The present invention relates to a folding machine comprising a blade folding
unit and a method for folding products by means of a blade folding unit.
Folding machines for producing folded products generally comprise a plurality
of different folding units. In this case, a differentiation 5 is generally
made between buckle folding units and blade folding units. In order to obtain
a product which is folded as desired and which has different folding
directions, it is generally necessary to combine buckle folding units and
blade folding units. For example, a multi-part buckle folding machine initially
10 generates a plurality of parallel folds in the foldable product. The cross-fold
is than generally generated by a further buckle folding unit, and at least one
blade folding unit may follow said further buckle folding unit. Buckle folding
units, however, are generally expensive to purchase and require relatively
long installation times and a great deal of experience in the set-up, which
15 cannot be easily automated. Known blade folding units in turn permit the
action of the folding blade only on the upper face of the foldable product, so
that their field of use is limited, and the blade folding units have to be combined
with buckle folding units in the cross-fold region in order to increase
the flexibility of the folding machine or in order to increase the variety of
20 folded products.
It is an object of the present invention to provide a folding machine and a
method for folding products which permit a high degree of flexibility and
variety in the design of the folded products and at the same time a reduc25
tion in the costs and the required installation times.
According to the invention, a folding machine comprises a first blade folding
unit comprising a first and a second folding roller, wherein the first folding
roller has a first folding roller axis and the second folding roller has a sec30
ond folding roller axis which is arranged spaced apart and parallel to the
first folding roller axis, so that the first and the second folding roller axes
3
define a first folding roller plane. The first blade folding unit also comprises
a first folding blade which is oriented and is movable in a first folding blade
plane, wherein the first folding blade plane is oriented perpendicularly to the
first folding roller plane and intersects the first folding roller plane in a first
intersection line. The first folding blade is movable between 5 a retracted position
and an extended position, wherein the first folding blade is arranged
in the extended position closer to the first folding roller plane than in the
retracted position. The first folding blade is arranged in the retracted position
in or below a horizontal plane which comprises the first intersection
10 line. The two folding rollers are arranged one behind the other relative to an
inlet direction of the foldable product into the first blade folding unit.
In this manner, a folding machine is provided with a blade folding unit in
which the folding blade acts on a lower face of the foldable product, without
15 having to rotate a product to be folded in a complex manner in advance,
while a folding blade of hitherto known blade folding units acts on the upper
face of the foldable product. Thus, the foldable products are folded by
means of the folding machine according to the invention in the opposing
direction in comparison with hitherto known blade folding units, whereby the
20 flexibility in the configuration of folded products by blade folding units is increased.
Without sacrificing flexibility and product variety, a buckle folding
unit can be dispensed with in the cross-fold region, whereby costs are
saved and installation times reduced.
25 A foldable product can be a flat medium in this case, in particular a sheet of
paper, cardboard or a similar material. The foldable product can correspond
to a flat medium which is not yet folded, for example a sheet to be folded, or
an intermediate product, such as for example a sheet which has already
been folded once or repeatedly. In the first case, therefore, the first blade
30 folding unit generates a first fold. In the second case, the first blade folding
4
unit generates an additional fold to the one or more already existing folds,
preferably in a direction perpendicular to the first fold.
Generally, the folding machine according to the invention is used as a paper
folding machine, in particular when processing thin printing 5 paper. The
folded end product can be an outsert, for example.
The folding machine according to the invention processes individual sheets.
10 The first and the second folding roller axes are located in the first folding
roller plane.
The first folding blade plane is oriented perpendicularly to the first folding
roller plane and intersects the first folding roller plane in the first intersection
15 line. The first folding blade is arranged and oriented in the first folding blade
plane and is movable therein between the retracted position and the extended
position.
The first folding blade has a front edge which runs in a longitudinal direction
20 of the first folding blade. The longitudinal direction of the first folding blade
is preferably oriented parallel to the first and to the second folding roller axis.
The front edge is located in the folding blade plane.
The folding blade is clamped at an end portion of the first folding blade
25 which opposes the front edge. Preferably, the first blade folding unit comprises
a drive device for moving the first folding blade between the retracted
position and the extended position in the folding blade plane. The drive device
thus comprises a clamping device for clamping the end portion of the
first folding blade.
30 In order to permit the first folding blade to act on the lower face of a foldable
product, the first folding blade is arranged in the retracted position in or be5
low the horizontal plane which comprises the first intersection line. The first
intersection line extends horizontally and is oriented or arranged in the horizontal
plane.
In a preferred embodiment, the first folding blade is arranged 5 in the retracted
position below and perpendicularly to the horizontal plane which comprises
the first intersection line. In this embodiment, the first folding roller
plane is oriented horizontally and the first folding blade plane is oriented
perpendicularly to the horizontal plane which comprises the first intersection
10 line. In this embodiment, the first folding roller plane is located in the horizontal
plane which comprises the first intersection line, and the first folding
blade is arranged below the first folding roller plane.
In an alternative embodiment, the first folding blade is arranged parallel to
15 and in the horizontal plane which comprises the first intersection line. The
first folding blade plane is thus located in the horizontal plane, i.e. is itself a
horizontal plane. In this embodiment, the first folding roller plane is oriented
vertically and the first folding blade plane is oriented parallel to and in the
horizontal plane which comprises the first intersection line.
20
In a further alternative embodiment, the first folding blade plane is oriented
in an acute angle to the horizontal plane which comprises the first intersection
line and the first folding blade is arranged in the retracted position below
the horizontal plane.
25
A first angle between the horizontal plane and the first folding blade plane is
defined on the side of the first folding blade plane on which foldable products
are fed into a folding region between the first and the second folding
roller and the first folding blade. Additionally, the first angle below the hori30
zontal plane is defined between the horizontal plane and the first folding
blade plane.
6
If the first folding blade is arranged perpendicularly to the horizontal plane,
which comprises the first intersection line, the first angle is 90º.
If the first folding blade is arranged parallel to and in the horizontal plane,
which comprises the first intersection 5 line, the first angle is 0º.
If the first folding blade plane is oriented at an acute angle to the horizontal
plane, preferably the first angle is an acute angle of greater than 0º and
less than 90º. Preferably the acute angle is between 5º and 85º, preferably
10 between 15º and 75º, further preferably between 30º and 60º, particularly
preferably between 40º and 50º. In the two last preferred regions, the overall
height of the blade folding unit is relatively low, while at the same time an
easy accessibility to the components of the blade folding unit is ensured for
service personnel. It goes without saying, however, that in principle any
15 angle can be selected from the specified ranges and thus all values contained
in the ranges can also be regarded individually as belonging to the invention.

We Claim:
1. A folding machine (2) comprising a first blade folding unit (4), wherein
the first blade folding unit (4) comprises:
a first and a second folding roller (10, 12), wherein the 5 first folding roller
(10) has a first folding roller axis (10a) and the second folding roller
(12) has a second folding roller axis (12a) which is arranged spaced
apart and parallel to the first folding roller axis (10a), so that the first
and the second folding roller axes (10a, 12a) define a first folding roll10
er plane (14) which comprises both the first and the second folding
roller axis (10a, 12a);
a first folding blade (16) which is oriented and is movable in a first folding
blade plane (18), wherein the first folding blade plane (18) is oriented
perpendicularly to the first folding roller plane (14) and inter15
sects the first folding roller plane (14) in a first intersection line (20),
wherein the first folding blade (16) is movable between a retracted position
and an extended position, wherein the first folding blade (16) is
arranged in the extended position closer to the first folding roller plane
(14) than in the retracted position;
20 wherein the first folding blade (16) is arranged in the retracted position
in or below a horizontal plane (33) which comprises the first intersection
line (20).
2. The folding machine (2) as claimed in claim 1, characterized in that it
25 further comprises a first conveying device (6) with an endless first
conveying means (22) and an endless second conveying means (24)
for conveying foldable products (29) to the first blade folding unit (4),
wherein the first and the second conveying means (22, 24) run parallel
to one another from an inlet region (26) to an outlet region (28) of the
30 first conveying device (6), in order to receive foldable products (29)
36
therebetween, wherein the first conveying means (22) is configured to
carry a foldable product (29) at least in the inlet region (26) and the
second conveying means (24) is configured to hold down a foldable
product (29) on the first conveying means (22) at least in the inlet region
(26), wherein the first and the second conveying 5 means (22, 24)
are arranged in the outlet region (28) in each case substantially parallel
to the first folding roller plane (14) and perpendicularly to the folding
roller axes (10a, 12a), wherein the first folding blade (16) is arranged
in the retracted position closer to a portion of the first conveying
10 means (22) in the outlet region (28) than to a portion of the second
conveying means (24) in the outlet region (28).
3. The folding machine (2) as claimed in claim 2, characterized in that
the second conveying means (24) is arranged in the inlet region (26)
above the first conveying means (22).
15 4. The folding machine (2) as claimed in claim 2 or 3, characterized in
that the first and second conveying means (22, 24) is an endless band
or an endless belt.
5. The folding machine (2) as claimed in one of claims 2 to 4, characterized
in that a plurality, preferably two, first conveying means (22)
20 which run spaced apart and parallel to one another are present and/or
in that a plurality, preferably two, second conveying means (24) which
run spaced apart and parallel to one another are present.
6. The folding machine as claimed in one of the preceding claims, characterized
in that the first folding roller plane (14) is oriented at an
25 acute angle (α) to the horizontal plane (33) which comprises the first
intersection line, and the first folding blade (16) is arranged in the retracted
position below the horizontal plane (33).
7. The folding machine (2) as claimed in claim 6, characterized in that
the acute angle (α) is between 30º and 60º, preferably between 40º
30 and 50º.
37
8. The folding machine (2) as claimed in one of the preceding claims,
characterized in that it also comprises a second conveying device (8)
with an endless third conveying means (34) and an endless fourth
conveying means (36) for conveying products away from the first
blade folding unit (4), wherein the third and 5 the fourth conveying
means (34, 36) run parallel to one another from an inlet region (38) to
an outlet region (40) of the second conveying device (8) in order to receive
products (29) therebetween, wherein the inlet region (38) opposes
the first folding blade (16) relative to the folding roller plane
10 (14).
9. The folding machine (2) as claimed in one of the preceding claims,
characterized in that it comprises a second blade folding unit (42),
wherein the second blade folding unit (42) comprises:
a third and a fourth folding roller (56, 58), wherein the third folding roll15
er (56) has a third folding roller axis (56a) and the fourth folding roller
(58) has a fourth folding roller axis (58a) which is arranged spaced
apart and parallel to the third folding roller axis (56a), so that the third
and the fourth folding roller axes (56a, 58a) define a second folding
roller plane (60) which comprises both the third and the fourth folding
20 roller axis (56a, 58a);
a second folding blade (62) which is oriented and movable in a second
folding blade plane (64), wherein the second folding blade plane (64)
is oriented perpendicularly to the second folding roller plane (60) and
intersects the second folding roller plane (60) in a second intersection
25 line (66), wherein the second folding blade (62) is movable between a
retracted position and an extended position, wherein the second folding
blade (62) is arranged in the extended position closer to the second
folding roller plane (60) than in the retracted position;
38
wherein the second folding blade (62) is arranged in the retracted position
above a horizontal plane (67) which comprises the second intersection
line (66).
10. The folding machine (2) as claimed in claim 9, characterized in that it
further comprises a buckle folding unit (5 76), wherein the buckle folding
unit (76) is configured to fold a foldable product repeatedly, preferably
at least 8 times, further preferably at least 10 times, further preferably
at least 12 times, in parallel in a first direction, and the first blade folding
unit (4) and the second blade folding unit (42) are configured to
10 fold the foldable product in a second direction perpendicularly to the
first direction.
11. The folding machine (2) as claimed in claim 10, characterized in that
the second blade folding unit (42) is arranged such that it undertakes
the first folding action in the second direction, and the first blade fold15
ing unit (4) is arranged downstream of the second blade folding unit
(4) such that it folds the foldable product once again in the second direction.
12. The folding machine (2) as claimed in claim 11, characterized in that a
further second blade folding unit (42) is arranged downstream of the
20 first blade folding unit (4), such that it folds the foldable product once
again in the second direction.
13. The folding machine (2) as claimed in one of claims 9 to 12, characterized
in that in the cross-fold region in which folding actions are carried
out in the second direction, the folding machine has exclusively first
25 and second blade folding units (4, 42) but no buckle folding unit.
14. The folding machine (2) as claimed in claim 13, characterized in that
in the cross-fold region a total of exactly three, four or five blade folding
units (4, 42) are arranged one after the other, exactly one or exactly
two thereof being first blade folding units (4) and the remaining
30 blade folding units being second blade folding units (42).
39
15. The folding machine (2) as claimed in one of the preceding claims,
characterized in that it has a device (80) for applying an adhesive or
an adhesive label to the folded product in order to hold the finished
folded product in the closed state.
16. A method for folding products by using a blade 5 folding unit (4) which
comprises a first and a second folding roller (10, 12) and a folding
blade (16), wherein the method comprises the steps of:
receiving a foldable product (29) by means of a conveying device (6)
in an inlet region (26) of the conveying device (6) such that the folda10
ble product (29) is received between a first endless conveying means
(22) and a second endless conveying means (24) of the conveying
device (6), wherein the first conveying means (22) bears against a
lower face (29a) of the foldable product (29) which faces downwardly
in the inlet region (26), and the second conveying means (24) bears
15 against an upper face (29b) of the foldable product (29) which faces
upwardly in the inlet region (26);
conveying the foldable product (29) by means of the conveying device
(6) in a conveying direction (F) from the inlet region (26) to an outlet
region (28) of the conveying device (6) which is arranged adjacent to a
20 folding region (30) between the folding blade (16) and the first and the
second folding roller (10, 12), wherein between the inlet region (26)
and the outlet region (28) the orientation of the foldable product (29) is
maintained relative to a longitudinal axis (29e) of the foldable product
(29), which is oriented parallel to the conveying direction (F) in the in25
let region (26);
arranging the foldable product (29) in the folding region (30), wherein
the upper face (29b) of the foldable product (29) faces the first and
second folding roller (10, 12) and the lower face (29a) of the foldable
product (29) faces the folding blade (16);
30
40
moving the folding blade (16) in a folding blade plane (18) in the direction
of the lower face (29a) of the foldable product (29), and the folding
blade (16) acting on the lower face (29a) of the foldable product (29),
so that the foldable product (29) is forced between the first and the
second 5 folding roller (10, 12); and
pulling the foldable product (29) through the first and second folding
roller (10, 12) and thereby generating a fold line transversely to the
longitudinal axis (29e) of the foldable product (29).
17. The method as claimed in claim 16, characterized in that the move10
ment of the folding blade (16) takes place in a direction which is oriented
upwardly.
18. The method as claimed in claim 16 or 17, characterized in that the
second conveying means (24) is arranged in the inlet region (26)
above the first conveying means (24) so that the upper face (29b) of
15 the foldable product (29) faces upwardly in the inlet region (26) of the
conveying device (6) and the lower face (29a) of the foldable product
(29) faces downwardly in the inlet region (26) of the conveying device
(6).