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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. An apparatus for separating a stack of folded sheets, disposed in a stacking region extending along a folded sheet path defining a downstream direction, into packs having a desired number of folded sheets, wherein the folded sheets in the stack have successive folds in the stack alternatively dis

1. An apparatus for separating a stack of folded sheets, disposed in a stacking region extending along a folded sheet path defining a downstream direction, 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 the 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 apparatus comprising: first, second, third and fourth count fingers configured and operatively connected for sequential insertion, starting with the first count finger and ending with the fourth count finger, into the stack to separate the stack, between the second and third count fingers into a completed pack downstream from the second count finger and further into a next pack upstream from the third count finger;wherein:each of the count fingers is fixedly attached to a separate endless drive member for independent movement along a separate closed count finger path having a working segment thereof disposed in a portion of the count finger path extending substantially parallel to the folded sheet path along at least a portion of the stacking region;the first and third count fingers being attached to first and third count finger endless drive members disposed on a first transverse side of the stacking region. with the working segment of the closed count finger path for the first count finger endless drive member being disposed in a substantially parallel side-by-side operating relationship to the working segment of the closed count finger path for the third count finger endless drive member; andthe second and fourth count fingers being attached to second and fourth count finger endless drive members disposed on a second opposite transverse side of the stacking region, with the working segment of the closed count finger path for the second count finger endless drive member being disposed in a substantially parallel side-by-side operating relationship to the working segment of the closed count finger path for the fourth count finger endless drive member. 2. The apparatus of claim 1, wherein, the count fingers are configured and operatively connected such that: the first and second count fingers are insertable into the stack at opposite transverse edges of a penultimate panel of a last folded sheet of the completed pack, with the first and second count fingers being insertable downstream and upstream respectively from the penultimate panel; andthe third and fourth count fingers are insertable into the stack at opposite transverse edges of a second panel of a first sheet of the next pack, with the third and fourth count fingers being insertable upstream and downstream respectively from the second panel. 3. The apparatus of claim 2, wherein, the count fingers are further configured and operatively connected in such a manner that the first and second count fingers are movable away from the third and fourth count fingers in the downstream direction, for pulling the completed pack away from the remainder or the stack. 4. The apparatus of claim 3, wherein, the count fingers are each individually mounted for independent movement along the folded sheet path. 5. The apparatus of claim 2, wherein, the count fingers are configured and operatively connected such that the first and second count fingers are separable from the third and fourth count fingers after all four count fingers are inserted into the four successive openings to form a gap between the second and third count fingers. 6. The apparatus of claim 5, wherein, the count fingers are configured and operatively connected such that the first and second count fingers are movable away from the third and fourth count fingers in the downstream direction after all four count fingers are inserted into the four successive openings to form the gap. 7. The apparatus of claim 5, wherein, the count fingers are configured and operatively connected such that, after all four count fingers are inserted into the four successive openings, the third and fourth count fingers can be momentarily stopped from movement in the downstream direction while the first and second count fingers are moved in the downstream direction, to form the gap. 8. The method of claim 5, wherein, the count fingers are configured and operatively connected such that, after all four count fingers are inserted into the four successive openings, the third and fourth count fingers are movable in the upstream direction, to form the gap. 9. The apparatus of claim 2, 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;the first and third count fingers are inserted into the stack substantially at the first intersection point; andthe second and fourth count fingers are inserted into the stack substantially at the second intersection point. 10. The apparatus of claim 9, further comprising, at least one folded sheet guide operatively disposed at one of the points of intersection to facilitate stripping the sheets from the folding roll having a periphery forming the one of the intersection points. 11. The apparatus 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 member 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. 12. The apparatus of claim 1 further comprising: a folding roll rotatably mounted about a roll axis for providing a stream of folded sheets to the stacking region downstream from the roll, with the roll having an annular groove opening outward through the periphery of the roll; anda count finger cassette having a portion thereof operatively disposed within the annular groove, wherein the count finger cassette includes the first count finger. 13. The apparatus of claim 12, wherein, the count finger cassette drive arrangement further comprises a folded sheet guide for urging movement of the sheets away from the periphery of the roll. 14. The apparatus of claim 13, wherein, the cassette frame includes the folded sheet guide. 15. The apparatus of claim 14, wherein, the folded sheet guide is defined by a portion of the cassette frame extending into the groove in the folding roll. 16. The apparatus of claim 12, 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;the first and third count fingers are inserted into the stack substantially at the first intersection point; andthe second and fourth count fingers are inserted into the stack substantially at the second intersection point. 17. The apparatus of claim 16, wherein, the folded sheet guide is defined by the portion of the cassette frame extending into the annular groove. 18. The folding and separating apparatus of claim 12, wherein, the count finger cassette also includes the second count finger, the count finger cassette further comprises: a frame, first and second rotatable drive elements, first and second rotatable primary idler elements, 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 member 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. 19. The apparatus of claim 1, further comprising, a strip finger operatively connected for insertion between the count fingers for supporting an upstream end of the completed pack during movement of the completed pack out of a stacking region. 20. The apparatus of claim 19, further comprising: a build finger operatively connected for supporting a downstream end of the completed pack; andan arrangement for moving the completed pack out of the stacking region while supporting the downstream end of the competed pack with the build finger;the build finger being further operatively connected to be repositioned in the stacking region for supporting a downstream end of a next pack. 21. The apparatus of claim 1, 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 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. 22. An apparatus for separating a stack of folded sheets, disposed in a stacking region extending along a folded sheet path defining a downstream direction, 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 the 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 apparatus comprising; first, second, third and fourth count fingers configured and operatively connected for sequential insertion, starting with the first count finger and ending with the fourth count finger, into the stack to separate the stack, between the second and third count fingers into a completed pack downstream from the second count finger and further into a next pack upstream from the third count finger;wherein, the count fingers are configured and operatively connected such that: the first und second count fingers are insertable into the stack at opposite transverse edges of a penultimate panel of a last folded sheet of the completed pack, with the first and second count fingers being insertable downstream and upstream respectively from the penultimate panel; andthe third and fourth count fingers are insertable into the stack at opposite transverse edges of a second panel of a first sheet of the next pack, with the third and fourth count fingers being insertable upstream and downstream respectively from the second panel,wherein, the count fingers are further configured and operatively connected in such a manner that the first and second count fingers are movable away from the third and fourth count fingers in the downstream direction, for pulling the completed pack away from the remainder or the stackwherein, the count fingers are each individually mounted for independent movement along the folded sheet path;wherein: each of the count fingers is fixedly attached to a separate endless drive member for independent movement along a separate closed count finger path having a working segment thereof disposed in a portion of the count finger path extending substantially parallel to the folded sheet path along at least a portion of the stacking region;the first and third count fingers being attached to first and third count finger endless drive members disposed on a first transverse side of the stacking region, with the working segment of the closed count finger path for the first count finger endless drive member being disposed in a substantially parallel side-by-side operating relationship to the working segment of the closed count finger path for the third count finger endless drive member; andthe second and fourth count fingers being attached to second and fourth count finger endless drive members disposed on a second opposite transverse side of the stacking region, with the working segment of the closed count finger path for the second count finger endless drive member being disposed in a substantially parallel side-by-side operating relationship to the working segment of the closed count finger path for the fourth count finger endless drive member. 23. The apparatus of claim 22, wherein, at least one of the respective count fingers and the endless drive member to which the respective count finger is attached are part of a count finger cassette drive arrangement having a rotatable drive element and at least one rotatable idler element mounted for rotation with respect to a cassette frame member for moving the endless drive member and count finger around the closed count finger path. 24. An apparatus for separating a stack of folded sheets, disposed in a stacking region extending along a folded sheet path defining a downstream direction, 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 the 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 apparatus comprising: first, second, third and fourth count fingers configured and operatively connected for sequential insertion, starting with the first count finger and ending with the fourth count finger, into the stack to separate the stack, between the second and third count fingers into a completed pack downstream from the second count finger and further into a next pack upstream from the third count finger;each of the first, second, third and fourth count fingers being fixedly attached to a separate endless drive member for independent movement along a separate closed count finger path.