MXPA98004782A - Improved sheet products for use in an automatic supplier and a method for forming them from extended bands - Google Patents

Abstract

An improved method for forming overlapping sheet layers suitable for use in an automatic supply system is shown. The leaves (810, 811) are separated from the bands (S10, S11) which in principle have ends essentially parallel to the longitudinal axis of the band. At least one side end of each band is tensioned to form a knee-shaped protrusion, with the opposite lateral end substantially parallel to the longitudinal axis of the band, or also extended to form one or more knee-shaped protuberances at the opposite end . The bands (R10, R11) are then aligned so that the knee-shaped protrusion at one end aligns with either of the essentially parallel ends of an adjacent band or a knee-shaped protrusion at the lateral end of an adjacent band. After the phase adjustment, the bands overlap to create a series of predetermined areas of adjacent areas of greater overlap with less or no overlap, so that the successive bands are joined only by the entire interfacial intersection of each band. By overlapping multiple bands in this manner, layers are formed which are then folded to intersperse the bands. The resulting stack (75) of interleaved strips is cut in the direction essentially normal to the longitudinal axis of the strips at predetermined intervals to form a block (78) of individual interleaved sheets (S10, S11). The process can be completed manually or in a continuous production process

Description

IMPROVED SHEET PRODUCTS FOR USE IN AN AUTOMATIC SUPPLIER AND A METHOD FOR TRAINING THROUGH BANDS EXTENDED.

FIELD OF THE INVENTION This invention relates to an improved stratum arrangement of sheets for use in an automatic supply system, and a method of forming sheets from webs that are oriented in substantially continuous layers.

BACKGROUND OF THE INVENTION Towels and similar sheet products, generally known as "handkerchiefs", which are supplied from a container, or from individually wrapped packages, have become part of today's society. For example, handkerchiefs are used for hygienic purposes as well as for cleaning dirt and dust. The size, shape, thickness, durability, moisture content and handkerchief lotion content can be adjusted for a variety of uses, and the versatility of such products has contributed to the popularity of handkerchiefs in general.

Due to the variety of uses of leaf products, such as handkerchiefs, they have acquired numerous physical forms, and their delivery mechanisms have varied in the same way. There are a variety of supply mechanisms that include containers and others that do not. For example, rolls of paper towels for drying and toilet paper do not require containers due to their low moisture content. "Dry" leaf products often include lotions or other additives and are not necessarily free of moisture. More than "dry" leaf products, they are leaves with a low moisture content that usually dry out in contact with an average consumer. Paper towels and toilet paper are usually in the form of continuous rolled sheets with perforations that define the individual sheets. The consumer unrolls the amount of paper he needs and separates it from the roll along the perforations between the sheets. Frequently, the sheets are pre-moistened with lotions, cleaning agents or the like. A popular method for supplying wetted sheets, "wet tissues", is the combination between the perforated roll and the container supplier. The webs of the leaves are usually punched, rolled, placed in a rigid container and then the lotions and / or cleaning agents are added. -For delivery, the individual wet tissues are usually removed through a small opening in the container and the cutouts are cut to remove the sheet. Problems with such arrangements may arise, since the dispenser opening is typically small to minimize the loss of the wetting agent from the products closer to the edge. The smaller opening, in turn, requires an increase in force to remove the tissue from the supplier. The increase in force can result in the premature separation of the perforations between the products to be supplied; or perhaps it is required to design perforations with an increase of resistance to separation, so that more force will be needed by the user to separate a product for its use. Often both hands are needed to extract a "wet handkerchief" or treated (for example, one hand to remove the handkerchief and the other to secure the container while removing the handkerchief from the container and separating from the next handkerchief). However, unfortunately leaf products, such as handkerchiefs, are often needed when only one hand is available (for example, when a baby is being cleaned), which makes supplying the perforated tissues from a container a undesirable combination. Another common form of handkerchiefs that are not supplied from a rigid container includes individually pre-packaged wet handkerchiefs that are usually given in restaurants or on airplanes. Usually, Id] is damp handkerchiefs are folded and placed in moisture resistant sachets, then the lotion and / or a cleaning agent is added, and the pouch is sealed hot. The consumer opens the package to use the handkerchief, and then discards the bag and handkerchief. This is also typically a two-handed operation, and there is considerable waste created in the form of individual bags, making this method of packaging and supply also undesirable. Generally the dried leaves, a known way to supply individual sheets (ie, pre-cut, interfolded, non-perforated) is through the supply container. The supply container can be a box with a lid that opens each time a sheet is needed; it can be a box with a lid and an opening through which the individual sheets are pulled, or it can be the combination of a lid and an opening. Generally the dried leaves supplied through a box with opening are typically rectangular and interfolded. Handkerchiefs and paper towels in toilets are usually supplied in this way. As in the current practice, supplying an interfolded sheet has to do with pulling up.?through an essentially rectangular sheet from the supplier. The interleaved portion of the two sheets serves to pull the adjacent portion of the next sheet due to the interfacial interaction of the two sheets in the overlapping area. After the first sheet has been pulled completely through the opening, the two interfolded sheets begin to separate rapidly. When the two sheets are completely separated, there must be a sufficient amount of the next sheet extending out of the dispenser opening to allow easy subsequent access to the second sheet. The portion of the second sheet remaining in the supplier is commonly referred to as "glue". The dried sheets or tissues supplied in this manner generally have a larger area of overlap consisting of a whole side of rectangular sheet interfolded with one edge of the next sheet. However, since moisture is added to a sheet product, the large surface area of overlap often results in excessive interactive forces between the two sheets, causing a second sheet to be supplied along with the first, due to the greater force required to separate the two sheets. Reducing the area of the surface is difficult, since the reduction decreases the adhesive force, which controls the amount of the second sheet removed from the supplier (to provide the "tail" for the subsequent supply). At present, the leaves that are wet, thick and those that are not joined can not be supplied when the leaves are interleaved due to the adhesion between the leaves caused by the presence of high humidity levels; The force required to separate the two leaves is so great, that often several leaves are detached from a pole (which is sometimes called "chaining"). Therefore, the sheets are typically folded individually, stacked one on top of the other and placed in the supplier's container. This delivery method is less than optimal, as there is no tail to hold when a sheet is needed, which generally results in a two-handed supply procedure. U.S. Patent No. 5,332, 118 to Muckenfuhs (Patent 118), shows a series of designs for sheets that can be folded and used in an automatic supply mechanism without the supply difficulties described above. The entire sample of the patent 118 is hereby incorporated by reference. An improved sheet design and a method for forming the sheet products, as described in patent 118, for use in automatic supply applications are provided herein. Automated methods for bending a series of continuous bands in continuous layers of overlapped sheets for use in an automatic supply system are known in the art. Machines of this type have been used to fold the webs having ends that are essentially straight and parallel to the longitudinal axis of the webs, such as the handkerchiefs. Once the web has been interfolded, interspersed continuous stacking occurs, which is cut into blocks suitable for use in an automatic supplier. Obviously, the above devices separately show the specific folding means; but it has been necessary the continuous improvement of the sheet products for the improved operation of the automatic suppliers, as well as a better method to produce such products economically and efficiently. There is a continuing need to improve the sheet products and a method for making sheets that can be used effectively in an automatic supply system. In addition, there is a need for an improved process whereby the webs can be tensioned, properly and consistently overlapped, folded and cut into layers for use in an automatic supply system.

BRIEF DESCRIPTION OF THE INVENTION It is a principal object of this invention to provide an improved sheet, a method for forming substantially continuous layers of such sheets for use in an interleaved automatic supply system.

It is the object of this invention to allow sheet products for automatic supply applications to be cut more efficiently and tensioned individually or continuously from a wider web of continuous material. It is also an object of this invention to produce the improved sheets of this invention by minimizing waste. It is also another object of this invention to meet all of the above production improvements for wet and dry leaves. According to one aspect of this invention, there is provided a method of forming webs of sheet material having a longitudinal axis between the two opposite lateral ends, and extending the lateral ends of the webs to form one or more protuberances in the webs. knee shape on the lateral ends. The knee-shaped protuberances of a band align in a predetermined manner with the protuberances of an adjacent band and overlap the aligned bands to create predetermined areas of larger overlap and smaller overlap between them. Then, the aligned and overlapping bands are folded into continuous layers and cut into small blocks of individual layers interspersed for use in the automatic supply system.

In another preferred embodiment, a method of forming webs having a longitudinal axis and two opposing side ends is provided, then a side end of the webs is tensioned to form one or more knee-shaped protrusions the entire length. The opposite lateral end of the band remains essentially parallel to the longitudinal axis of the band. Subsequently, the knee-shaped protuberances of the band align with the essentially parallel lateral ends of an adjacent band. Then, the bands aligned in this manner overlap, creating an area of greater overlap between the knee-shaped protuberances of a band and the essentially parallel end of the adjacent band. Each larger overlap area is linked by an area of least overlap between the adjacent bands. The multiple bands can overlap in this manner by forming substantially continuous strata of bands which are then folded into a continuous layer of interleaved bands. The continuous layer is then cut in a direction essentially normal to the longitudinal axis of the bands, forming small blocks of sheets interspersed individually. In a preferred embodiment, the substantially continuous piles are cut close to the midpoint in each knee-shaped protuberance, and are cut again approximately in the middle of the space between the knee-shaped protuberances.

The processes discussed above can be carried out in a continuous fabling process where the webs are cut and tensioned from a wider web.

BRIEF DESCRIPTION OF THE DRAWINGS Since the specification concludes with the claims that they particularly point out, and clearly claim the present invention, it is believed that it will be better understood from the following description that is given together with the attached drawings in which: FIGURE A is a partial schematic plan view of a band of anterior material to cross the directional extension, with arrows indicating the direction of force with which the band will extend; FIGURE IB is a partial schematic plan view of the band of FIGURE IA after the spread; FIGURE 2A is a partial schematic plan view of a band of prior material for an angular directional extension, with arrows indicating the direction of the force with which the band will extend; FIGURE 2B is a partial schematic plan view of the band of FIGURE 2A after the spread; FIGURE 3 is an enlarged plan view of a sheet and sections of the band from which the sheet was cut, wherein the sheet has a single knee-shaped protrusion that is formed next to one of its four corners; FIGURE 4 is an enlarged plan view of a sheet and two sections of the band that were cut from the sheet, where the knee-shaped protrusions formed along both lateral ends of the band, causing the sheet have knee-shaped protrusions next to two of its four corners; FIGURE 5 is a partial view of the three successive sheets that were cut from the bands, which extended to form knee-shaped protuberances at both opposite lateral ends, and where the sheets are shown with predetermined areas of overlap, no overlap and the lines where they fold to intercalate the leaves; FIGURE 6 is a partial perspective view of a continuous mechanical extension arrangement for implementing the method of the present invention; FIGURE 7 is a partial perspective view of a band extended by the arrangement of FIGURE 6; FIGURE 8 is a partial schematic view of an extension arrangement of one side of the present invention, wherein knee-shaped protuberances are formed at only one end of a band; FIGURE 9 is a partial plan view of a band extended by an arrangement such as FIGURE 8 with knee-shaped protuberances formed at a single end; and FIGURE 10 is a partial perspective view of a partial block of interleaved and folded sheets, cut from a substantially continuous stack of interleaved and folded webs.

DETAILED DESCRIPTION OF THE INVENTION Making a detailed reference of the drawings, where equal numbers indicate the same elements in all the views, and where the elements that have the same two final digits (that is, 12, 112, 212) indicate the comparable elements of several modalities Preferred, FIGURE IA illustrates a partial plan view of the Rl band with two opposite lateral ends 12 and 14 deposed on a longitudinal axis Ll. Beside the lateral ends 12 and 14, a plurality of periodically spaced forces, indicated by arrows (i.e., 16 and 18), are schematically illustrated. The forces indicated by the arrows 16 and 18 are shown approximately perpendicular to the longitudinal axis Ll of the band R1 and substantially perpendicular to the relatively parallel lateral ends 12 and 14 of the band R1 before extension. As will be discussed in more detail, the forces applied in this manner form knee-shaped protrusions at the lateral ends as described in FIGS. IB, 20 and 21. As used herein, the term "protuberance" "Knee-shaped" is a portion of the fabric material which, after the fabric has spread, extends beyond the longitudinal axis of the side end band before extension. A variety of alternatives for the shapes and designs of the knee-shaped protrusions can be found in the aforementioned Muckenfuhs patent. The crossed directional width of a CD10 band before the extension, is the distance from the point at one end 14 of a band R1 where an extension force 16 is to be applied, to the nearest point at the opposite lateral end. wherein an extension force 18 is to be applied. FIGURE IB further shows a band Rl with two side ends 12 and 14 deposed on a longitudinal axis Ll which has been extended to increase the cross directional width CD20. Joining each knee-shaped protrusion 20 and 21 in a corresponding recess, or cavity 22 and 23 respectively, which represents the area of the band that has not extended or that is at the opposite lateral end (for example 23). ) from a point where the extension force has been applied and a knee-shaped protrusion has formed (ie, 20): FIGURE 2A is another partial plan view of a band R2 having two opposite lateral ends 212 and 214 centered approximately on a longitudinal axis L2 with the direction of the extension forces shown with arrows (i.e. 26 and 28). In order to form the sheets of this invention, the bands can be extended so that in any way they effectively produce the knee-shaped protuberances in at least one lateral end. The forces 26 and 28 are generally oriented in a direction different from that of the longitudinal axis L2 as well as 16 and 18 of FIGURE A, and both will produce the knee-shaped protrusion (i.e., FIGURES IB, 20 and FIG. twenty-one) . It is likely that the shape of the knee-shaped protuberances (ie, FIGURES '2B, 29) formed by angular forces (ie, FIGURES 2A, 26 and 28), do not have the same shape as the protuberances in shape. of knee formed by the perpendicular forces (that is, FIGURES IA, 16 and 18). The ability to adjust the size and shape of the knee-shaped protrusions formed at the end of the bands can help the sheet designer optimize the geometry of the end of the strip to produce sheets with superior delivery qualities. The Rl and R2 bands can be manufactured with the current methods. Preferably, the webs are manufactured with a continuous process wherein a wide ed of material passes through a cutting station and is cut into webs having ends essentially parallel to the machine direction of the network. The cutting can be carried out with a variety of means, i.e., lasers, water jet, blades or the like. The bands can also be formed by passing a substantially continuous network through a rotary cutter that cuts the network into uniform individual bands. Generally, it is preferable that at least four bands be formed from a network of relatively broad material. FIGURE 3 shows a plan view of a plurality of adjacent sheets SI, S2 and S3 cut from a band R3, where the knee-shaped protuberances have formed at one end 37 of the band R3. The opposite lateral end 36 is illustrated as essentially parallel to the longitudinal axis L3 of the band R3. The band R3 is cut approximately at the midpoint of each knee-shaped protrusion (ie, along the line 48) and again approximately in the middle of the knee-shaped protrusions (i.e. line 51) to form the individual sheets. The sheets extended and cut in this way have only one corner 41 in which a knee-shaped protrusion 31 is formed. FIGURE 4 describes an alternate sheet configuration similar to that shown in FIGURE 3, except that the protuber Knee-shaped segments 32 and 33 are formed on two sides of the band R4 to form individual sheets as shown in S4, S5 and S6 respectively. There are knee-shaped protrusions 32 and 33 formed in two of the corners 42 and 43. The corners 46 and 47 are preferably illustrated located where there are no knee-shaped protuberances, ie, the corners 46 and 47 are in the hollows or cavities 38 and 39 at the ends of the band R4 which is approximately in the middle of the knee-shaped protuberances. The cutting lines 49 and 53 are illustrated located approximately at the midpoint of each knee-shaped protuberance 32 and 33, which in this case is also half of the knee-shaped protuberances at the opposite lateral ends. As is to be understood, it is preferred to cut the adjacent sheets S4-S6 approximately at the mid points of the knee-shaped protuberances, and again at the points equidistant between each successive knee-shaped protrusion, because this method creates two Knee-shaped protrusions on adjacent sheets, from a knee shaped protrusion formed at the end of the band, thus simplifying the manufacturing process. FIGURES 3 and 4 show the extent of the crossed directional distance when the bands (i.e., R3 and R4) extend to form knee-shaped protuberances. In Sheet S2 of FIGURE 3, for example, the crossed directional distance CD120 is greater in length than the crossed directional distance CDllO, where CD120 is the distance between the corners 40 and 41, and where the corner 41 contains a knee-shaped protrusion 31. CDllO is the distance between the corners 44 and 45, where no corner has a knee-shaped protrusion. Similarly, FIGURE 4 shows the diagonals CD210 and CD220 of Sheet S5, where the cross directional CD220 is the distance between the corners 42 and 43, which have knee-shaped protrusions (ie, 32 and 33) formed in the same. The crossed directional distance CD220 has extended to a length significantly longer than the crossed directional distance CD210. The crossed directional distance CD210 is the distance between the corners 46 and 47 of the sheet S5 where 46 and 47 fall approximately to the midpoint of the voids or cavities formed between the adjacent knee-shaped protuberances. FIGURE 5 is a perspective view of the three sheets S7, S8 and S9 made in accordance with the object of the invention, wherein the sheets have been overlapped and interfolded. The sheets S7, S8 and S9 were cut from the bands that extended on both sides to form knee-shaped protrusions (ie, 84 and 86 of S7) at the two corners (ie, 56 and 54 of the S7 sheet). ). The corners 57 and 55 again are preferably located coincidently with the recesses or cavities of the ends 138 and 139 respectively of the sheet S7. The corner 58 of the sheet S8 overlaps with the corner 56 of the sheet S7 forming the overlap area 50. The corners 57 of the sheet S7 and 59 of the sheet S8, which are preferably located coincident with the openings or cavities of the respective ends 139 and 238 of the sheets S7 and S8 respectively, form the smaller area of the overlap 52. The distance D is equal to the distance between the sheets S7 and S8 in the position where there is the least overlap between the two leaves. The distance D is a critical dimension discussed in greater detail below with respect to the appropriate range of the adjacent overlap sheets for use in automatic suppliers and the like. It is crucial to understand that distance D can be a number greater than, less than, or equal to zero, where values for D greater than zero indicate a gap between the two corners (ie, 57 and 59) without overlapping; where a value of D equal to zero indicates that the two corners (i.e., 57 and 59) touch each other but do not overlap and where; a value for D less than 0 is an area of overlap between the two corners (ie, 57 and 59). FIGURE 6 is a partial perspective view of a continuous automatic array for extending the webs of the sheet material according to this object of the invention. The band R5 travels in a predetermined machine direction (ie, MD) illustrated as being essentially parallel to the longitudinal axis L5 of the R5 band, and through an extension station 66. The extension station 66 comprises individual extension devices, evenly spaced (ie, 60, 61 and 62) which are in contact with the band to apply an extension force essentially perpendicular to the longitudinal axis L5, each extension device applies an opposite force in the direction of the extension devices that are applied to it. unite (ie, 61 and 62). The direction of the force applied by the extension devices 61 and 62 are generally indicated by arrows 63 and 64 respectively. FIGURE 7 shows the R5 band after it has been extended by passing it through an extension station (ie, FIGURES 6, 66). The effect of the extension devices is better observed with respect to the longitudinal axis L5. The first knee-shaped protrusion 121 is formed by an extension device 61 that applies a force in the direction of arrow 163. The apex 71 of the knee-shaped protrusion 121. is significantly further from the longitudinal axis L5 than the knee. area 122 at the opposite lateral end 312. The knee-shaped protrusion 121 adjacent the lateral end 314 is a recess or cavity 123 created by the extension device of FIGS. 6, 62 which applies a force in the direction of the arrow 164 in FIGURE 7. The extension device 62 creates the knee-shaped protrusion 120. The directional distance crossed from the apex 70 of a knee-shaped protrusion 120 to the nearest vertex 71 of a knee-shaped protrusion at the end opposite 121 is CD320. The distance between the knee-shaped protuberances at the opposite ends is considerably longer than the crossed directional distance CD310, which is the distance between the cavities (ie, 122 and 123) at opposite ends 312 and 314. The formation of the knee-shaped protrusions (ie 120 and 121) at the ends of a band (ie 312 and 314 of R5) is important for the final operation of the layers made in accordance with this invention, since they are the areas resulting from the greater and smaller overlap between the knee-shaped protuberances in the sheets that produce the superior delivery qualities for the layers made in accordance with the present invention. However, the crossed directional distances CD320 and CD310 are useful for characterizing the shape of the resultant web before overlapping, folding and interleaving of the webs before they are cut into individual layers. FIGURE 8 shows a partial schematic illustration of a preferred extension station 166, wherein a stationary longitudinal clamp device 68 holds a band R6 near its lateral end 412, while a plurality of lateral extension devices (i.e. ) are located on the opposite side end 414 of the R6 band. The extension devices (i.e., 16L- ') move in the direction indicated by the arrows (i.e., 67), generally away from the longitudinal axis L6 to form a knee-shaped protrusion (i.e., FIG. 9). ) at the lateral end 414. FIGURE 9 is a partial plan view of the R6 band after it has been extended at the extension station 166 as described in FIGURE 8. The knee-shaped protrusions (i.e. ) and the corresponding voids or cavities (ie, 222) between the protuberances are formed at the lateral end 414 of the band R6. The opposite lateral end 412 of the band R6 remains essentially parallel to the longitudinal axis L6 as a result of the longitudinal gripper device 68. After the extension, a plurality of substantially identical bands align and overlap so that a knee-shaped protrusion in the end of one band overlaps with a knee-shaped protrusion in the adjacent band, or overlaps with one end that is essentially parallel with the longitudinal axis of the band. This creates areas of greater overlap 50 and of less overlap 52 between the adjacent bands as shown in FIGURE 5, a plurality of overlapped bands is created, referred to herein as strata. As discussed below, the strata are folded and cut into individual blocks that are essentially folded strata of leaves. Therefore, the term strata is used to describe the overlapped and covered nature of the sheet material, regardless of whether the material is in the form of bands or sheets. A critical design dimension that optimizes the supply parameters for the individual sheets (ie, S7, S8 and S9) is described in FIGURE 5 as "D". D is the nominal distance from one end of the sheet (ie, 238 of S8) to the adjacent sheet end (ie, 139 of S7) at the point of least overlap. As previously described, the distance D can be greater than, less than, or equal to zero to be taken into account in a gap between the corners of the adjacent sheets, an area of overlap between the corners of the sheets, or when the corners of the adjacent sheets make contact but do not overlap, respectively. For hand blades and the like, for example, a target distance for D can be from 2mm to approximately 12mm at the point of least overlap, or more preferably between 5mm and 7mm. The size and shape of the area of the protrusion, and subsequently the size and shape of the overlap area, can also be adjusted while maintaining a constant gap distance D. The patent for Muckenfuhs (patent 118), incorporated herein by reference, deals in detail with the aslapping, interleaving and supply of the sheet. Although the sheet products and the method of manufacture of the present invention are not discussed in the Muckenfuhs patent, the general principles of the areas of greater overlap and less overlap between the sheets apply to the present invention. An example of suitable web material for making the webs of the present invention, which is soft, highly elastic (in the cross machine direction) and non-knit, has the properties (based on drying) of: PROPERTY UNITS RESULT Grip tensioner, dry MD grams 7536 Grip tensioner, dry CD grams 2497 Dry MD gripper 0 0 37.3 Dry CD gripper 0 178.5 Base weight g / m2 61.5 Absorbent capacity g / g 11.1 second dive 1.3 Beam overlap, MD meters 0.067 Beam overlap, CD meters 0.029 Thickness, Ames micras 704 Such material is commercially available in Veratec, 100 Elm Street, alpole, MA under the trade name of "HEF # BD94-18". This example material is a 50/50 blend of polyester and rayon and is consolidated by hydrotection. Once a plurality of bands have been overlapped in a close relationship, they should be folded into piles (as shown in FIGS. 10, 75) of the RIO and Rll interleaved bands and then cut into blocks 76 of interleaved sheets. individual SIO and Sil. Folding machines can be used for the automatic folding of continuous layers of overlapped webs. Interleaving and folding machines are well known in the "handkerchief" technique. To make it practical, the process of overlapping and folding of continuous webs can be completed essentially simultaneously in a folding machine such as the one currently used in the "handkerchief" industry. The overlap and fold steps are discussed separately in this document for purposes of greater clarity. Although the z-fold is the preferred method for the interleaved sheets of this invention, a variety of common folding processes can be used, including the folds in c and in u. As you can understand, the number of bands in a layer determines the number of sheets in a block. The desired number of sheets in the final block can be obtained by overlapping a corresponding number of bands (that is, to produce eighty tissue boxes, eighty bands are collected and interleaved, and each block is cut to contain eighty tissues). Another common process in the industry is the manufacture of "samples" of the product. A sample is a stack of sheets that is smaller in number than the desired final product. Sample folding and stacking machines common in the art produce stacks of four to ten bands that can be cut into samples of four to ten sheets. An adequate number of samples are stored on top of each other and each sample is intercalated, or freely attached to the contiguous sample so that a predetermined number of sheets is formed. The continuous stack cutting (ie 75, FIGURE 10) in small blocks (ie 76, FIGURE 10) of the individual interleaved sheets (i.e., SIO and Sil) is preferably performed approximately at the midpoint of each protuberance at knee shape, and approximately in the middle of the knee-shaped protuberances, ie, FIGURES 3, 48 and 51 respectively, in a direction essentially perpendicular to the longitudinal axis (ie, L3 of the R3 band). This method is preferred because each knee-shaped protrusion formed by the extension of the band is cut into two knee-shaped protuberances on each adjacent sheet. Thus, the number of knee-shaped protrusions that must ultimately be formed is reduced by half. However, any trimming line produces an area of greater overlap adjacent to an area of smaller overlap along the interleaved ends between the adjacent sheets is an acceptable trimming line. The individual blocks (ie, 76) of the leaves folded interleaves (ie, SIO and Sil) are placed in suppliers where one sheet per turn can be supplied, leaving a convenient tail for the next supply. Preferably, lotion (which may contain humectants, cleansing agents, water, etc.) is added to the block of sheets while packaging. However, as can be seen, the lotion can be added at any convenient point during the manufacturing process. As will be appreciated, after the block of individual interleaved sheets is placed in a supplier, the tail of the The first sheet is pulled out of the supplier, which in turn pulls the overlapped section through the supplier opening. The physical interaction between the sheet that is being supplied and the next sheet in the supplier causes the two sheets to be joined long enough to remove the area of greater overlap from the supplier. Since the area of greater overlap was removed, a separation front is created in the area of least overlap. Since the interaction - * "between the two leaves is decreasing, the separation front continues through the interface between the two leaves, the separation front continues until the two leaves are separated, leaving a convenient tail of the next sheet. which remains in the container Having shown and described the preferred embodiments of the present invention, another adaptation of the improved sheet products and the forming method described herein can be accomplished by means of suitable applications made by a common expert in the art. the technique without departing from the subject matter of the present invention A number of alternatives and modifications have been described herein, and others will be apparent to those skilled in the art For example, particular extension operations can be performed manually, and / or the number, location and configuration of the knee-shaped protuberances and the areas of voids or cavities can be modified for a variety of products and applications. Accordingly, the subject of the present invention should be considered in the terms of the following claims, and it is understood that they will not be limited to the details of the structures and methods shown and described in the specification and the drawings.

Claims (10)

1. An improved method of forming layers of overlap sheets suitable for s? use in an automatic supply system, such method is characterized by the steps of: forming a plurality of webs of sheet material, with each web having a longitudinal axis and a first and second opposite side portions and a first and second side ends separated transversally from the longitudinal axis, characterized in that the first lateral end has one or more knee-shaped protuberances, and the second lateral end is substantially parallel with the longitudinal axis or includes one or more knee-shaped protrusions extending outward from the longitudinal axis in an opposite direction from the protrusion on the first side; - forming knee-shaped protuberances at one end of the band by tensioning the end portion in a direction substantially away from the longitudinal axis by increasing the cross-directional dimension of the band; - aligning two or more bands adjacent to each other; - overlapping at least a portion of the knee-shaped protrusion of the first lateral portion with the second lateral portion of the adjacent aligned bands to form overlapping strata of bands, creating a series of areas of greater overlap with areas of less overlap; - folding the strata of the overlapping bands to form a stack of interleaved folded strips; and - cutting the stack of interleaved bands folded across the longitudinal axis to form a plurality of individual interleaved sheet blocks.

2. The method of claim 1, further characterized in that the adjacent strips are aligned in a direction parallel to their longitudinal axis so that a knee-shaped protrusion of a first lateral end of a strip is aligned with a substantially parallel second lateral end or a corresponding knee-shaped protrusion of a second lateral end of an adjacent band resulting in a predetermined area of overlap between the lateral ends of the adjacent bands.

3. The method of any of claims 1 or 3, further characterized in that such formation and extension of the plurality of bands is carried out under a substantially continuous process, wherein such bands are passed through an extension station where each band it extends cross-directionally to form the knee-shaped protrusions at the end portions of the bands, and preferably such an extension station comprises at least one extension device that can be moved in a direction transverse to the direction of travel. the machine for selectively providing the knee-shaped protrusions along a side end of the bands formed therein.

4. The method of any of claims 1-3, wherein the extension station is further characterized in that it comprises at least one clamp device substantially stationary in relation to. the longitudinal axis, since the band is extended in the cross direction, thereby providing a lateral end which is substantially parallel with the longitudinal axis of the band.

5. The method of any of claims 1-4, further characterized in that the areas of least overlap between the bands are areas without overlap between the aligned ends of the adjacent sheets.

6. The method of any of claims 1-5, further characterized in that the stack of interleaved strips is cut in a direction substantially normal to the longitudinal axis and at an approximate midpoint of each overlapped protuberance, and again at equidistant points between each successive overlapped protrusion. to form a plurality of blocks of individual interleaved sheets.

7. An improved interleaved sheet layout for use in an automatic supply system, such arrangement is characterized by a block of individual, partially overlapping sheet products obtainable by: - forming a plurality of webs of sheet material with each web having a longitudinal axis and a first and second side portions and a first, and second ends laterals transversely spaced from the longitudinal axis, characterized in that the first lateral end has one or more knee-shaped protuberances with the longitudinal axis or includes one or more knee-shaped protrusions extending outwardly from the longitudinal axis in the opposite direction from the Knee-shaped protrusion at the first lateral end; - forming the knee-shaped protuberances at one end of the band by extending the end portion in a direction substantially away from the longitudinal axis, increasing the cross-directional dimension of the band; - aligning two or more bands adjacent to each other; - overlapping at least a portion of the knee-shaped protrusion of the first lateral end with the second lateral end portion of an adjacent band aligned to form strata of overlapping bands, creating a series of areas of greater overlap of adjacent areas of less overlap; - folding the strata of the overlapping bands to form a stack of interleaved folded strips; and - cutting such a stack of interleaved strips folded across the longitudinal axis to form a plurality of individual interleaved sheet blocks.

8. The improved interleaved sheet arrangement of claim 7, further characterized in that the adjacent strips are aligned in a direction parallel to their longitudinal axis such that the knee-shaped protrusion of the first lateral end of the band is aligned with the second lateral end. This is substantially parallel to the corresponding knee-shaped protrusion of the second lateral end of the adjacent band, resulting in a predetermined area of overlap between the lateral ends of the adjacent bands.

9. The improved interleaved sheet arrangement of any of claims 7 or 8, further characterized in that the formation and extension of the strip plu- rality is carried out under a substantially continuous process, wherein the bands pass through a station. of extension wherein each band is tensioned cross-directionally to form the knee-shaped protuberances at the end portions of the bands, and the extension station preferably characterized in that at least one extension device is movable in the transverse direction to the direction of the machine for selectively providing knee-shaped protrusions along the lateral ends of the bands formed therein.

10. The improved interleaved sheet arrangement of claim 18, wherein the base web of material moves in the predetermined direction of the machine, and wherein a base web of the sheet material is passed through the cutting station, to that the plurality of bands is formed with their lateral ends separated in a direction transverse to the machine direction. SUMMARY OF THE INVENTION An improved method for forming overlapping sheet layers suitable for use in an automatic supply system is shown. The sheets (S10, Sil) are separated from the bands (RIO, Rll) which in principle have ends essentially parallel to the longitudinal axis of the band. At least one side end of each band is tensioned to form a knee-shaped protrusion, with the opposite lateral end substantially parallel to the longitudinal axis of the band, or also extended to form one or more knee-shaped protuberances at the opposite end . The bands (RIO, Rll) are then aligned so that the knee-shaped protrusion at one end aligns with either of the essentially parallel ends of an adjacent band or a knee-shaped protrusion at the lateral end of an adjacent band. After the phase adjustment, the bands overlap to create a series of predetermined areas of adjacent areas of greater overlap with less or no overlap, so that the successive bands are joined only by the interfacial interaction between each band. By overlapping multiple bands in this manner, layers are formed which are then folded to intersperse the bands. The resulting stack (75) of interleaved strips is cut in the direction essentially normal to the longitudinal axis of the strips at predetermined intervals to form block (76) of individual interleaved sheets (SIO, Sil). The process can be completed manually or in a continuous production process.