Abstract: An apparatus and method for forming zig-zag folded logs of web material is provided. The apparatus and method allows for forming logs having different sheet lengths on a same machine. Logs of web material having weakened regions at different locations between folds in the zig-zag folded web are also provided.

Abstract: 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.

Abstract: A web processing roll for handling a web of material using vacuum is provided. The web processing roll includes a roll body. The roll body defines an outer periphery against which the web of material is held. The roll body defines a vacuum passage. At least one first vacuum hole fluidly connects to the vacuum passage provides vacuum proximate the outer periphery of the roll body to hold the web of material against the outer periphery with vacuum supplied to the at least one first vacuum hole by the vacuum passage. A first flow path of the vacuum hole extends at a first angle that is non-perpendicular to the rotational axis and is directed, at least in part, axially toward one of the first and second ends at the first outlet end of the at least one first vacuum hole.

Abstract: A web processing roll for handling a web of material using vacuum is provided. The web processing roll includes a roll body. The roll body defines an outer periphery against which the web of material is held. The roll body defines a vacuum passage. At least one first vacuum hole fluidly connects to the vacuum passage provides vacuum proximate the outer periphery of the roll body to hold the web of material against the outer periphery with vacuum supplied to the at least one first vacuum hole by the vacuum passage. A first flow path of the vacuum hole extends at a first angle that is non-perpendicular to the rotational axis and is directed, at least in part, axially toward one of the first and second ends at the first outlet end of the at least one first vacuum hole.

Abstract: 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.

Abstract: A processing roll having rotatable outer tube mounted on a non-rotatable inner tube by a fluid valving arrangement, is provided. The fluid valving arrangement provides angularly controlled transfer of fluid between a cavity on the inside of the inner tube and ports distributed longitudinally along an outer surface of the outer tube, while also providing distributed bearing support of either the outer tube on the inner tube, or the inner tube on the outer tube, at a plurality of locations along a longitudinal axis of the processing roll.

Abstract: A method and apparatus are provided, for forming a stack of interfolded sheets of porous material including a leading panel having a partial-panel width joined along a fold line to a trailing panel having a full-panel width, by controlling the position of leading edges of the sheets both upstream and downstream from the nip between the interfolding rolls of the folding machine with vacuum applied through corresponding vacuum ports disposed in the periphery of the folding rolls at circumferential distances equal to the partial panel length ahead of each gripper and tucker in the direction of rotation. Sufficient suction is applied to hold both the leading edge of the leading panel of a given sheet and an underlying portion of the trailing panel of the immediately preceding sheet against the periphery of one of the other of the rolls downstream from the nip.

Abstract: A processing roll having rotatable outer tube mounted on a non-rotatable inner tube by a fluid valving arrangement, is provided. The fluid valving arrangement provides angularly controlled transfer of fluid between a cavity on the inside of the inner tube and ports distributed longitudinally along an outer surface of the outer tube, while also providing distributed bearing support of either the outer tube on the inner tube, or the inner tube on the outer tube, at a plurality of locations along a longitudinal axis of the processing roll.

Abstract: Apparatuses and methods of forming discrete stacks of a plurality of zig-zag folded panels are provided. The apparatus and methods include defining a sheet to form all of the panels of the discrete stack of panels. The sheet may be defined by cutting the sheet from the web prior to folding the web into the interconnected panels for each sheet. The sheet may be defined by forming a separation line prior to folding the web into the interconnected panels for each sheet and then separating the sheet from the web of material at the separation line after the web of material is folded into the interconnected panels.

Abstract: A method and apparatus are provided, for forming a stack of interfolded sheets of porous material including a leading panel having a partial-panel width joined along a fold line to a trailing panel having a full-panel width, by controlling the position of leading edges of the sheets both upstream and downstream from the nip between the interfolding rolls of the folding machine with vacuum applied through corresponding vacuum ports disposed in the periphery of the folding rolls at circumferential distances equal to the partial panel length ahead of each gripper and tucker in the direction of rotation. Sufficient suction is applied to hold both the leading edge of the leading panel of a given sheet and an underlying portion of the trailing panel of the immediately preceding sheet against the periphery of one of the other of the rolls downstream from the nip.

Abstract: An interfolding apparatus including first and second interfolding rolls. The interfolding rolls issue a stream of web material to form a stack of interfolded web material. A first packer finger is movable with respect to the first interfolding roll and includes a retracted position at least partially received within the first interfolding roll and an extended position at least partially inserted into the stream of interfolded web material. A second packer finger is movable with respect to the first interfolding roll and includes a retracted position at least partially received within the first interfolding roll and an extended position at least partially inserted into the stream of interfolded web material.

Abstract: A fluid valve for controlling fluid flow and/or vacuum to a plurality of ports and fluid lines in a rotating member has a rotary phase plate with a plurality of apertures therein which can be brought into fluid communication with selected ports and fluid lines in the rotating member by rotation of the rotary phase plate to one of at least two rotational positions with respect to the rotating member. Preferably, the fluid valve has at least a rotary union adapter coupling the rotary phase plate to a one-port rotary union or a roll adapter coupling the rotary phase plate to the rotating member. Most preferably, the fluid valve has both such adapters.