Tissue packaging apparatus

Abstract

The present invention provides an apparatus and method for controlling the height of a clip of sheet material that is independent from the other steps of the manufacturing, converting and packaging operations. The invention comprises introducing positive pressure air flow after the clip has been at least partially inserted into a carton. Positive pressure air flow is provided in a direction substantially parallel to the longitudinal axis of the clip and transverse to the cut end of the sheet causing the clip to increase in height. The degree of increase may be controlled by controlling the positive air pressure, while the carton acts as a restraint for the clip.

What is claimed is: 
     
         1 . A method of producing a carton of sheet material comprising the steps of: providing a clip of individual sheet material, the clip having a longitudinal central axis passing through a first and a second end; providing a carton; advancing the clip towards the carton by a pusher assembly contacting either the first or the second end of the clip to at least partially dispose the clip in the carton; conveying the at least partially filled carton; and applying positive air pressure across the clip in a direction substantially parallel to its longitudinal central axis. 
     
     
         2 . The method of  claim 1  wherein the clip has an initial height (h 1 ) when at least partially disposed in the carton and a second height (h 2 ) after the step of applying positive air pressure wherein h 2  is greater than h 1 . 
     
     
         3 . The method  claim 1  wherein h 2  is at least about 10 percent greater than h 1 . 
     
     
         4 . The method of  claim 1  further comprising the step of measuring the clip height after the step of applying positive air pressure. 
     
     
         5 . The method of  claim 4  further comprising the steps of generating a signal based upon the clip height measurement, communicating the signal to the air jet and adjusting the air jet positive pressure based upon the signal. 
     
     
         6 . The method of  claim 1  wherein the clip is entirely disposed within the carton and the carton has a Fill Ratio greater than about 90 percent. 
     
     
         7 . The method of  claim 1  wherein the carton comprises a first and a second end formed from a plurality of end flaps and further comprising the steps of sealing the first end flaps to form a first closed end and sealing the second end flaps to form a second closed end. 
     
     
         8 . The method of  claim 1  wherein the individual sheet materials are interfolded facial tissue sheets. 
     
     
         9 . An apparatus for packaging a clip of sheet material comprising: a bucket for receiving a clip of individual sheet material, the clip having a longitudinal central axis passing through a first and a second end; a pusher arm assembly for urging the clip into a carton to at least partially fill the carton; a conveying means for conveying the at least partially filled carton; and a first positive air supply means for directing a flow of air at the clip. 
     
     
         10 . The apparatus of  claim 9  wherein the first air supply means comprises a source of pressurized air and a nozzle in flow communication with the pressurized air source of the first air supply means. 
     
     
         11 . The apparatus of  claim 9  wherein the nozzle is located in a plane substantially coincident with the center of the clip measured in a direction transverse to direction of conveyance. 
     
     
         12 . The apparatus of  claim 9  wherein the first positive air supply means comprises a source of pressurized air and a nozzle in flow communication with the pressurized air source of the first air supply means, the nozzle integrated with the pusher arm. 
     
     
         13 . The apparatus of  claim 9  further comprising a second positive air supply means for directing a flow of air at the clip, the second air supply means including a source of pressurized air and a nozzle in flow communication with the pressurized air source means. 
     
     
         14 . The apparatus of  claim 10  wherein the pressurized air source of the first air supply means is selected to provide a stream of pressurized air of sufficient flow to travel through the clip and exit at the second end of the clip in a direction transverse to the direction of conveyance. 
     
     
         15 . The apparatus of  claim 10  wherein the nozzle of the first air supply means is of a cross-sectional shape substantially approximating a tear drop, an oval, a square, a circle or a rectangle. 
     
     
         16 . A method of producing a carton of sheet material comprising the steps of placing a clip of individually folded tissue sheets into a bucket, the clip having a longitudinal central axis passing through a first and a second end; advancing the clip towards a container by a pusher assembly contacting either the first or the second end of the clip, the pusher assembly moving in a direction parallel to the longitudinal central axis of the clip and thereby at least partially disposing the clip in the carton; and applying air flow substantially parallel to the longitudinal central axis of the clip whereby at least a portion of the individually folded tissue sheets are separated from one another. 
     
     
         17 . The method of  claim 16  wherein the clip has an initial height (h 1 ) when at least partially disposed in the carton and a second height (h 2 ) after the step of applying air flow wherein h 2  is greater than h 1 . 
     
     
         18 . The method  claim 17  wherein h 2  is at least about 10 percent greater than h 1 . 
     
     
         19 . The method of  claim 16  further comprising the steps of measuring the clip height after the step of applying positive air pressure, generating a signal based upon the clip height measurement, adjusting the air flow based upon the signal. 
     
     
         20 . The method of  claim 16  wherein the clip is entirely disposed within the carton and the carton has a Fill Ratio greater than about 90 percent.