Apparatus for separating folded web

A web separator comprising:

• means for cutting a web at predetermined separation locations;
• means, positioned downstream of the means for cutting, for folding the web at predetermined fold locations;
• means, positioned downstream of the means for folding, for supporting the folded web in a zig-zag stack;
• said means for folding including swinging director means to guide advancing sections of web to opposing fold edges of the zig-zag stack wherein the swinging director means includes retracting finger means that elevates and extends a directing distance of the advancing web sections when the director is positioned relative to the furthest of the opposing fold edges;
• means for driving the web through the means for cutting into the director means at selected times;
• and
• means for determining each of separation and fold locations upon the web, each of the separation and fold locations being positionable independently of one another so that predetermined sections of web can be folded and cut to sizes different than other sections of web in a zig-zag group of sections.

A web separator comprising:

• means for cutting a web at predetermined separation location;
• means, positioned downstream of the means for cutting, for folding the web at predetermined fold location;
• means, positioned downstream of the means for folding, for supporting the folded web in a zig-zag stack;
• said means for folding including swinging director means to guide advancing sections of web to opposing fold edges of the zig-zag stack;
• means for driving the web through the means for cutting into the director means at selected times;
• means for determining each of separation and fold locations upon the web, each of the separation and fold locations being positionable independently of one another whereby predetermined sections of web can be folded and cut to sizes different than other sections of web in a zig-zag group of sections;
• and
• conveyor means disposed to transport away the zig-zag stack received from the means for supporting, the conveyor means including an upper conveyor belt and lower conveyor belt, the lower conveyor belt being disposed proximately below the upper conveyor belt and extending beyond an end of the upper conveyor belt, each of the upper conveyor belt and lower conveyor belt being separately powered and separately operable.

A method for directing web to opposing sides of a folder that folds a zig-zag pattern in the web comprising the steps of:

• providing a swinging director chute that directs a continuous web in a downstream direction along a path of web travel to a folder;
• rotating the director chute through an arc between each of opposing points;
• providing a secondary surface at a downstream end of the director chute, the secondary surface extending into a position along the path of web travel and retracting away from the path of web travel at selected times;
• and
• extending the secondary surface to provide additional support to the web when the swinging director chute is positioned proximate at least one of the opposing predetermined points.

A web separator comprising:

• a web drive that drives a continuous web in a downstream direction from a source;
• a cutter positioned downstream of the drive that separates the web at predetermined locations;
• a swinging director chute positioned downstream of and substantially adjacent the cutter, the director chute guiding the web therethrough and swinging through a predetermined arc to each of opposing points thereof;
• a folder positioned downstream of the swinging director chute, that folds the web from the director chute into a zig-zag pattern, the web having opposing zig-zag fold edges positioned with respect to each of the opposing predetermined points of the arc as the web is folded;
• and another web drive located on the director chute, constructed and arranged to drive the web out of the director chute and into the folder.