High speed interfolder

A method for interfolding sheets cut sequentially from a single web of material, the method comprising:

• issuing a single web of material in a downstream direction from a source;
• cutting with a knife roll the stream of web material into successive sheets following substantially the same path during interfolding;
• rotating an additional roll at a first roll speed;
• transferring each sheet to the additional roll;
• rotating a folding roll at a second roll speed;
• transferring each sheet to the folding roll;
• slowing the sheet with the folding roll, overlapping adjacent portions of the successive sheets onto the folding roll;
• and
• interfolding the overlapped sheets.

An interfolding apparatus, for interfolding sheets cut sequentially from a single web of material, comprising:

• a knife roll rotatable about an axis and operable to cut sheets from a stream of the single web of material issuing from a source in a downstream direction;
• a folding roll positioned downstream of the knife roll and adapted to receive the sheets, the folding roll rotatable in a first direction;
• and
• a lap roll adjacent the folding roll rotatable about an axis in a second direction, the lap and folding roll defining a nip therebetween;
• wherein the sheets are directly transferred from the lap roll to the folding roll to overlap adjacent portions of successive sheets cut from the single web of material onto the folding roll.

A method for interfolding sheets cut sequentially from a single web of material the method comprising:

• issuing a single web of material in a downstream direction from a source;
• cutting with a knife roll the stream of web material into successive sheets which successively follow substantially the same path during interfolding;
• transferring each sheet to a rotating lap roll;
• transferring each sheet directly from the lap roll to a rotating folding roll;
• overlapping a trailing edge of a first sheet with a leading edge of a second successive sheet on the folding roll;
• and
• interfolding the overlapped sheets.