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The invention provides a method and apparatus for separating a stack of folded sheets by inserting a first, second, third and fourth count fingers into four successive openings in the stack, and separating the stack between the second and third count fingers. Where separation is carried out after a

The invention provides a method and apparatus for separating a stack of folded sheets by inserting a first, second, third and fourth count fingers into four successive openings in the stack, and separating the stack between the second and third count fingers. Where separation is carried out after a desired number of folded sheets have passed the third count finger, a completed pack having the desired number of sheets may be formed downstream from the third count finger. The count fingers may be operatively mounted in count finger cassettes.

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1. A method for separating a stack of folded sheets disposed in a stacking region extending from an upstream to a downstream direction along a folded sheet path into packs having a desired number of folded sheets, wherein the folded sheets in the stack have successive folds in the stack alternativel

1. A method for separating a stack of folded sheets disposed in a stacking region extending from an upstream to a downstream direction along a folded sheet path into packs having a desired number of folded sheets, wherein the folded sheets in the stack have successive folds in the stack alternatively disposed on opposite sides of folded sheet path with each fold joining two successive panels opening from one another on the opposite side of the folded sheet path to form an opening between successive folds, the method comprising: insetting at least a first and a second count finger operatively mounted on endless drive members into the stack respectively into at least two successive openings in the stack, and separating the stack between the count fingers to form a completed pack downstream from the count fingers; andfurther comprising, successively inserting first, second, third and fourth count fingers each mounted on a separate respective endless drive member into four successive openings in the stack, and separating the stack between the second and third fingers to form a completed pack downstream from the second count finger. 2. The method of claim 1, further comprising, moving the completed pack out of the stacking region. 3. The method of claim 2, further comprising inserting a fold finger in a fold adjacent to a first panel of a next pack upstream of the completed pack. 4. The method of claim 3, further comprising advancing the fourth count finger downstream of the next pack prior to inserting the fold finger. 5. The method of claim 3, comprising inserting the fold finger such that the fold finger is positioned upstream of the second count finger and downstream of the third count finger such that the fold finger and third count finger are positioned within adjacent folds of the next pack, and thereafter advancing the fourth count finger. 6. The method of claim 3, further comprising the step of directing a blast of air at the first panel of the next stack to fold the first panel about the fold finger to place the first panel in a generally upright presentation. 7. The method of claim 3, comprising inserting the fold finger into the stacking region upstream of the strip finger and the build finger. 8. The method of claim 1, further comprising, supporting a downstream end of the completed pack with a build finger. 9. The method of claim 1, further comprising, pulling the completed pack away from the remainder of the stack by moving the inserted first and second count fingers together in a downstream direction. 10. The method of claim 1, further comprising: inserting the first and second count fingers into the stack at opposite transverse edges of a penultimate panel of a last folded sheet of the completed pack downstream and upstream respectively from the penultimate panel; andinserting the third and fourth count fingers into the stack at opposite transverse edges of a second panel of a first sheet of the next pack upstream and downstream respectively from the second panel. 11. The method of claim 1, further comprising, inserting a strip finger between the second and third count fingers over a penultimate panel of the completed pack. 12. The method of claim 1, further comprising, positioning a build finger downstream from a first panel of a next pack, for supporting the downstream end of the next pack, and retracting the third and fourth count fingers. 13. The method of claim 1, further comprising, moving the first and second count fingers away from the third and fourth count fingers after all four count fingers are inserted into the four successive openings. 14. The method of claim 13, further comprising, moving the first and second count fingers away from the third and fourth count fingers in the downstream direction after all four count fingers are inserted into the four successive openings. 15. The method of claim 13, further comprising, momentarily stopping movement in the downstream direction of the first and second count fingers while continuing to move the third and fourth count fingers in the downstream direction, after all four count fingers are inserted into the four successive openings. 16. The method of claim 13, further comprising, moving the first and second count fingers in the upstream direction after all four count fingers are inserted into the four successive openings. 17. The method of claim 13, further comprising, inserting a strip finger into the stack between the second and third count fingers and then moving the strip finger in the downstream direction together with the first and second count fingers. 18. The method of claim 17, further comprising, inserting a build finger between the second and third count fingers, downstream from a first panel of a next pack, for supporting the downstream end of the next pack, and retracting the third and fourth count fingers. 19. The method of claim 1, wherein: the stack of folded sheets is moving at a build rate in a downstream direction along the folded sheet path as folded sheets are added to an upstream end of the stack in the folding region; andthe method further includes, inserting the four count fingers into the moving stack and moving the four count fingers in a downstream direction along the folded sheet path as the stack continues to build upstream from the count fingers in the folding region. 20. The method of claim 1, further comprising, moving the first and second count fingers away from the third and fourth count fingers after all four count fingers are inserted into the four successive openings, to thereby create a gap between the second and third count fingers. 21. The method of claim 20, further comprising, forming the gap by moving the first and second count fingers away from the third and fourth count fingers in the downstream direction after all four count fingers are inserted into the four successive openings. 22. The method of claim 20, further comprising, forming the gap by momentarily stopping movement in the downstream direction of the third and fourth count fingers while continuing to move the first and second count fingers in the downstream direction, after all four count fingers are inserted into the four successive openings. 23. The method of claim 20, further comprising, forming the gap by moving the third and fourth count fingers in the upstream direction after all four count fingers are inserted into the four successive openings. 24. The method of claim 20, further comprising, inserting a strip finger into the gap between the second and third count fingers and then moving the strip finger in the downstream direction together with the first and second count fingers. 25. The method of claim 20, further comprising, inserting a build finger into the gap downstream from the third and fourth count fingers, for supporting the downstream end of a next pack, and then retracting the third and fourth count fingers. 26. The method of claim 25, further comprising: supporting a downstream end of the completed pack with the build finger positioned downstream from the first and second count fingers;moving the completed pack out of the stacking region; andthen repositioning the build finger downstream from the third and fourth count fingers for supporting the downstream end of the next pack. 27. The method of claim 20, further comprising: inserting a strip finger into the gap between the second and third count fingers over a penultimate panel of the completed pack; andthen moving the strip finger in the downstream direction together with the first and second count fingers. 28. The method of claim 27, further comprising: inserting a build finger downstream from a first panel of a next pack, for supporting the downstream end of the next pack; andthen retracting the third and fourth count fingers. 29. The method of claim 28, further comprising, moving the completed pack out of the folding region. 30. The method of claim 1, further comprising, using the same set of four count fingers for making each and every separation of the stack into packs. 31. The method of claim 1, further comprising, using another set of four count fingers for making the next separation in the stack, in the same manner as the separation was performed using the first set of count fingers to perform the first separation. 32. The method of claim 1, further comprising, driving each count finger independently. 33. The method of claim 1, wherein: the sheets have at least one full-width panel defining a full panel width W formed by interaction of first and second folding rolls having respective peripheries thereof operatively disposed to form a nip therebetween, with the folded sheet path extending through the nip;the stacking region is partly defined by first and second datum planes disposed on opposite sides of the sheet path and spaced from the sheet path at respective datum spacings (w) substantially equal to one-half of the full-panel width W, to form a first point of intersection between the periphery of the first folding roll and the first datum plane at an upstream end of the stacking region and a second point of intersection between the periphery of the second folding roll and the second datum plane at an upstream end of the stacking region;and the method further comprises, inserting the first and third count fingers into the stack substantially at one of the first and second intersection points and inserting the second and fourth count fingers into the stack substantially at the other of the first and second intersection points. 34. The method of claim 33, further comprising, stripping the sheets from the first and second rolls substantially at the respective first and second points of intersection. 35. The method of claim 34, further comprising, positioning a folded sheet guide at one or both of the points of intersection for urging separation of the sheets from the periphery of the roll. 36. The method for separating a stack of folded sheets of claim 1, wherein the stack of folded sheets is being continually built in a stacking region extending from an upstream to a downstream direction along a folded sheet path with the stack moving generally downstream at a build rate, the packs having a desired number of folded sheets, the method further comprising: supporting the downstream end of each pack being built with a build finger;when one of the packs being built has reached the desired number of folded sheets, sequentially inserting the first, second, third and fourth count fingers into the four successive openings in the stack to define a completed one of the packs downstream from the first and second count fingers as the stack continues to build upstream from the third and fourth count fingers, with the first and second count fingers being inserted into the stack at opposite transverse edges of a penultimate panel of a last folded sheet of the completed pack downstream and upstream respectively from the penultimate panel, and the third and fourth count fingers being inserted into the stack at opposite transverse edges of a second panel of a first sheet of a next pack, upstream and downstream respectively from the second panel;moving the count fingers downstream at the build rate until all of the count fingers have been inserted, and then moving the first and second count fingers in a downstream direction away from the third and fourth count fingers at a speed faster than the build rate to form a gap between the second and third count fingers, to pull the completed pack away from the remainder of the stack;inserting a strip finger into the gap between the second and third count fingers over the penultimate panel of the completed pack; andmoving the completed pack out of the stacking region with the strip and build fingers. 37. The method of claim 36, further comprising: removing the completed pack from the build and strip fingers; andtransferring the downstream end of the next pack from the third and fourth count fingers to the build finger. 38. The method of claim 37, further comprising, repeating the method of claim 33 to separate the next complete pack from the stack. 39. The method of claim 36, further comprising: releasing the completed pack by retracting the build and strip fingers;removing the completed pack from alignment with the stacking region; andtransferring the downstream end of the next pack from the third and fourth count fingers to the build finger. 40. The method of claim 39, further comprising, repeating the method of claim 36 to separate the next complete pack from the stack. 41. The method of claim 36, wherein: the sheets have at least one full-width panel defining a full panel width W formed by interaction of first and second folding rolls having respective peripheries thereof operatively disposed to form a nip therebetween, with the folded sheet path extending through the nip;the stacking region is partly defined by first and second datum planes disposed on opposite sides of the sheet path and spaced from the sheet path at respective datum spacings (w) substantially equal to one-half of the full-panel width W, to form a first point of intersection between the periphery of the first folding roll and the first datum plane at an upstream end of the stacking region and a second point of intersection between the periphery of the second folding roll and the second datum plane at an upstream end of the stacking region;and the method further comprises, inserting the first and third count fingers into the stack substantially at the first intersection point and inserting the second and fourth count fingers in to the stack substantially at the second intersection point. 42. The method of claim 41, further comprising, stripping the sheets from the first and second rolls substantially at the respective first and second points of intersection. 43. The method of claim 42, further comprising, positioning a folded sheet guide at one or both of the points of intersection to facilitate stripping the sheets. 44. The method of claim 36, further comprising inserting a fold finger downstream of the third and fourth count fingers and thereafter moving the fourth count finger downstream of the third count finger at the speed faster than the build rate. 45. The method of claim 36, further comprising moving the fourth count finger in the downstream direction at the speed faster than the build rate downstream of the third count finger and thereafter inserting a fold finger into the stacking region downstream of the third count finger and upstream of the fourth count finger. 46. The method of claim 45, further comprising the step of removing the completed pack from the build and strip fingers, and directing a blast of air at a first panel of the next pack to fold the first panel about the fold finger while the completed pack is removed from the strip and build fingers. 47. The method of claim 46, further comprising the step transferring the downstream end of the next pack from the third count finger and the fold finger to the build finger after the step of directing the blast of air. 48. The method of claim 1, wherein the first and second count fingers are part of a first count finger cassette and the third and fourth count fingers are part of a second count finger cassette, each count finger cassette comprising: a frame, first and second rotatable drive elements, first and second rotatable primary idler elements, first and second endless drive members each having at least one count finger extending outward therefrom, and a guide element;the frame defining first and second spaced parallel rotational axes;the first and second drive elements being respectively journaled for rotation independent of one another about the first and second rotational drive axes, with the first drive element being adapted to receive a first driving input for driving the first drive element about the first drive axis, and with the second drive element being adapted to receive a second driving input for driving the second drive element about the second drive axis;the first primary idler element being journaled for rotation upon and independently from the second rotatable drive element about the second rotational axis;the second primary idler element being journaled for rotation upon and independently from the first rotatable drive element about the first rotational axis;the first endless drive member being drivingly engaged with a portion of the outer peripheries of the first primary idler element and the first rotatable drive element to thereby at least partly define a first substantially planar path for travel of the first endless drive member extending generally perpendicular to, and around the first and second rotational axes;the second endless drive member being drivingly engaged with a portion of the outer peripheries of the second primary idler element and the second rotatable drive element to thereby at least partly define a second substantially planar path for travel of the second endless element extending generally perpendicular to, and around the first and second rotational axes, and lying in a substantially side-by-side relationship to the first substantially planar path; andthe guide element being attached to the frame and configured for urging both the first and second endless drive members to travel substantially in parallel with one another along a substantially straight line for a portion of the respective paths of travel of the first and second endless members. 49. The method of claim 48, wherein, the first and second rotatable drive elements include respective central bores therein for passage therethrough of respective first and second drive shafts, with the drive shafts being drivingly securable to the first and second drive elements. 50. The method of claim 49, further comprising, one or more additional idler elements mounted to the frame for rotation about respective additional idler element axes and operatively connected to one or the other of the endless drive members for defining the path of the one or the other endless drive members. 51. The method of claim 50, further comprising at least one separator element disposed between adjacent rotatable parts mounted for rotation about the same axis. 52. The method of claim 1, further comprising, moving the completed pack out of the stacking region. 53. The method of claim 52, further comprising, inserting a strip finger between the count fingers for supporting an upstream end of the completed pack during movement of the completed pack out of the stacking region. 54. The method of claim 53, further comprising inserting a fold finger into the stacking region between the count fingers upstream of the strip finger. 55. The method of claim 1, further comprising, supporting a downstream end of the completed pack with a build finger. 56. The method of claim 55, further comprising, moving the completed pack out of the stacking region. 57. The method of claim 56, further comprising, inserting a strip finger between the count fingers for supporting an upstream end of the completed pack during movement of the completed pack out of the stacking region. 58. The method of claim 57, further comprising inserting a fold finger into the stacking region between the count fingers upstream of the strip finger and the build finger. 59. The method of claim 56, wherein, the count fingers and endless drive members are operatively connected in one or more count finger cassettes with the endless drive members being adapted to be driven in a separately controllable manner, and the method further comprises, driving the endless drive members in a controlled manner to affect separation of the stack between the count fingers into a completed stack downstream from the count fingers and a next stack upstream from the count fingers. 60. The method of claim 59, further comprising, inserting a strip finger between the count fingers for supporting an upstream end of the completed pack during movement of the completed pack out of the stacking region. 61. The method of claim 60, further comprising, moving the completed pack out of the stacking region. 62. The method of claim 61, further comprising, inserting a strip finger between the count fingers for supporting an upstream end of the completed pack during movement of the completed pack out of the stacking region. 63. The method of claim 59, further comprising: supporting a downstream end of the completed pack with a build finger;moving the completed pack out of the stacking region while supporting the downstream end of the competed pack with the build finger; andthen repositioning the build finger in the stacking region for supporting a downstream end of a next pack. 64. The method of claim 55, further comprising inserting a fold finger into the stacking region between the count fingers upstream of the build finger. 65. The method of claim 1, further comprising: supporting a downstream end of the completed pack with a build finger;moving the completed pack out of the stacking region while supporting the downstream end of the competed pack with the build finger; andthen repositioning the build finger in the stacking region for supporting a downstream end of a next pack. 66. The method of claim 65, further comprising supporting the downstream end of the next pack upstream from the completed pack with a fold finger while supporting the downstream end of the completed pack with the build finger. 67. The method of claim 66, further comprising moving the fold finger out of the stacking region prior to supporting the downstream end of the next pack with the build finger.