Apparatus and method for forming a block of folded material

Abstract

The invention includes an apparatus for forming a block of folded material, and a method for forming a block of folded material. The inventive apparatus includes a folder for folding a web onto a block, a holder holding an end of the web from a bottom layer of the block. The apparatus further includes a cutter for providing an end portion from an uppermost layer of the block. The inventive method includes the steps of folding a web onto a receiving element until a portion of the web forms a folded block of a preselected height, and feeding the uppermost web layer to a cutter. The inventive method further includes cutting an uppermost web layer to form an end portion, and laying the end portion from a bottom layer of the block at least partly on top of the block.

What is claimed:  
     
         1 . An apparatus for forming a block of folded material, comprising: 
 a folder for folding a web onto a block;    a holder holding an end of the web to extend from a bottom layer of the block;    a cutter for providing an end portion from an uppermost layer of the block.    
     
     
         2 . An apparatus as in    claim 1   , wherein the holder includes a roller for winding and unwinding a portion of the web.  
     
     
         3 . An apparatus as in    claim 1   , further including a receiving element on which the block is formed, the receiving element being movable in both a vertical and horizontal direction.  
     
     
         4 . An apparatus as in    claim 1   , wherein the cutter includes a sledge and a cutting knife movable on the sledge.  
     
     
         5 . An apparatus as in    claim 4   , wherein the cutter includes a clamping bar for fixing a web portion on the sledge.  
     
     
         6 . An apparatus as in    claim 4   , wherein the holder includes a needle roller having protruding needles which are insertable into the web.  
     
     
         7 . An apparatus as in    claim 6   , further comprising notches formed on the sledge, the notches being formed to allow the needles to pass through during rotation of the roller.  
     
     
         8 . An apparatus as in    claim 6   , further comprising a stripper adjacent the roller, the stripper positioned adjacent the roller in order to remove the web from the roller.  
     
     
         9 . The apparatus as in    claim 1   , wherein the holder is movable to put the end of the web on top of the block.  
     
     
         10 . An apparatus for forming a block of folded material, comprising: 
 a folder for folding a web onto a block;    a cutter for providing an end portion from an uppermost layer of the block;    a holder for holding an end of the web to extend from a bottom layer of the block, the holder having a roller with protruding needles which are insertable into the web; and    wherein the cutter includes notches formed to allow the needles to pass therethrough when the roller rotates.    
     
     
         11 . A method for forming a block of folded material, the folded material having loose ends accessible for connection, the method comprising the steps of: 
 folding a web on a receiving element until a portion of the web forms a folded block of a preselected height;    feeding an uppermost web layer to a cutter;    cutting the uppermost web layer to form an end portion;    laying an end portion from a bottom layer of the block at least partly on top of the block.    
     
     
         12 . The method as in    claim 11   , further comprising the step of withholding an end portion of the bottom layer on a holder before starting to form the block.  
     
     
         13 . The method as in    claim 12   , further comprising the step of unwinding the end portion of the bottom layer while forming the block.  
     
     
         14 . The method as in    claim 12   , further comprising the steps of moving the receiving element in the horizontal direction, and laying the end portion of the bottom layer on top of the block.  
     
     
         15 . The method as in    claim 14   , further comprising the step of cutting the uppermost web layer so that its end portion falls down on one side of the block.  
     
     
         16 . A method for forming a block of folded material, the folded material having loose ends accessible for connection, the method comprising the steps of: 
 withholding an end portion of a bottom layer of the material on a holder;    folding a web on a receiving element until a portion of the web forms a folded block of a selected height;    feeding an uppermost web layer to a cutter;    cutting the uppermost web layer to form the end portion;    laying the end portion from the bottom layer of the block at least partly on top of the block;    unwinding the end portion of the bottom layer while forming the block; and    cutting the uppermost web layer so that its end portion falls down on one side of the block.