 for each sheet 5. The interfolding pattern is also such that fold line 6 of one of the web sections 2, 3 is provided at each perforation line 4 of the other of the web sections 2, 3. In this way, the interfolding pattern provides a fold line 6 for the first web section 2 at a perforation line 4 for the second web section 3 and correspondingly a perforation line 4 for the first web section 2 at a fold line 6 of the second web section 3.

(10) The example given in FIG. 1 is just one manner of interfolding first and second web sections 2, 3 providing separable sheets 5 in an offset manner relative to a dispensing opening containing the stack 1. Other implementations can be provided. For example, the perforation lines 4 may be positioned offset from the fold lines 6 of the other web, rather than being aligned with a fold line 6 as shown in FIG. 1. Further, the first and second web sections 2, 3 may be folded such that each sheet 5 can be of any length. Each sheet includes more than two panels 7, 8 as shown, such as three, four, five or more panels. The variable length leads to panels having a size different to that of adjacent panels which could e.g. sum up to a total length of 4.2 panels.

(11) Further, shown in FIGS. 1 and 2, is a top surface 10 of the stack 1 which is a planar surface that can be seen when the stack 1 is viewed from above looking down at the top of the stack 1. The top surface 10 is defined partly by a top panel 11 of the first web section 2 and partly by a top panel 12 of the second web section 3. The top panel 11 of the first web section 2 overlays the top panel 12 of the second web section 3 but is cut away along an end edge 13 (FIG. 2) so as to reveal the underlaying top panel 12 of the second web section 3. As can be seen in FIGS. 1 and 2, the size of the top panel 11 is smaller than that of the adjacent panel of the same sheet. This makes it possible to use an adherence layer 14 which, in the present embodiment, is partly applied on the top panel 11 of the first web section 2 and partly on the top panel 12 of the second web section 3. The adherence layer can be embodied by doubled sided adhesive tape. One side of the adhesive tape 14 is adhered to the top panels 11, 12. The double sided adhesive tape 14 may include a release liner to shield the underlaying sticky tape during processing and which is to be removed when the stack is positioned against an adjacent stack in the dispenser so that the two stacks a secured together.

(12) In the embodiments as shown in FIGS. 1 and 2, the adherence layer 14 is elongate and extends parallel to the fold lines 6. The adherence layer could also be applied perpendicular to the configuration shown and still be able to serve the purpose of being applied on both the first and the second web sections 2, 3 so as to stick both first and second web sections 2, 3 to the last hygiene products or product of a preceding stack in a dispenser. Other adherence layers may be used than double sided adhesive tape with a release liner. For example a strip of glue may be rolled or sprayed on the first and second web sections 2, 3. Another example would be the use of one component of a hook and/of loop fastener which may require the other component of the hook and/or loop fastener to be provided at the bottom of the preceding stack in a dispenser. Alternatively, a hook component could be provided that it is adhereable directly to the material, e.g. on paper based material, at the bottom of a preceding stack by nature of the fineness of the hooks. In this alternative a mating loop component would not be necessary. However, in many cases a mating component is included as shown with reference numeral 15 in FIG. 1.

(13) FIGS. 3a and 3b additionally show the top panel 12 of the second web section 3 which has a size different to the top panel 11 of the first web section 2. Accordingly, there is a second end edge 13b at a distance a.sub.2 to the side edge of the stack 1 which is different to the distance a.sub.1 of the end edge 13 of the first web section 2. The distances a.sub.1, a.sub.2 are only represented by way of example. The inventive method and device gives total freedom with regard to the dimensions of the individual top panels.

(14) Referring now to the corresponding adherence layer 15 as shown in FIG. 1, which is provided at a bottom surface 16 of the stack, it can be seen that the bottom surface 16 of the stack 1 is defined partly by a bottom panel 17 of the second web section 3 and a bottom panel 18 of the first web section 2. The bottom panel 17 of the second web section 3 overlays the bottom panel 18 of the first web section 2 and has been cut away in a complementary way to that as described above for the top panels 11, 12 of the first and second web sections 2, 3. This complementary end edge at opposing ends of the stack 1 is a convenient result of the manufacturing process in that cutting way a top panel of the stack 1 so as to reveal an underlaying panel will provide a complementary cut in the next stack in the manufacturing process, thereby resulting in each stack produced having complementary end edges at the top and bottom surfaces thereof.

(15) It should be noted that the configuration as shown in FIG. 2 is also applicable to a product with only one single web section. Due to the complementary position of the end edges on the top surface and bottom surface of the stack 1, the same position of the adherence layer 14 on top and on bottom of the stack ensures an appropriate fixing together of subsequent stacks. Further, the geometry can be selected such that service personnel does not have to differentiate what is the top surface and what is the bottom surface of the stack. Top surface and bottom surface can be provided symmetrically.

(16) FIG. 4 schematically shows the method and apparatus for producing a stack of interfolded sheets as shown in FIG. 1.

(17) A first continuous web 2a and a second continuous web 2b are continuously conveyed to a first tensioning device 20, respectively. The first tensioning device consists of two rollers which are rotated in opposite directions A and B and around which the first web 2a and second web 2b are wound in an S-shaped manner. There is a gap between the two rollers 21, 22 so that the webs 2a, 2b are not pinched in a nip between the two tensioning rollers. Due to the S-shaped contact of the webs around the rollers 21, 22, a high contact area between the web and the rollers is generated leading to a high friction between the webs and the rollers. In order to increase the friction, conventional methods can be applied like varying the surface roughness of the circumferential surface of rollers 21, 22. A convenient way of increasing the friction is to cover the circumferential surfaces of the rollers with tungsten. Due to the friction between the webs 2a, 2b and the first tensioning device 20, the transport speed of the webs 2a, 2b is brought exactly to the circumferential speed of rollers 21, 22.

(18) After leaving the first tensioning device 20, the webs 2a, 2b are directed to perforation stations 27 with perforation rollers 24 which act against anvil elements 25, respectively. The perforation rollers 24 are rotated at a circumferential speed which can be different to the transport speed of the webs 2a, 2b. The circumferential speed of the perforation rollers can be adjusted within a range of −60% and +40% relative to the conveying speed of the webs 2a, 2b.

(19) The perforation rollers are provided with several perforation knives 26 which, according to a preferred embodiment, can be selectively activated or put in an idle state. This serves to use the device as schematically shown in FIG. 3 for various types of sheets consisting of two, three, four or even a higher number of panels for each sheet.

(20) The perforation rollers generate perforation lines which run perpendicular to the length direction of the webs 2a, 2b. In order to avoid vibration of the perforation rollers, the time period of the perforation action can be extended by providing helical perforating elements to generate a continuously moving position at which a perforating element penetrates into the webs 2a, 2b.

(21) Subsequent to the perforation rollers 24, there is a second tensioning device 20 which uses the same principle as explained above for the first tensioning device.

(22) Preferably, the conveying speed of webs 2a, 2b at the second tensioning device is slightly higher than the conveying speed of the webs at the first tensioning device. The difference in speed can be up to 1%. This serves to tighten the web at the position at which the webs run through the perforating stations 27.

(23) After leaving the second tensioning device, the webs 2a, 2b are directed to a cutting station 31 comprising anvil rollers 37 and cutting knives 38 which are functionally coupled to a suitable mechanism 39 which moves the cutting knife 38 in a reciprocating manner. When operated, the cutting knife 38 provides either a clean cut or a tab-bond so as to divide the webs 2a, 2b into individual web sections 2, 3. The web sections are then transported to the vacuum folding device generally denoted by reference numeral 40. The mechanism 39 can be a cam mechanism or an electrically operated mechanism like a piezoelectric actuator.

(24) When leaving the cutting station 31, the web sections 2, 3 are directed to a vacuum station 40 with vacuum folding rollers 32 which are connected to a device 33 generating sub-atmospheric pressure at parts of the circumference of the vacuum folding rollers 32. This serves to make the webs alternately adhere to one of the two vacuum folding rollers which operatively cooperate with packer fingers 34 which are moved in the direction of arrows E and are used to separate the two web sections 2, 3 from the vacuum folding rolls 32 and to direct the folded web sections 2, 3 into the stacking station 50.

(25) The stacking device 36 can be of any conventional type known to a skilled person. It is provided with a loader finger 42 adapted for a reciprocating movement in the direction of arrow F, separator fingers 43 moving upwards and downwards in the vertical stacking arrangement as shown in FIG. 3 and count fingers 44 which work together to count a predetermined number of folded sheets before the separator fingers cut off the web sections in case of still existing tab-bonds and before a finished stack is moved downwards and conveyed by loader finger 42 in the direction perpendicular to the stacking direction and away from the device.

(26) FIG. 5 is very similar to FIG. 4 and serves to schematically show a different type of tensioning device. In FIG. 5, tensioning devices 28 upstream and downstream the perforating device 27 are used which are embodied as the nip between two rollers 29, 30 rotating in opposite directions C, D. The first and second tensioning devices 20, 28 as shown in FIGS. 4 and 5 are only examples of possibilities to provide a tensioning of webs 2a, 2b and any variation of S-wraps around rollers and nips between rollers can be freely varied.

(27) Although in the schematical representation in FIG. 3 a horizontal stacking machine has been shown, the key aspect of the embodiment can also be realized when using a horizontal stacking machine. It is the key aspect of the embodiment that besides the perforating device 27, a separate cutting device 31 is provided so that the position of the end edges of the top panels within one stack can be freely selected according to the specific needs of the user. The perforation lines can be made mechanically strong enough so that they can withstand the gravity force in an upwards dispensing dispenser with a considerable height of its supply magazine. Further, free selection can be made whether clear cuts or tap-bonds are realized in the cutting station since this operation is fully independent of the perforation step. When interfolding two web sections as shown in FIG. 3, the webs 2a, 2b are processed independently up to the folding rollers. Nevertheless, a central control unit is provided so that the perforation lines and clear cuts or tab-bonds can be adequately provided and positioned offset to each other in order to realize a stack as explained above with reference to FIG. 1.