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An interfolder separator apparatus and method utilize a pair of count fingers that are movable longitudinally along and transversely to a stream of folded sheets, for temporarily supporting each successive pack formed by the separator and then releasing each successive pack when partly completed to

An interfolder separator apparatus and method utilize a pair of count fingers that are movable longitudinally along and transversely to a stream of folded sheets, for temporarily supporting each successive pack formed by the separator and then releasing each successive pack when partly completed to alternating build fingers, so that the operation of separating successive packs from one another is performed separately from the operations of completing the build of each pack and transporting the completed packs to downstream operations. The count fingers may be mounted to pivot about axes that are movable longitudinally along and transversely to the stream of sheets. A first or last panel of the completed pack may also be folded back partly upon itself, after the partly completed pack is released by the count fingers. Some or all of the fingers may be spring loaded and automatically resettable for clearing jams.

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1. An apparatus for forming completed packs containing a desired number of folded sheets formed in a stacking region below a pair of folding rolls along a sheet path extending through a nip between the pair of folding rolls by a continuously flowing sheet stream of folded sheets issuing downstream f

1. An apparatus for forming completed packs containing a desired number of folded sheets formed in a stacking region below a pair of folding rolls along a sheet path extending through a nip between the pair of folding rolls by a continuously flowing sheet stream of folded sheets issuing downstream from the pair of folding rolls along the sheet path and having adjacent panels forming successive folds opening alternately in opposite directions substantially transversely to the sheet path, the apparatus comprising: a count finger arrangement having a first and a second count finger, a build and transport arrangement having two or more build fingers, and at least one strip finger;the first and second count fingers being operatively configured and connected to the pack build and transport arrangement for periodic pivotable motion about respective first and second count finger axes into successive oppositely opening folds to form a completed pack downstream from the count fingers;the count fingers also being operatively configured and connected to the pack build and transport arrangement for movement of the count finger axes in a downstream direction while continuing to partly build the next pack on upstream surfaces of the count fingers as a pack build and transport arrangement moves the completed pack out of the stacking region;the count fingers further being operatively configured and connected to the pack build and transport arrangement for retracting the count fingers by moving them substantially linearly oppositely from one another outward from the sheet path to transfer the partly completed next pack to the pack build and transport arrangement after the pack build and transport has transported the previously completed pack out of the stacking region;the two or more build fingers of the build and transport arrangement being alternately positionable in the stacking region and configured for receiving partly completed packs from the count fingers, for receiving additional folded sheets from the sheet stream to complete the next pack after the count fingers are retracted, and for transporting completed packs out of the stacking region;the at least one strip finger being configured and operatively connected to the count and build fingers such that the at least one stripping finger is insertable at least partly across an upstream surface of the last panel while the count fingers are supporting the next pack, prior to transporting the completed pack out of the stacking region;the at least one strip finger also being configured and operatively connected to the build fingers in such a manner that the strip finger moves longitudinally along the sheet path with the build finger supporting the completed pack, to thereby facilitate pulling the completed pack away from the count fingers;the at least one strip finger being further configured and operatively connected such that the strip finger retracts in a transverse direction from the build finger supporting the completed pack prior to the build finger supporting the completed pack transporting the completed pack out of the stacking region; anda controller operably connected to the two or more build fingers, the controller configured to operatively control the two or more build fingers for alternately positioning in the stacking region and for receiving partly completed packs from the count fingers, for receiving additional folded sheets from the sheet stream to complete the next pack after the count fingers are retracted, and for transporting completed packs out of the stacking region. 2. The apparatus of claim 1, further comprising, a panel folding arrangement for folding at least one of the first and last panels at least partly back upon itself. 3. The apparatus of claim 1, further comprising, a conveying arrangement receiving completed packs from the build fingers and transporting the completed packs to a location outside of the stacking region. 4. The apparatus of claim 3, further comprising a control arrangement for recognizing a defective pack and diverting the defective pack to a defective pack receiving arrangement. 5. The apparatus of claim 3, wherein, the conveying arrangement is alternately positionable in a first position aligned with the sheet path for receiving completed packs, and in a second position out-of alignment with the sheet path for allowing defective packs to bypass the conveying arrangement. 6. The apparatus of claim 1, wherein, at least one of the build or strip fingers is pivotable from a working position to a bypass position to allow passage of a clog. 7. The apparatus of claim 6, wherein, the at least one of the build and strip fingers is spring loaded to reset itself to the working position after being pivoted to the bypass position. 8. The apparatus of claim 7, wherein, the at least one of the build and strip fingers is pivotable in either an upstream or a downstream direction. 9. The apparatus of claim 1, wherein, each of the count fingers is operatively attached to a respective count-finger arm arrangement movable longitudinally along the sheet path by a first actuator. 10. The apparatus of claim 9, wherein, the count-finger arm arrangement comprises: a first member movable longitudinally along the sheet path by the first actuator, for moving the count finger axis in a longitudinal direction; anda second member operatively connected to the first member and movable transversely thereupon in a transverse direction between extended and retracted transverse positions thereof by a second actuator operatively connected between the first and second members, with the second member defining the count finger axis and having the count finger mounted thereupon for pivoting motion about the count finger axis from a retracted angular position, whereat the count finger is angularly positioned for not engaging the fold, to an extended angular position of the count finger about the count finger axis, whereat the count finger is angularly positioned for engaging the fold. 11. The apparatus of claim 10, wherein, the count finger is operatively coupled to the first member of the count-finger arm arrangement in such a manner that: movement of the second member from the extended to the retracted transverse position thereof urges movement of the count finger about the count finger axis from the extended to the retracted angular position of the count finger; andmovement of the second member from the retracted to the extended transverse position thereof urges movement of the count finger about the count finger axis from the retracted to the extended angular position of the count finger. 12. The apparatus of claim 1, wherein the first count finger, second count finger, the at least one strip finger, and the two or more build fingers are independently moveable linearly toward and away from the sheet path as well as parallel to the sheet path independent of the movement of the other ones of the first count finger, second count finger, the at least one strip finger, and the two or more build fingers. 13. The apparatus of claim 1, wherein, each of the count fingers is operatively attached to a respective count-finger arm arrangement linearly movable longitudinally along the sheet path by a first actuator. 14. The apparatus of claim 1, wherein the controller is operatively connected to the first and second count fingers, the at least one strip finger, and the two or more build fingers and configured to control the movement and operation of the first and second count fingers, the at least one strip finger, and the two or more build fingers. 15. An apparatus for forming completed packs containing a desired number of folded sheets formed in a stacking region below a pair of folding rolls along a sheet path extending through a nip between the pair of folding rolls by a continuously flowing sheet stream of folded sheets issuing downstream from the pair of folding rolls along the sheet path and having adjacent panels forming successive folds opening alternately in opposite directions substantially transversely to the sheet path, the apparatus comprising: a count finger arrangement having a first and a second count finger, a build and transport arrangement having two or more build fingers, and at least one strip finger;the first and second count fingers being operatively configured and connected to the pack build and transport arrangement for periodic pivotable motion about respective first and second count finger axes into successive oppositely opening folds to form a completed pack downstream from the count fingers;the count fingers also being operatively configured and connected to the pack build and transport arrangement for movement of the count finger axes in a downstream direction while continuing to partly build the next pack on upstream surfaces of the count fingers as a pack build and transport arrangement moves the completed pack out of the stacking region;the count fingers further being operatively configured and connected to the pack build and transport arrangement for retracting the count fingers by moving them substantially linearly oppositely from one another outward from the sheet path to transfer the partly completed next pack to the pack build and transport arrangement after the pack build and transport has transported the previously completed pack out of the stacking region;the two or more build fingers of the build and transport arrangement being alternately positionable in the stacking region and configured for receiving partly completed packs from the count fingers, for receiving additional folded sheets from the sheet stream to complete the next pack after the count fingers are retracted, and for transporting completed packs out of the stacking region;the at least one strip finger being configured and operatively connected to the count and build fingers such that the at least one stripping finger is insertable at least partly across an upstream surface of the last panel while the count fingers are supporting the next pack, prior to transporting the completed pack out of the stacking region;the at least one strip finger also being configured and operatively connected to the build fingers in such a manner that the strip finger moves longitudinally along the sheet path with the build finger supporting the completed pack, to thereby facilitate pulling the completed pack away from the count fingers;the at least one strip finger being further configured and operatively connected such that the strip finger retracts in a transverse direction from the build finger supporting the completed pack prior to the build finger supporting the completed pack transporting the completed pack out of the stacking region;wherein, each of the count fingers is operatively attached to a respective count-finger arm arrangement movable longitudinally along the sheet path by a first actuator;wherein, the count-finger arm arrangement comprises:a first member movable longitudinally along the sheet path by the first actuator, for moving the count finger axis in a longitudinal direction; anda second member operatively connected to the first member and movable transversely thereupon in a transverse direction between extended and retracted transverse positions thereof by a second actuator operatively connected between the first and second members, with the second member defining the count finger axis and having the count finger mounted thereupon for pivoting motion about the count finger axis from a retracted angular position, whereat the count finger is angularly positioned for not engaging the fold, to an extended angular position of the count finger about the count finger axis, whereat the count finger is angularly positioned for engaging the fold;wherein, the count finger is operatively coupled to the first member of the count-finger arm arrangement in such a manner that:movement of the second member from the extended to the retracted transverse position thereof urges movement of the count finger about the count finger axis from the extended to the retracted angular position of the count finger; andmovement of the second member from the retracted to the extended transverse position thereof urges movement of the count finger about the count finger axis from the retracted to the extended angular position of the count finger;wherein, the count finger is further operatively connected to the first member of the count-finger arm arrangement by a cam and follower arrangement for urging movement of the count finger in response to relative transverse movement between the first and second members of the count-finger arm arrangement. 16. The apparatus of claim 15, wherein, the count finger is further operatively connected to the first member of the count-finger arm arrangement by a rocker shaft and linkage arrangement, for urging movement of the count finger in response to relative transverse movement between the first and second members of the count-finger arm arrangement. 17. The apparatus of claim 16, wherein, the rocker shaft and linkage arrangement includes an elongated connecting link operatively connecting the count finger to the first member, with a first end of the connecting link operatively connected to the count finger and a second end of the pushrod operatively connected to the first member, and the pushrod being configured to elastically buckle to thereby allow the count finger to pivot about the count finger axis in the event that the count finger becomes overloaded on an upper surface of the count finger, and to further urge the count finger to return to its normal position when the overload has been cleared. 18. An apparatus for forming completed packs containing a desired number of folded sheets formed in a stacking region below a pair of folding rolls along a sheet path extending through a nip between the pair of folding rolls by a continuously flowing sheet stream of folded sheets issuing downstream from the pair of folding rolls along the sheet path and having adjacent panels forming successive folds opening alternately in opposite directions substantially transversely to the sheet path, the apparatus comprising: a count finger arrangement having a first and a second count finger, a build and transport arrangement having two or more build fingers, and at least one strip finger;the first and second count fingers being operatively configured and connected to the pack build and transport arrangement for periodic pivotable motion about respective first and second count finger axes into successive oppositely opening folds to form a completed pack downstream from the count fingers;the count fingers also being operatively configured and connected to the pack build and transport arrangement for movement of the count finger axes in a downstream direction while continuing to partly build the next pack on upstream surfaces of the count fingers as a pack build and transport arrangement moves the completed pack out of the stacking region;the count fingers further being operatively configured and connected to the pack build and transport arrangement for retracting the count fingers by moving them substantially linearly oppositely from one another outward from the sheet path to transfer the partly completed next pack to the pack build and transport arrangement after the pack build and transport has transported the previously completed pack out of the stacking region;the two or more build fingers of the build and transport arrangement being alternately positionable in the stacking region and configured for receiving partly completed packs from the count fingers, for receiving additional folded sheets from the sheet stream to complete the next pack after the count fingers are retracted, and for transporting completed packs out of the stacking region;the at least one strip finger being configured and operatively connected to the count and build fingers such that the at least one stripping finger is insertable at least partly across an upstream surface of the last panel while the count fingers are supporting the next pack, prior to transporting the completed pack out of the stacking region;the at least one strip finger also being configured and operatively connected to the build fingers in such a manner that the strip finger moves longitudinally along the sheet path with the build finger supporting the completed pack, to thereby facilitate pulling the completed pack away from the count fingers;the at least one strip finger being further configured and operatively connected such that the strip finger retracts in a transverse direction from the build finger supporting the completed pack prior to the build finger supporting the completed pack transporting the completed pack out of the stacking region;wherein, each of the count fingers is operatively attached to a respective count-finger arm arrangement movable longitudinally along the sheet path by a first actuator;wherein, the count-finger arm arrangement comprises:a first member movable longitudinally along the sheet path by the first actuator, for moving the count finger axis in a longitudinal direction; anda second member operatively connected to the first member and movable transversely thereupon in a transverse direction between extended and retracted transverse positions thereof by a second actuator operatively connected between the first and second members, with the second member defining the count finger axis and having the count finger mounted thereupon for pivoting motion about the count finger axis from a retracted angular position, whereat the count finger is angularly positioned for not engaging the fold, to an extended angular position of the count finger about the count finger axis, whereat the count finger is angularly positioned for engaging the fold;wherein, the count finger is operatively coupled to the first member of the count-finger arm arrangement in such a manner that:movement of the second member from the extended to the retracted transverse position thereof urges movement of the count finger about the count finger axis from the extended to the retracted angular position of the count finger; andmovement of the second member from the retracted to the extended transverse position thereof urges movement of the count finger about the count finger axis from the retracted to the extended angular position of the count finger; andfurther comprising, a second strip finger, with the first and second strip fingers being operatively connected to the count fingers and the build fingers on opposite sides of the sheet path, in such a manner that one of the first and second strip fingers is utilized for packs having an even number of folded sheets and both of the first and second strip fingers is utilized for packs having an odd number of folded sheets. 19. The apparatus of claim 18, further comprising, a panel folding arrangement for folding at least one of the first and last panels at least partly back upon itself. 20. The apparatus of claim 19, wherein, the panel folding arrangement further comprises first and second panel folding fingers: the first panel folding finger being is operatively connected to the first stripping finger and configured to be inserted in an extended position thereof below the build finger supporting the completed pack for folding the first panel of the completed pack at least partly back upon itself by folding a portion of the last panel around a distal end of the first folding finger in the extended position, prior to retracting the first stripping finger from the extended position; andthe second panel folding finger being is operatively connected to the second stripping finger and configured to be inserted in an extended position thereof below the build finger supporting the completed pack for folding the first panel of the completed pack at least partly back upon itself by folding a portion of the last panel around a distal end of the second folding finger in the extended position, prior to retracting the second stripping finger from the extended position. 21. The apparatus of claim 20, wherein, the first and second panel folding fingers are operable for extension to and retraction from their respective extended positions while the first and second strip fingers remain extended across the last sheet of the completed pack. 22. The apparatus of claim 19, wherein, the strip finger and panel folding arrangement are operatively connected and configured for folding the last panels at least partly back upon itself by folding a portion of the last panel around a distal end of the strip finger prior to retracting the strip finger. 23. The apparatus of claim 22, wherein, the panel folding arrangement further comprises a first panel folding finger that is operatively connected and configured to be inserted in an extended position thereof below the build finger supporting the completed pack for folding the first panel of the completed pack at least partly back upon itself by folding a portion of the last panel around a distal end of the folding finger in the extended position, prior to retracting the strip finger from the extended position. 24. An apparatus for forming completed packs containing a desired number of folded sheets formed in a stacking region below a pair of folding rolls along a sheet path extending through a nip between the pair of folding rolls by a continuously flowing sheet stream of folded sheets issuing downstream from the pair of folding rolls along the sheet path and having adjacent panels forming successive folds opening alternately in opposite directions substantially transversely to the sheet path, the apparatus comprising: a count finger arrangement having a first and a second count finger, a build and transport arrangement having two or more build fingers, and at least one strip finger;the first and second count fingers being operatively configured and connected to the pack build and transport arrangement for periodic pivotable motion about respective first and second count finger axes into successive oppositely opening folds to form a completed pack downstream from the count fingers;the count fingers also being operatively configured and connected to the pack build and transport arrangement for movement of the count finger axes in a downstream direction while continuing to partly build the next pack on upstream surfaces of the count fingers as a pack build and transport arrangement moves the completed pack out of the stacking region;the count fingers further being operatively configured and connected to the pack build and transport arrangement for retracting the count fingers by moving them substantially linearly oppositely from one another outward from the sheet path to transfer the partly completed next pack to the pack build and transport arrangement after the pack build and transport has transported the previously completed pack out of the stacking region;the two or more build fingers of the build and transport arrangement being alternately positionable in the stacking region and configured for receiving partly completed packs from the count fingers, for receiving additional folded sheets from the sheet stream to complete the next pack after the count fingers are retracted, and for transporting completed packs out of the stacking region;the at least one strip finger being configured and operatively connected to the count and build fingers such that the at least one stripping finger is insertable at least partly across an upstream surface of the last panel while the count fingers are supporting the next pack, prior to transporting the completed pack out of the stacking region;the at least one strip finger also being configured and operatively connected to the build fingers in such a manner that the strip finger moves longitudinally along the sheet path with the build finger supporting the completed pack, to thereby facilitate pulling the completed pack away from the count fingers;the at least one strip finger being further configured and operatively connected such that the strip finger retracts in a transverse direction from the build finger supporting the completed pack prior to the build finger supporting the completed pack transporting the completed pack out of the stacking region; andwherein first count finger is attached to a first carriage, the second count finger is attached to a second carriage, the at least one strip finger is attached to a third carriage, one of the build fingers is attached to a fourth carriage and another one of the build fingers is attached to a fifth carriage, the first, second, third, fourth, and fifth carriages each being independently moveable toward and away from the sheet path as well as parallel to the sheet path independent of the movement of the other ones of the first, second, third, fourth and fifth carriages. 25. An apparatus for forming completed packs containing a desired number of folded sheets formed in a stacking region below a pair of folding rolls along a sheet path extending through a nip between the pair of folding rolls by a continuously flowing sheet stream of folded sheets issuing downstream from the pair of folding rolls along the sheet path and having adjacent panels forming successive folds opening alternately in opposite directions substantially transversely to the sheet path, the apparatus comprising: a count finger arrangement having a first and a second count finger, a build and transport arrangement having two or more build fingers, and at least one strip finger;the first and second count fingers being operatively configured and connected to the pack build and transport arrangement for periodic pivotable motion about respective first and second count finger axes into successive oppositely opening folds to form a completed pack downstream from the count fingers;the count fingers also being operatively configured and connected to the pack build and transport arrangement for movement of the count finger axes in a downstream direction while continuing to partly build the next pack on upstream surfaces of the count fingers as a pack build and transport arrangement moves the completed pack out of the stacking region;the count fingers further being operatively configured and connected to the pack build and transport arrangement for retracting the count fingers by moving them substantially linearly oppositely from one another outward from the sheet path to transfer the partly completed next pack to the pack build and transport arrangement after the pack build and transport has transported the previously completed pack out of the stacking region;the two or more build fingers of the build and transport arrangement being alternately positionable in the stacking region and configured for receiving partly completed packs from the count fingers, for receiving additional folded sheets from the sheet stream to complete the next pack after the count fingers are retracted, and for transporting completed packs out of the stacking region;the at least one strip finger being configured and operatively connected to the count and build fingers such that the at least one stripping finger is insertable at least partly across an upstream surface of the last panel while the count fingers are supporting the next pack, prior to transporting the completed pack out of the stacking region;the at least one strip finger also being configured and operatively connected to the build fingers in such a manner that the strip finger moves longitudinally along the sheet path with the build finger supporting the completed pack, to thereby facilitate pulling the completed pack away from the count fingers;the at least one strip finger being further configured and operatively connected such that the strip finger retracts in a transverse direction from the build finger supporting the completed pack prior to the build finger supporting the completed pack transporting the completed pack out of the stacking region;further comprising a controller operatively connected to the first and second count fingers, the at least one strip finger, and the two or more build fingers;the controller configured to operatively control the first and second count fingers for periodic pivotable motion about respective first and second count finger axes into successive oppositely opening folds to form a completed pack downstream from the count fingers;the controller configured to operatively control the count fingers for movement of the count finger axes in a downstream direction while continuing to partly build the next pack on upstream surfaces of the count fingers as a pack build and transport arrangement moves the completed pack out of the stacking region;the controller configured for retracting the count fingers by moving them substantially linearly oppositely from one another outward from the sheet path to transfer the partly completed next pack to the pack build and transport arrangement after the pack build and transport has transported the previously completed pack out of the stacking region;the controller configured to operatively control the two or more build fingers for alternately positioning in the stacking region and for receiving partly completed packs from the count fingers, for receiving additional folded sheets from the sheet stream to complete the next pack after the count fingers are retracted, and for transporting completed packs out of the stacking region;the controller configured to operatively control the at least one strip finger to insert the at least one strip finger at least partly across an upstream surface of the last panel while the count fingers are supporting the next pack, prior to transporting the completed pack out of the stacking region;the controller configured to operatively control the at least one strip finger in such a manner that the strip finger moves longitudinally along the sheet path with the build finger supporting the completed pack, to thereby facilitate pulling the completed pack away from the count fingers;the controller configured to operatively control the at least one strip finger to retract the at least one strip finger in a transverse direction from the build finger supporting the completed pack prior to the build finger supporting the completed pack transporting the completed pack out of the stacking region.