Apparatus and method for high speed cross folding

A machine for folding discrete items comprising:

• a first conveying unit for carrying said discrete items on a first side at a first velocity in a machine direction;
• a first rotating drum rotating in a machine direction, said first rotating drum carrying said discrete items on a second side at a leading portion, said first rotating drum providing a holding force to said second side of said discrete items;
• a folding finger disposed in a folding plane over which said discrete items are folded, said folding finger disposed in a constant cross-machine direction orientation and traveling in said folding plane so as to be maintained in said folding plane, said folding finger contacting a midsection of said discrete items on said second side;
• and
• a second rotating drum rotating in said machine direction and carrying said leading portion of said discrete items on said first side at said first velocity, and laying down said leading portion of said discrete items atop a trailing edge of said discrete items, said second rotating drum providing a holding force to said first side of said discrete items;
• wherein said folding finger travels about a travel path such that said folding finger passes between said first rotating drum and said first conveying unit as said first rotating drum carries said second side, and such that said folding finger passes between said second rotating drum and said first conveying unit as said second rotating drum carries said first side;
• wherein said folding finger is maintained in said constant cross-machine direction orientation and in said folding plane as said folding finger travels about an entirety of said travel path.

A machine for folding discrete items comprising:

• a first conveying unit for carrying said discrete items at a first velocity on a first side in a machine direction during a folding operation;
• a first rotating drum rotating in a machine direction, said first rotating drum carrying said discrete items on a second side at a leading portion, said first rotating drum providing a holding force to said discrete items;
• a folding finger contacting a midsection of said discrete items on said second side, said folding finger carried at a first point of said folding finger by a first rotating unit, said first rotating unit spaced at a first cross-machine direction distance from said first conveying unit;
• said folding finger carried at a second point of said folding finger by a second rotating unit, said second rotating unit spaced at a second cross-machine direction distance from said first conveying unit, said second cross-machine direction distance greater than said first cross-machine direction distance;
• said first and second rotating units operating to retain said folding finger in substantially the same plane throughout rotation thereof, about an entirety of a travel path about which said folding finger travels;
• said first and second points of said folding finger spaced apart at a constant cross-machine direction distance from each other, and said first and second points of said folding finger spaced apart at a variable cross-machine direction distance from said first conveying unit;
• a second rotating drum rotating in the machine direction and carrying said leading portion of said discrete items on said first side at said first velocity, and laying down said leading portion of said discrete items atop a trailing edge of said discrete items, said second rotating drum providing a holding force to said discrete items;
• wherein said folding finger is maintained in a constant cross-machine direction orientation throughout rotation thereof about said travel path by said first and second rotating units.