WO2011022363A2 - Appareil et procédé pour imprimer, relier et massicoter un livre relié parfait imprimé à la demande - Google Patents

Appareil et procédé pour imprimer, relier et massicoter un livre relié parfait imprimé à la demande Download PDF

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Publication number
WO2011022363A2
WO2011022363A2 PCT/US2010/045708 US2010045708W WO2011022363A2 WO 2011022363 A2 WO2011022363 A2 WO 2011022363A2 US 2010045708 W US2010045708 W US 2010045708W WO 2011022363 A2 WO2011022363 A2 WO 2011022363A2
Authority
WO
WIPO (PCT)
Prior art keywords
book block
spine
book
adhesive
fixture
Prior art date
Application number
PCT/US2010/045708
Other languages
English (en)
Other versions
WO2011022363A3 (fr
Inventor
Jeffrey D. Marsh
Lynn W. Swenson
Brett E. Denny
Original Assignee
Perfect Systems, Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Perfect Systems, Llc filed Critical Perfect Systems, Llc
Publication of WO2011022363A2 publication Critical patent/WO2011022363A2/fr
Publication of WO2011022363A3 publication Critical patent/WO2011022363A3/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B42—BOOKBINDING; ALBUMS; FILES; SPECIAL PRINTED MATTER
    • B42C—BOOKBINDING
    • B42C9/00—Applying glue or adhesive peculiar to bookbinding
    • B42C9/0006—Applying glue or adhesive peculiar to bookbinding by applying adhesive to a stack of sheets
    • B42C9/0012—Applying glue or adhesive peculiar to bookbinding by applying adhesive to a stack of sheets with a roller
    • B42C9/0018—Applying glue or adhesive peculiar to bookbinding by applying adhesive to a stack of sheets with a roller for binding stacks of sheets one at the time
    • B42C9/0025—Applying glue or adhesive peculiar to bookbinding by applying adhesive to a stack of sheets with a roller for binding stacks of sheets one at the time and subsequently applying a cover
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
    • B26D7/00—Details of apparatus for cutting, cutting-out, stamping-out, punching, perforating, or severing by means other than cutting
    • B26D7/01—Means for holding or positioning work
    • B26D7/015—Means for holding or positioning work for sheet material or piles of sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B42—BOOKBINDING; ALBUMS; FILES; SPECIAL PRINTED MATTER
    • B42C—BOOKBINDING
    • B42C19/00—Multi-step processes for making books
    • B42C19/02—Multi-step processes for making books starting with single sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B42—BOOKBINDING; ALBUMS; FILES; SPECIAL PRINTED MATTER
    • B42C—BOOKBINDING
    • B42C19/00—Multi-step processes for making books
    • B42C19/08—Conveying between operating stations in machines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B42—BOOKBINDING; ALBUMS; FILES; SPECIAL PRINTED MATTER
    • B42C—BOOKBINDING
    • B42C5/00—Preparing the edges or backs of leaves or signatures for binding
    • B42C5/04—Preparing the edges or backs of leaves or signatures for binding by notching or roughening
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
    • B26D5/00—Arrangements for operating and controlling machines or devices for cutting, cutting-out, stamping-out, punching, perforating, or severing by means other than cutting
    • B26D5/02—Means for moving the cutting member into its operative position for cutting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
    • B26D7/00—Details of apparatus for cutting, cutting-out, stamping-out, punching, perforating, or severing by means other than cutting
    • B26D7/01—Means for holding or positioning work
    • B26D7/02—Means for holding or positioning work with clamping means
    • B26D7/025—Means for holding or positioning work with clamping means acting upon planar surfaces

Definitions

  • the book block was inserted in a clamp or carriage and moved along an elongate workpath from a position at which the book block was deposited in the carriage to a milling station at which the spine of the book block was roughened by a rotary driven blade so as to better accept the adhesive that would bind the cover to the spine of the book block. Then, the book block was transported to an adhesive application station where adhesive was applied to the spine. The book block was then moved to a binding station at which the cover had been positioned and the spine of the book block with adhesive applied thereto was brought into engagement with the inside of the cover at a desired location and the cover was clamped to the book block proximate the spine so as to adhesively bind the cover to the book block.
  • the bound book was transferred to a trimming station at which excess margins were trimmed from one or more and preferably from three sides of the book so as to produce a book of a predetermined finished size.
  • Whil ⁇ such print on demand book printing, binding and trimming apparatus, as described in the above-noted U. S. Patent 7,014,182, worked well, the resulting apparatus was large, extending approximately 10 feet in length, and requiring a "footprint" of over 30 square feet or about 2.7 square meters. There was a need to make the apparatus more compact because it was intended to be installed in retail stores, libraries, offices and the like.
  • an adhesive application station AS was provided along the workpath WP.
  • the adhesive application station had a rotary adhesive application wheel or drum that was at least partially immersed in a bath of hot melt adhesive that was heated to a desired application temperature (e.g., about 350 - 400 Q F, depending on the characteristics of the particular adhesive being used) sufficient to liquefy the hot melt adhesive.
  • the wheel was rotatably driven about a horizontal axis generally perpendicular to the direction of relative movement between the book block and the wheel. As the wheel rotated up out of the bath of the liquefied adhesive, the peripheral edge of the wheel picked up a quantity of the adhesive thereon.
  • the bottom edge of the spine was positioned so as to have an operatively relationship with the upper peripheral surface of the wheel (i.e., to be clear of the wheel but to be in contact with the layer of adhesive on the wheel) as the book block moved relative to the wheel so that a coating of the adhesive was applied across the width of the spine and along the length of the spine.
  • the amount of adhesive carried by the wheel and applied to the spine could not be controlled and thus the same amount (thickness) of adhesive was applied to the spine, regardless of the thickness (width) of the spine. Counterintuitively, this has been found to result in excess adhesive being applied to thicker book blocks and insufficient adhesive applied to thinner book blocks.
  • Apparatus for binding a perfect bound book where the book has a book block and a cover adhesively bound to one edge of the book block, the one edge of the book block and of the book constituting a spine.
  • the book block has a plurality of sheets of paper.
  • the cover is adapted to wrap around the spine of the book block and to be adhesively adhered to the book block spine.
  • the apparatus disclosed herein comprises a fixture receiving the sheets of paper and forming the book block on the fixture.
  • a first clamp is provided for holding the book block relative to the fixture in a known position and with the spine of the book block exposed for the application of adhesive thereto and for adhesively binding the spine to a cover.
  • An adhesive application station applies adhesive to the spine of the book block and a binding station is provided.
  • the fixture is movable from a first position in which the fixture is positioned to receive the sheets to a second position in which the book block held by the first clamp is positioned relative to the adhesive application station for the application of adhesive to the spine.
  • a drive is provided for moving the adhesive application station relative to the book block for the application of adhesive to the spine of the book block.
  • the fixture moves the book block downwardly to the binding station where the spine of the book block is brought into binding engagement with a cover positioned at the binding station such that upon the binding clamp engaging the cover adjacent the spine the cover is adhesively bound to the spine of the book block.
  • the binding clamp clamps the cover and the book block at the binding station
  • the first clamp releases the book block and the fixture along with the first clamp moves vertically along the book block and the first clamp re-grips the book block at a point distal from the spine.
  • the first clamp moves the bound book downwardly past the binding station so as to position the resulting bound book in an indexing clamp, which positions the book relative to a trimming station.
  • a method of binding a perfect bound book is also disclosed where sheets of paper are accumulated on a fixture so as to form the book block.
  • the book block is positioned on the fixture in a known position.
  • the book block is then clamped to the fixture.
  • the book block and the fixture are moved to an adhesive application station. With the book block positioned at an operative position with respect to the adhesive application station, movement of the adhesive application station relative to the book block is effected for the application of adhesive to the spine. After the adhesive has been applied to the book block spine, the book block is moved downwardly to a binding station.
  • a cover may be positioned at the binding station.
  • the spine of the book block is brought into contact with the cover, and the cover is clamped to the book block adjacent the spine. W the cover is clamped to the book block at the binding station, the first clamp releases the book block and is moved vertically and re-grips the book block at a position spaced from the spine. Then, the book is released from the binding station and moved downwardly relative to the binding station toward a trimming station.
  • FIG. 1 is a perspective view of a print on demand (POD) book printing, binding and trimming apparatus of the present disclosure
  • Fig. 2 is a perspective view of a page accumulator/fixture, which is part of the apparatus shown in Fig. 1 , illustrated in its raised, page accumulation position for receiving pages printed by a page printer and for forming a book block thereon;
  • Fig. 3 is another perspective view of the page accumulator/fixture in its raised, page accumulation position illustrating an adhesive application station and a binding station therebelow;
  • Fig. 4 is another perspective view of the accumulator/fixture similar to Fig.
  • Fig. 5 is still another perspective view of the accumulator/fixture in which the book block has been clamped to the bed of the accumulator/fixture by an accumulator clamp, in which the book block stop plate has been moved to a retracted position, and in which the accumulator has been moved (rotated) to a second or vertical position in which the book block is vertical with the spine of the book extending below the fixture;
  • Fig. 6 is a perspective view of the adhesive application station shown in
  • Fig. 3 having a roughener for roughening the spine of the book block and a glue pot or adhesive reservoir which contains a bath of a liquid adhesive (preferably a liquefied hot melt adhesive) and which has a rotary driven adhesive application drum or wheel partially immersed in the adhesive for applying a coating of adhesive to the spine of the book block, with the roughener and the adhesive reservoir being movable lengthwise of the spine of a book block positioned at the adhesive application station to roughen the spine and then to apply adhesive to the roughened spine;
  • a liquid adhesive preferably a liquefied hot melt adhesive
  • Fig. 7 is an right end elevational view of the accumulator/fixture and book block on a somewhat enlarged scale with the spine of the book block positioned at the adhesive application station for the application of adhesive to the spine with the spine spaced from the uppermost peripheral surface of the adhesive application drum by a gap;
  • Fig. 8 is a perspective view of the accumulator/fixture holding the book block vertically at the binding station after adhesive has been applied to the spine, the binding station having a binding clamp engageable with a cover (shown in phantom) positioned above the binding clamp for clamping the cover to the spine and to the sides of the book block proximate the spine thereby to bind the cover to the spine of the book block;
  • Fig. 9 is a perspective view of the binding station with the binding clamp in its open position and with the book block being held by the accumulator/fixture clamp along the margin of the book block opposite the spine so that the accumulator/fixture may lower the bound book through the binding station so as to deliver the bound book to an indexing clamp for trimming of the margins of the book by a trimming station;
  • Fig. 10 is a cross sectional view of the adhesive application station illustrating a rotary adhesive application drum as it is partially immersed in a reservoir or bath of liquid hot melt adhesive and illustrating a coating of adhesive coating the peripheral surface of the drum, and further illustrating a standing wave of increased thickness of the adhesive on the upper regions of the drum for application to the spine of the book block.
  • FIG. 1 apparatus for printing, binding and trimming print on demand (POD) books of the present disclosure is indicated in its entirety at 1 .
  • This apparatus is shown to have a text page printer 3, a cover printer 5, and a binding and trimming module 7.
  • Page printer 3 is preferably a duplex printer capable of printing the pages of the book on one or both sides of sheets of paper. It will be understood that one or both faces of a sheet in the book block may be blank. It will be further understood that the term "paper” as used herein would include not only paper in the ordinary sense of that word, but would also include sheets made of other suitable material, such as plastic film or the like.
  • the page printer 7 may be a black and white or a color printer.
  • the page printer 3 is positioned on a raised platform or cart 9 of such height that the sheets printed by the page printer and ejected therefrom are at a height so that the pages enter a page de-curler 13 (as shown in Fig. 3) and are discharged into an accumulator/fixture 1 1 (which may also be referred to as a carriage) where the text pages are accumulated so as to form a book block BB.
  • a page de-curler 13 as shown in Fig. 3
  • an accumulator/fixture 1 1 which may also be referred to as a carriage
  • de-curler 13 may be omitted, so that the text pages may be discharged directly in the accumulator as they are ejected from the page printer.
  • text pages refers to the pages of a book B between the front and back cover of the book whether they have text, photos, or other figures printed thereon, or whether the pages are blank.
  • the text pages may also include the title page, the table of contents, index, and appendices.
  • page printer 3 is preferably a duplex printer that prints on both sides of the sheets of paper that make up the book block, but a simplex may be used as well.
  • book block BB is shown to be generally rectangular or square. As shown in Fig. 10 of U. S. Patent 7,014,182, which is herein incorporated by reference in its entirety, the book block has major and minor sides with one of the major sides constituting spine S of the book block. Likewise, a perfect bound book B formed from book block BB is also rectangular. However, those skilled in the art will recognize that other polygonal shapes for a book block may be employed in accordance with this disclosure. It will be further understood that if the book block is square, the major and minor sides of such a square book block are of the same length. In such case, the spine may be along one of the sides of the square book block.
  • the binding and trimming module 7 has a frame F upon which the major components are mounted. Specifically, module 7 has accumulator/fixture 1 1 mounted on this frame F.
  • the accumulator has an accumulator bed or tray 15 upon which the text pages of the book are accumulated as they are printed by page printer 3 and either ejected directly from the printer or passed through de-curler 13 and then discharged into the accumulator.
  • Accumulator 1 1 has an accumulator frame, as generally indicated at 17 in Fig. 2.
  • the accumulator bed 15 and a side member 19 are carried by the accumulator frame with the side member extending perpendicular to the bed at one side thereof.
  • the accumulator frame 17 carries a stop plate 21 positioned at the end of bed 15 on the opposite side of the bed from where the text pages are ejected from de-curler 13 to as to provide a stop for the pages.
  • Stop plate 21 is pivotally mounted with respect to accumulator frame 17 for movement between a first position (as shown in Fig. 2) in which the stop plate is positioned to be engaged by the edge of each text page (or sheet) as the pages are discharged or deposited into the accumulator and a retracted position (as shown in Fig. 5) in which the stop plate is clear of the one edge of the book block BB, this one edge constituting the book block spine S.
  • the accumulator frame 17 may be rotated from its inclined position (as shown in Figs. 2 - 4) to a vertical position (as shown in Fig. 5).
  • accumulator frame 17 is pivotally mounted within an accumulator mounting frame 23 for pivotal movement about pivot points 25 between the above-described first or inclined position (as shown in Figs. 2 - 4) in which the accumulator (and particularly bed 15) is in position to receive and to accumulate the pages making up the book block BB., and a second or vertical position (as shown in Figs. 5 and 7) in which the book block BB carried by the accumulator is in a generally vertical position for purposes as will appear.
  • the accumulator frame 17 is moved between its first and second position by means of a fluid cylinder 27, preferably a pneumatic cylinder.
  • accumulator 1 1 is provided with an accumulator clamp for positively holding (clamping) the book block BB relative to the accumulator bed 15 as the accumulator rotates from its first to its second position.
  • This accumulator clamp 29 is sometimes referred to as a first clamp and it holds the book block BB in a predetermined position on bed 15 as the book block is transported to other stations along a work path WP, as indicated by an arrow in Fig. 7 and as will be described below.
  • Accumulator clamp 29 includes a clamp plate 30 engageable with the upper face of the book block BB when the accumulator is in its inclined position (as shown in Fig. 4) so as to firmly clamp the book block to bed 15.
  • the accumulator clamp includes a track, preferably slide rods 31 a, 31 b (as best shown in Fig. 2), at each end of clamp bar 30. These slide rods are slidably received in respective guides 33a, 33b mounted to accumulator frame 17 for slidable movement of the clamp plate 30 relative to bed 15 between its open retracted position (as shown in Figs. 2 and 3) in which the text pages are free to accumulate on bed 15 and its closed, clamping position (as shown in Figs.
  • the spine S of the book block BB extends out beyond bed 15 and out beyond clamp plate 30 a short distance (e.g., about 3/8 inch or 9.5 mm.) so as to expose the spine for having adhesive applied thereto and to allow the spine to be adhesively bound to the cover.
  • the outer ends of slide bars 31 a, 31 b are mounted to a cross bar 35.
  • Clamp member 30 is moved from its open or retracted position to its closed clamping position by means of a fluid cylinder 37 mounted between bed 17 and cross bar 35 so that upon actuation of cylinder 37 so as to extend its actuator rod 38 (as best shown in Fig.
  • the cross bar is caused to move away from bed 17 which in turn forcibly moves the clamp member 30 toward the bed via slides 33a, 33b sliding along slide rods 31 a, 31 b. In this manner, the book block is firmly clamped by clamp member 30 to bed 15.
  • stop plate 21 is mounted for pivotal movement relative to bed 15 between an operative position in which the stop plate is in position to be engaged by an edge of each page of the book block BB as the pages are ejected from de-curler 13 into accumulator 1 1 and a retracted position (as shown in Fig. 5) in which the stop plate is clear of the spine of the book block.
  • the stop plate 21 is carried on a rotatable shaft 41 which in turn is rotated by a fluid cylinder 43 (preferably an air cylinder) to selectively move the stop plate between its operative and retracted positions. Specifically, upon extending the actuator rod of cylinder 43, shaft 41 is forced to rotate the stop plate way from bed 15 thereby to expose spine S.
  • a fluid cylinder 43 preferably an air cylinder
  • a drive is provided for moving accumulator/fixture 1 1 in a vertical direction from a first position, as shown in Figs. 2 - 4, in which the bed 15 of the accumulator may be in its inclined position and/or in which bed 15 may be moved to its vertical position with book block BB held in place on the bed by accumulator clamp 29 to a first lowered position, as shown in Figs. 5 and 7, in which the exposed spine S of the book block is positioned to have adhesive applied thereto at an adhesive application station 57, as will be described hereinafter. Still further, continued operation of drive 45 will lower the book block from the adhesive application station to a binding station, as indicated at 59.
  • drive 45 may be further operated so as to lower the now bound book B from the binding station to a trimming station 61 .
  • This above-described vertical movement of the accumulator clamp constitutes the work path WP (as illustrated in Fig. 7) that has the above-noted stations therealong. This will be described in greater detail below.
  • Drive 45 includes a drive 47 (preferably a stepper gearmotor) that rotates a vertically disposed drive screw 49, which threadably engages accumulator frame 23 and thus effects vertical movement of the accumulator/fixture 1 1 along at least a portion of workpath WP. More specifically, upon operation of motor 47 in one direction, the drive screw moves the accumulator frame 23, the accumulator 1 1 , and the book block BB held therein downwardly along the work path WP, and operation of the motor in the opposite direction moves the accumulator upwardly. Of course, upon de-energization of motor 47, the accumulator and the book block held thereby are effectively held stationary at any position along the workpath.
  • a drive 47 preferably a stepper gearmotor
  • a vertical track is provided for accumulator mounting frame 23 for vertical movement along the workpath.
  • a page tapper 51 is provided for tapping each sheet (or small groups of sheets) delivered to the accumulator 1 1 so as to tap each sheet toward stop plate 21 .
  • Another page tapper 53 is provided to tap each sheet in sideways direction toward the fixed accumulator side 19. These tappers thus insure that each sheet (or group of sheets) of the book block BB is properly and evenly positioned on bed 15. With the sheets making up book block BB firmly against the stop plate and against the accumulator side, the book block is accurately positioned in accumulator 1 1 in a known position.
  • a computer control system CS of the apparatus also "knows” the position of the text printed on the pages and thus "knows” how much of the margins of the bound book must be trimmed to produce a trimmed book of a predetermined finished size.
  • This known position of the book block BB is maintained by the accumulator clamp 29 as the book block is moved from the accumulator 1 1 in the position as shown in Fig. 2 to the adhesive application station 57 and then is moved to a the binding station or table 59. Further, in a manner as will be disclosed, the known position of the bound book is maintained in the trimming station so that the book may be trimmed to a predetermined finished size.
  • the computer control system CS is not shown in the drawings, but it will be understood that such a computer control system may perform many of the functions described in the above-noted U. S. Patent 7,014,182, which is herein incorporated by reference in its entirety.
  • This computer control system may be mounted at any convenient location within apparatus 1 .
  • a preferred computer control system CS may be a programmable logic controller (PLC), such as a model IC200UDD064 VersaMax Micro PLC commercially available from GE Fanuc of Charlottesville, VA.
  • PLC programmable logic controller
  • Tappers 51 and 53 are of similar construction and operation. These tappers comprise fingers 55 carried by a rotary solenoid motor energized after each sheet (or small group of sheets) has been delivered to the accumulator the fingers tap each sheet toward stop plate 21 and toward side 19 so as to insure all of the pages in book block BB are properly positioned relative to one another and to insure that none of the sheets of the book block hang up or are uneven. In this way, it is insured that as each sheet or each group of sheets or pages are deposited in the accumulator, these last deposited pages can be readily moved relative to the accumulator and to the previously deposited pages so that all of the pages of the book block BB are accurately positioned in known positions relative to side plate 19 and stop plate 21 .
  • the apparatus 1 may print, bind and trim a wide range of book sizes and thickness within a limited range.
  • the pages of the book block are preferably printed on a standard size sheets of a suitable paper (e.g., 8 Vz x 1 1 , A4, or the like) in known locations on the sheets such that the excess margins of the sheets may be determined by the computer control system CS and such that these excess margins may be trimmed at a trimming station 61 so as to produce a finished book of a predetermined size.
  • a suitable paper e.g., 8 Vz x 1 1 , A4, or the like
  • the matter to be printed will be centered heightwise relative to the spine (e.g., one of the major sides of the sheets) and spaced a short distance (one half of the gutter of the printed book, i.e., the blank space between facing pages of the book) from the major side that will constitute the spine S of the book block BB.
  • the margins along the major side of the book block opposite spine S and the margins along the top and bottom side of the book block may be readily calculated by the computer control system CS so that the book may be trimmed to have a predetermined finished dimension.
  • books of a wide range of thicknesses may be printed, bound, and trimmed by the apparatus 1 preferably ranging between about 50 pages (about 25 sheets) to about 850 pages (about 425 sheets) or more. It will also be appreciated that the size of the book and the number of pages in the book block for a particular book are part of the information regarding the printing and binding and trimming of the book given to the computer control system CS controlling operation of the apparatus.
  • accumulator 1 1 is moved from its inclined to its vertical position as shown in Fig. 4, the accumulator is movable vertically downwardly along the workpath WP toward an adhesive application station 57 below the first position of the accumulator, then to a binding station 59 below the adhesive application station (as shown in Figs. 3 - 5), and then to trimming station 61 (as best illustrated in Figs. 10 - 17) located generally below the binding station.
  • a suitable adhesive preferably a liquefied hot melt adhesive is applied to spine S of the book block BB, preferably, but not necessarily, in the manner as hereinafter described.
  • cover C (a portion of which is shown in Fig. 8) has been pre-positioned so that a desired area of the inner face of the cover, preferably the center portion of the cover, is positioned to be adhesively joined to the spine.
  • Cover C is preferably printed in cover printer 5 while the pages of the book block are printed by page printer 3, but it will be understood that cover C may be pre-printed and delivered to apparatus as required.
  • adhesive application station 57 includes a spine roughener 63 having a blade housing 64 with one or more blades 65 positioned to extend transversely to spine S.
  • These blades are preferably sharp blades have their cutting edges facing upwardly and are biased upwardly by springs (not shown) so that their cutting edges are generally coplanar, with the cutting edges being disposed to firmly engage the spine of the book block as the roughener is moved lengthwise along the spine so that the blades will scrape along the length of the spine over the full width of the spine so as to roughen the edges of the paper sheets forming the book block spine.
  • the stationary blades 65 for roughening the spine as the blades are moved relative to the spine, the need for an electric motor to drive the prior rotary spine milling devices, such as shown in the above-noted U. S. Patent 7,014,182, has been eliminated.
  • the stationary blades do not generate substantial amounts of paper residue as such prior rotary milling devices so there is less debris to be disposed.
  • the rotary milling station as described in the above-noted U. S. Patent 7,014,182 may be used in place of the above-described roughener 63.
  • the adhesive applicator as described in the '182 patent, may be used in place of the adhesive application system described below.
  • Adhesive application station 57 further includes an adhesive reservoir
  • Adhesive pot or reservoir 59 is preferably heated to an elevated temperature if a hot melt adhesive is used by means of electric resistance cartridge heaters 70 (not shown) incorporated in the reservoir and controlled by an automatic temperature control (not shown) well known to those of ordinary skill in the art. Depending on the particular hot melt adhesive used, the adhesive is heated to a temperature sufficient to melt and to liquefy the adhesive and then is maintained at a desired application temperature without undue degradation of the adhesive over an extended period of time.
  • this temperature may range as high as about 400 5 F or more, depending on the particular adhesive used.
  • adhesive HM8101 commercially available from Capital Adhesives of Mooresville, IN. This adhesive is commercially available in various forms, such as briquettes or pellets, which may be added from time to time to reservoir 69 so they will be melted and thus replenish the supply of adhesive in the reservoir. It will be understood that he level of the adhesive in the reservoir can vary considerably. Of course, after a predetermined number of books have been bound, a warning can be sent by the computer control system CS for the operator to replenish the amount of the adhesive in the reservoir.
  • Adhesiv ⁇ application station 57 includes an adhesive application drum or wheel 71 .
  • This drum is rotatably mounted with respect to reservoir 69 for rotation about a horizontal central axis such that the lower portion of the wheel is immersed in the above-noted liquefied adhesive in the reservoir 69.
  • the wheel 71 is rotatably driven by a variable speed drive motor 73.
  • This motor may be energized by the computer control system CS just prior to the application of adhesive to the spine S of a book block so that as the drum rotates up out of the adhesive, its outer peripheral surface carries a coating of the liquefied adhesive thereon which is applied to the spine of the book block, preferably in the manner as will be described below.
  • the drum is partially immersed within the heated adhesive within the reservoir, the drum is also heated to an elevated temperature and thus helps maintain the elevated temperature of the adhesive on its peripheral surface prior to application to the spine. This helps insure that the adhesive will have adequate working time to be moved from the adhesive application station to the binding station 59 so that cover C is properly adhesively bound to the spine of the book block.
  • the adhesive coating on the drum distributes itself over the peripheral surface of the drum so as to form the above-noted adhesive coating across the width of the drum and around the drum at least a portion of the periphery of the drum.
  • the adhesive coating encounters a first wiper bar or rod 74a extending transversely of the width of the drum and positioned somewhat closer to the drum than the adhesive coating, which causes the adhesive coating for form a standing or stationary wave (or bulge) proximate the rod 74a.
  • This standing wave is a region of increased adhesive thickness at the top of drum 71 for purposes as will appear. The height of this standing wave is dependent on the speed at which the drum is rotated, the temperature of the adhesive coating, and the properties of the adhesive.
  • adhesive pot 67 is provided with two additional wiper bars 74b and 74c ⁇ xtending from one side to the other of the adhesive pot.
  • the first wiper bar 74a is positioned so that it will encounter the above-noted adhesive coating on wheel 71 so as to help form standing adhesive wave SW on the drum proximate the first wiper bar.
  • This standing wave thus constitutes a "target" of increased adhesive thickness of the drum into which the spine S of the book block may be submerged to substantially uniformly coat the spine S with adhesive across the width of the spine and along its length as the adhesive station 57 is moved lengthwise along the spine. It has been found that this standing wave is stable over a usable range of wheel rotational speeds and over a range of adhesive temperatures.
  • the second wiper bar 74b strikes off excess adhesive applied to the spine, and the third wiper bar 74c catches any drips or strings of adhesive that may extend down from the spine so as to prevent these drips from being carried to the inside face of cover C during the binding operation.
  • a drive screw 77 rotatably driven by a suitable reversible drive motor (preferably a stepper motor) 79, where the drive screw is threadably engaged with carriage 75.
  • motor 79 may be a stepper motor under the control of the computer control system CS of the apparatus 1 .
  • Wheel or drum 71 may be driven by motor 73 in counterclockwise direction
  • Wheel 71 may be rotated in either direction to apply adhesive to spine S. That is, as shown in Fig. 6, wheel 71 may be rotated in counterclockwise direction so that the wheel "rolls" along the spine (even though the topmost surface of the wheel does not touch the spine) to apply the adhesive. In this mode of operation, the surface speed of the rotating wheel may nearly match the lineal speed at which the adhesive application station 57 is moved along track 75 relative to the stationary book block BB. This results in an even application of a coating of the adhesive on the spine.
  • the wheel be rotated in the opposite (clockwise) direction upon movement of the adhesive application station along the track. More specifically, it has been found that if the wheel is rotated in the opposite direction (clockwise, as shown in Fig. 6), wiper rod 74a should be moved to the opposite side of the top of wheel 71 from its position shown in Fig. 6. With the wheel rotated in such clockwise direction and when the adhesive station is moved relative to the spine and when the spine first encounters the adhesive on the wheel, a large build-up of adhesive will result at the leading end of the book block spine S. It will b ⁇ appreciated that the above-noted standing wave SW formed on the periphery of wheel 71 will be so formed regardless of the direction of rotation of the wheel.
  • the wheel When the wheel is rotated in the direction opposite to the direction of movement of the wheel relative to the stationary book block spine S and when it is desired to apply a heavy coating of adhesive to the spine, the wheel is rotated at a speed by motor 73 such that the standing wave will be formed at the upper reach of the wheel rotating into the spine in timed relation to the spine entering the adhesive application zone (e.g., the upper surface of wheel 71 ).
  • the adhesive application zone e.g., the upper surface of wheel 71 .
  • this same result could be achieved by speeding up the rotation of the wheel 71 after the leading end of the spine has entered the adhesive application zone.
  • the height of the standing wave SW is increased.
  • the adhesive By increasing the speed of rotation of the wheel, the height of the standing wave SW is increased.
  • the adhesive By applying adhesive to the spine at a faster rate and in an excess amount and then wiping off the excess adhesive, the adhesive will better wet the edges of the text pages making up the spine S and will better penetrate between the individual pages of the book block at the spine.
  • carriage 75 on which adhesive application station 57 and spine roughener 63 are mounted is slidably movable along track 76 generally lengthwise of spine S of the book block BB from an initial position at the right- hand end of the track (as viewed in Fig. 5) in which the roughener is clear of the first end of the book block spine S to be roughened.
  • the adhesive application station 57 is movable lengthwise along the entire length of the spine so that the roughener may roughen the entire length of the spine and so that the adhesive application drum 71 to apply adhesive along the entire length of the spine and across the entire width of the spine.
  • the speed of the relative movement of the adhesive application station 57 and spine roughener 63 may be increased or decreased by varying the speed at which motor 79 and drive screw 77 are driven.
  • Electric wires for the drum drive motor 73, the reservoir heaters 70, and any instrumentation wiring (not shown) are carried in a flexible cable tray 81 to permit the adhesive application station 57 and spine roughener 63 to be reciprocated along track 75 without damage to the wires.
  • the thickness of the adhesive coating AT applied to spine S by the adhesive application station 57 may be controlled or varied by adjusting gap G (see Fig. 7) between the spine of the book block and the topmost surface of wheel 71 .
  • accumulator 1 1 may be moved vertically along workpath WP by drive motor 47 and drive screw 49.
  • Motor 47 is preferably a stepper motor under the control of the computer control system CS.
  • motor 47 driving drive screw 49 is preferably a stepper gearmotor, as is readily commercially available from a number of sources. Such stepper motors are typically provided with an encoder (not shown) that has a predetermined number of counts for each revolution of the drive shaft of the motor. For example, motor 47 may have 2048 counts for each revolution of its drive shaft and for each revolution of the drive screw.
  • Drive screw 49 is preferably a threaded lead screw (or ball screw) and as such has a known pitch (i.e., the distance between two adjacent threads). For example, drive screw 49 may have a pitch of 0.25 inches (6.35 mm.).
  • drive 45 has a "home” position know to the computer control system CS, where this "home” position is used as a reference position for the book block as it moves along workpath WP.
  • this "home” position is used as a reference position for the book block as it moves along workpath WP.
  • the accumulator mounting frame 23 is in its fully raised position (as shown in Figs. 2 - 4) in which the accumulator 1 1 is in its inclined position to receive the printed text pages and to form (collate) the book block BB on accumulator bed 15
  • the position of the mounting frame 23 relative to the home position is known to the computer control system.
  • the vertical position of the mounting frame is known to the computer control system at any position along track 50.
  • the computer control system CS "knows" the position of the book block BB and of the spine S when the book block is in position at the adhesive application station 57, at the binding station 59, and at the trimming station 61 . Because the book block is accurately positioned in the accumulator 1 1 , as described above, the position of the book block and spine S are accurately known to the computer control system as the book block is moved to the various stations and can be controlled by the computer control system with great accuracy, theoretically to within about + 0.000122 inches (0.0031 mm.), as shown by the above example. By adjusting the height of the spine at the adhesive application station 57, the width of gap G may be controlled.
  • apparatus 1 Because each book produced by the apparatus 1 may be of a different size and/or thickness, as compared to the next or last book to be produced, and because the computer control system CS is given information concerning the size of the book block and the number of pages in the book block, apparatus 1 has the ability to accurately control the thickness of the adhesive applied to the spine, the ability to accurately place the book block spine relative to the cover, and the ability to accurately trim the margins of the book to predetermined dimensions for the book being printed on demand, apparatus 1 has the ability to accurately print, bind and trim books in a wide variety of sizes and thicknesses one after the other in a fully automatic mode with no operator intervention.
  • the thickness of the coating of adhesive applied to the spine S at the adhesive application station 57 may be varied in relation to the thickness of the book block of the book then being printed and bound. It will be appreciated that a first book to be printed, bound and trimmed by apparatus 1 may be relatively thin (e.g., 100 pages or 50 sheets) and the next book may be thick (e.g., 850 pages or 425 sheets). It has been found to be desirable to vary the thickness of the adhesive applied to the spine of book blocks in relation to the thickness of the book block. This is accomplished by varying the width of gap G (as shown in Fig. 7) between spine S and the upper reach of adhesive wheel 71 by accurately controlling the vertical position of the spine S relative to the topmost surface of wheel 71 .
  • the spine of the book block spine is lowered by drive 45 until it is positioned a predetermined distance from its home position, which as indicated may be an arbitrary reference position, thereby to establish an initial thickness of gap G.
  • a predetermined distance for example, it has been found that if the position of the spine is about 68,430 counts from its home position, gap G will be such that a suitable thickness of adhesive will be applied to a thin book block (e.g., a book block having about 50 pages or about 25 sheets). It has been found that if the thickness of the adhesive coating applied to spine S is varied in accordance with the thickness of the book block or spine, a better book block-to- cover binding is accomplished.
  • the number of pages (or sheets) in the book block is made known to the computer control PLC.
  • AT b + mX, where b is an initial position (e.g., 68,430 counts), where m is a constant factor (e.g., 0.5), and where X is the number of pages in the book block, in counts.
  • the gap G would be increased about 0.015 inches (0.38 mm.). In another example, if the thickness of the book block is 850 pages (425 sheets), the width of gap G would be increased about 0.025 inches (0.66 mm.).
  • cover C for the book being printed may be printed by cover printer 5 while the page printer 3 prints the pages for the book block.
  • cover conveyor 83 the cover is delivered to the binding station or binding table 59 by means of a cover conveyor 83.
  • a pre-printed cover may be delivered to cover conveyor 83.
  • This cover conveyor has power driven rollers 84 (as shown in Fig.
  • binding station or binding table 59 has a binding clamp, as generally indicated at 85, having a pair of self-centering binding clamp jaws 87a, 87b that are movable in horizontal direction perpendicular to the sides of the vertically disposed book block BB between a retracted position in which the jaws are clear of the book and a clamping position in which the jaws engage the cover C positioned at the binding station and the book block BB adjacent spine S.
  • these clamp jaws When in their clamping position, these clamp jaws forcibly press the cover against the sides of the book block. This in turn adhesively binds the cover to the spine to the spine of the book.
  • the clamping jaws are moved between their retracted and clamping positions by fluid cylinders 89a, 89b, preferably air cylinders.
  • a retractable floor plate or bed is provided at binding station 59 below clamping jaws 87a, 87b for supporting cover C and book block spine S between the clamping jaws as the clamping jaws close on the cover and book block.
  • floor plate 91 provides a solid surface to support the book block and the cover and gives support to the cover as the book block is moved downwardly into binding engagement with the cover. It will be understood that as accumulator clamp 29 moves the spine S of the book block BB into engagement with the center portion of cover C, the book block spine forces the cover downwardly into engagement with floor plate 91 . This insures that the cover is in contact with the adhesive on the spine as the clamp jaws close.
  • clamp jaws 87a, 87b remain in their closed position holding the cover on place on the book block for a time sufficient (e.g., a few seconds) to allow the adhesive to set and to adhere the cover to the spine.
  • a fluid cylinder 93 is actuated to retract bed plate 91 so as to clear a path through the binding station when clamp jaws 87a, 87b are open to permit the bound book to be conveyed downwardly to the trimming station 61 in a manner as will appear.
  • accumulator clamp 29 is operated to release its grip on the book block BB proximate spine S, and drive 45 is actuated to move the accumulator clamp upwardly toward the top edge of the book block distal from the spine.
  • accumulator clamp cylinder 37 is actuated so as to re-grip the book block adjacent the top edge of the book block so that as the book is re-gripped, its position is known to the computer control system CS.
  • cylinder 93 is actuated so as to retract binding floor 91 , clamp jaws 87a, 87b are opened, and drive 45 is actuated so as to lower the bound book spine first between the open clamp jaws toward trimming station 61.
  • the bound book B is moved downwardly between the open jaws 87a, 87b, the cover will be swept inwardly toward the book block by the jaws. It will be appreciated that when the clamp 29 re-grips the book block adjacent the top edge of the book block, the position of the book block and hence of the bound book B in both heightwise and widthwise direction continues to remain known to the computer control system CS.
  • a trimming index clamp As shown in Figs. 9 and 10, as drive 45 lowers the bound book B from the binding station 59 to the trimming station 61 , the spine S of the bound book is placed in a trimming index clamp, as generally indicated at 95.
  • this clamp has a fixed clamp jaw 97 and a movable clamp jaw 99 movable toward and away from the fixed jaw by means of a fluid cylinder 101 , preferably an air cylinder. Between jaws 97 and 99, a bearing surface 103 is provided against which the spine S of the bound book B will rest during the trimming operation. With the spine of the book bearing against surface 103, and with clamp 95 gripping the book along its spine, the position of the book in clamp 95 is known to the computer control system CS.
  • the control system also knows the desired finished size of the book being trimmed and the margins of the book that must be trimmed from one or more sides of the book to result in the desired finished size, the computer control system thus knows the amount the margins must be trimmed from one or more sides of the book to result in the finished book to be of the desired predetermined size.
  • a POD book to be printed is selected by a customer or by another person operating apparatus 1 .
  • a library of POD books is available, which library may contain a large number of books.
  • the books in this library may be of different sizes and, of course, the books will have different number of pages.
  • the data corresponding to the text of the book is sent to text page printer 3 and the data corresponding to the cover for the selected book is sent to cover printer 5.
  • These printers begin to print the book block BB and cover C for the selected book.
  • a wide variety of sizes of books may be printed on demand on a standard size paper, such as 8 Vz x 1 1 .
  • the text for the text pages of the book is centered heightwise on the page and is printed a prescribed distance from one major (long) edge of each text page that this one major edge will constitute the spine S of the book block BB. When the book is printed, this prescribed distance from this one edge will constitute the gutter of the book. This in turn allows the control system CS to "know" what margins of the bound book must be trimmed from the sides of the book B in order to produce a finished book of a predetermined size.
  • Other data corresponding to the book to be printed (e.g., the number of pages in the book, the finished trim size along each edge of the book, and the like) may be sent to computer control system CS for purposes as will appear, below.
  • pages printed by the page printer 3 are preferably de-curled by de-curler 13 and are deposited on the accumulator bed 15.
  • page tappers 51 and 53 are actuated so as to insure that one edge of each page (or small group of pages) of the book block being formed is in firm engagement with stop plate 21 and with side 19 thus positioning the book block in a known position within the accumulator/fixture 1 1 .
  • accumulator clamp 29 is actuated by means clamp cylinder 37 so as to firmly clamp the book block in position on the accumulator bed 15. Then, cylinder 43 is actuated so as to pivot stop plate 21 to its retracted position clear of the spine S of the book block. Then, accumulator pivot cylinder 27 is actuated so as to pivot accumulator frame 17 from its inclined position (as shown in Figs. 2 - 4) to its vertical position (as shown in Fig. 5).
  • the stop plate 21 when the stop plate 21 is moved to its retracted position and when the book block is clamped in the accumulator, the accumulator bed 15 and the clamp 29 are positioned in spaced relation to the spine S such that about 3/8 inches (9.5 mm.) of the book block proximate the spine is exposed.
  • motor 47 is energized so as to move the accumulator clamp 29 and the book block BB held by thereby downwardly from the position shown in Fig. 4 to the position shown in Fig. 7 in which the spine S of the book block BB held by clamp 29 is positioned just above the level of adhesive application wheel 71 with a space or gap G between spine S and the upper surface of wheel 71 .
  • the number of pages in the book block for that book is made known to the PLC computer controller CS.
  • Motor 73 is energized so as to rotate wheel 71 such that the peripheral surface of the wheel is coated with adhesive, as previously described.
  • Motor 79 is then energized so as to move spine roughener 63 and adhesive application wheel 71 relative to the stationary book block spine so that the roughener blades 65 will scrap along the spine so as to roughen the edges of the paper sheets comprising the spine.
  • the wheel 71 will apply a desired amount (thickness) of the adhesive to the spine in the manner heretofore described.
  • motor 47 is further energized so as to move the book block downwardly along work path WP from the adhesive application station 57 to the binding station 59.
  • cover C is printed by cover printer 5.
  • the cover is conveyed from the cover printer to binding station 59 by means of cover conveyor 83, which has rollers 84 controlled by the computer controller CS.
  • cover conveyor 83 which has rollers 84 controlled by the computer controller CS.
  • accumulator clamp cylinder 37 is actuated so as to release the grip of accumulator clamp 29 on the book block BB adjacent spine S (as shown in Fig. 7). Then motor 47 is energized so as to move the accumulator clamp upwardly to a position, as shown in Fig. 9, where the accumulator clamp cylinder 37 is actuated so that the accumulator clamp 29 re-grips the book block adjacent the edge of the book block opposite spine S.
  • cylinder 93 is actuated so as to retract binding bed 91 beneath binding clamp jaws 87a, 87b. Then cylinders 89a, 89b are actuated to release binding clamp 85 from the now bound book B.
  • Motor 47 is actuated so as to move the bound book downwardly between the now open clamp jaws 87a, 87b and the spine of the bound book is inserted in indexing clamp 95, as shown in Fig. 9.
  • Cylinder 101 is actuated so as to firmly clamp the bound book B in indexing clamp 95. In this manner, the position of the bound book relative to the indexing clamp remains known to the computer control system.
  • the computer control system may operate motors 1 1 1 , 1 15, and 130 so as to accurately position the ends and side of the bound book in clamp assembly 135 so that shear trimmer 135 may trim predetermined trim amounts of the margins of the book so as to produced a finished book of a predetermined size.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Forests & Forestry (AREA)
  • Folding Of Thin Sheet-Like Materials, Special Discharging Devices, And Others (AREA)

Abstract

L'invention porte sur un appareil pour imprimer, relier et massicoter des livres reliés parfaits imprimés à la demande (POD), dans lequel appareil une pluralité de feuilles sont accumulées sur un accumulateur de façon à former un bloc de livre. L'accumulateur est initialement dans une position inclinée de façon à recevoir les feuilles et de façon à former le bloc de livre. Lors de la formation du bloc de livre, la pince de bloc de livre est serrée sur l'accumulateur et l'accumulateur est déplacé d'une position inclinée à une position verticale, et est déplacé vers le bas le long d'un trajet de travail, vers une station d'application d'adhésif comportant un dispositif pour rendre rugueux un dos et un applicateur d'adhésif. La station d'application d'adhésif est déplacée par rapport au bloc de livre fixe de façon à rendre rugueux le dos du bloc de livre et à appliquer un adhésif au dos. Ensuite, l'accumulateur déplace le bloc de livre vers le bas le long d'un trajet de travail, vers une station de reliure, où le dos du bloc de livre est relié par adhérence à une couverture positionnée dans la station de reliure. Ensuite, le livre relié est déplacé vers le bas, à travers la station de reliure, vers une station de massicotage. Ce déplacement vers le bas du bloc de livre et du livre le long du trajet de travail produit en résultat un appareil plus compact.
PCT/US2010/045708 2009-08-18 2010-08-17 Appareil et procédé pour imprimer, relier et massicoter un livre relié parfait imprimé à la demande WO2011022363A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US23480009P 2009-08-18 2009-08-18
US61/234,800 2009-08-18

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WO2011022363A3 WO2011022363A3 (fr) 2011-05-12

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6460843B1 (en) * 2000-02-02 2002-10-08 Aprion Digital Ltd. Paperback finishing machine
US20070031213A1 (en) * 2005-06-15 2007-02-08 Nisca Corporation Bookmaking apparatus and image forming apparatus equipped with the same
JP2007118351A (ja) * 2005-10-27 2007-05-17 Canon Inc 画像形成システム
US20070286706A1 (en) * 2006-05-02 2007-12-13 Nisca Corporation Adhesive applicator and bookmaking apparatus using the same

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6460843B1 (en) * 2000-02-02 2002-10-08 Aprion Digital Ltd. Paperback finishing machine
US20070031213A1 (en) * 2005-06-15 2007-02-08 Nisca Corporation Bookmaking apparatus and image forming apparatus equipped with the same
JP2007118351A (ja) * 2005-10-27 2007-05-17 Canon Inc 画像形成システム
US20070286706A1 (en) * 2006-05-02 2007-12-13 Nisca Corporation Adhesive applicator and bookmaking apparatus using the same

Also Published As

Publication number Publication date
WO2011022363A3 (fr) 2011-05-12

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