Note: Descriptions are shown in the official language in which they were submitted.
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APPARATUS AND METHOD OF ON DEMAND PRINTING, BINDING,
AND TRIMMING A PERFECT BOUND BOOK
Technical Field
This invention relates to an apparatus and method of printing on
demand, binding and trimming a perfect bound soft cover book.
Background Art
Typically, such soft cover perfect bound books comprise a
stacked plurality of text pages (referred to as a book block) having one
edge which is referred to as the spine. The cover is of a suitable cover
stock that is generally thicker (heavier) than the text pages comprising
the book block. The cover has a front portion that overlies the front of
the book block, a back portion that overlies the back of the book block,
and a center portion spanning across the spine of the book block. A
suitable adhesive is applied between the spine of the book block and the
inside face of the center portion of the cover. The spine of the book
block (i.e., the edges of the text pages along one edge of the book
block) is imbedded in the adhesive which, upon curing, securely adheres
the pages of the book block to one another and to the center portion of
the cover, thereby permitting the book to be opened to any page without
the pages coming loose.
In high volume production processes for manufacturing such
perfect bound books, the pages of each book block are usually jogged
by specially developed machines prior to the application of adhesive so
as to insure that the edges of the pages are properly aligned with one
another. The adhesive, typically a suitable hot melt adhesive, is then
applied to the spine of the book block. The cover, which is usually pre-
printed, is then folded around the front, spine, and back of the book
block and is firmly clamped to the book block proximate the spine during
assembly. In this manner, the adhesive is firmly pressed between the
spine of the book block and the inner face of the center portion of the
cover to properly adhere the cover to the book block while
simultaneously adhering the pages to one another.
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Typically, such perfect bound books are printed on pages that are
somewhat larger than the desired size (i.e., the length and width) of the
finished and bound book to be produced. These books, after they are
bound, are typically trimmed along three sides to the desired final
dimension in a separate trimming machine. Heretofore, such operations
were carried out in separate machines that required considerable
adjustment to bind books of different sizes and thus were best suited for
production runs of many books. In addition, both prior art binding
machines and trimming machines were very expensive.
In recent years, book printing has undergone changes as
computer technology and laser printers have advanced. This new
technology now allows for machines capable printing perfect bound
books "on-demand". Such on-demand printed books come in a variety
of formats and thicknesses (i.e., the number of pages in the book).
Thus, there is a need for an economical printing and binding apparatus
and system which is sufficiently flexible to allow on-demand printed
books of varying size and thickness (at least within a limited range) to be
bound and trimmed, even if books of different formats (size) and
thickness must be bound one at a time (i.e., with production binding runs
consisting of a single book copy). There is a further need for such a
printing and binding apparatus and system where such printing and
binding operations are fully automated such that a store clerk or
attendant need merely to select a prepared data file stored on a
computer and send the file to the automated printing and binding
apparatus. Thus, the printing and binding apparatus would then
generate the printed pages of the book block and the cover of the book,
adhere the cover to the book block, and then trim the same. There is yet
a further need for such an apparatus and system that is capable of
producing various sizes and formats of perfect bound books without the
need for undue experimentation or adjustment of the apparatus to
produce such different size books.
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SummarYof the Invention
Among the several objects and features of the present invention
may be noted;
The provision of such a printing and binding apparatus which has
sufficient speed to print, bind, and trim one copy of a book using the
perfect binding method while another copy of the book (or a copy of a
different book) is being on-demand printed;
The provision of such a printing and binding apparatus which
incorporates a printer that prints the pages of a book block and
sequentially ejects the printed pages into an initial collator tray that
collates the printed pages of the book block;
The provision of such a printing and binding apparatus which jogs
the pages of the book block and mills the edges of the pages which form
the spine of the book block so as to better accept the adhesive;
The provision of such a printing and binding apparatus which
incorporates a book cover printer that prints in color a book cover for the
selected book and includes a transfer mechanism that automatically
feeds the printed book cover to the printing and binding apparatus where
it is then joined with the book block;
The provision of such a printing and binding apparatus which is
capable of applying a suitable adhesive disposed between the spine of
the book block and the inner face of the center portion of the cover;
The provision of such a printing and binding apparatus which
incorporates a clamping section that clamps the cover to margins of the
front and back of the book block proximate the spine, with the center
portion of the cover substantially aligned with the spine of the book, to
allow the adhesive to properly adhere the cover to the spine of the book
block and to adhere the pages of the book block to one another;
The provision of such a printing and binding apparatus which
includes a trimmer adapted to receive a bound book from the clamping
section so as to trim a first edge thereof, to turn the book 900 to trim a
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second edge thereof, and to turn the book another 900 to trim a third
edge thereof;
The provision of such a printing and binding apparatus which
automatically adjusts to print, bind, and trim books of different
thicknesses and sizes such that a single copy of such different sized
books may be reliably printed, bound, and trimmed to specified
dimensions without manual set up and without binding attempts of
sample book blocks and covers;
The provision of such a printing and binding apparatus having a
binding and trimming rate so as to be economical in a variety of
commercial settings;
The provision of such a printing and binding apparatus and
method which accommodates books within a wide range of sizes (for
example the width and length of the book ranging between about 5 x 7
inches and about 8'/2 x 11 inches) and within a wide range of
thicknesses (for example ranging from between 1/4 inch and
approximately 1'/2 inches, or ranging between about 25 pages and 1000
pages);
The provision of such a printing and binding apparatus which,
upon receiving data corresponding to the size (i.e., the length and width
of the book) and thickness (i.e., the number of pages) of the book to be
bound, automatically controls the book page printer to print the pages of
the book to be arranged in the book block, automatically controls the
cover printer to print the cover of the particular book to be bound,
automatically adjusts the clamping section to accommodate such book
with the cover properly aligned with respect to the spine of the book
block, and properly adjusts the trimmer so as to trim the excess width
and height of the bound book to produce a bound book corresponding to
the desired size for the finished book;
The provision of such a printing and binding apparatus in which
various sizes and formats of books may be accommodated and where
various adjustments within the apparatus for the different operations
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(e.g., positioning of the spine of the book block with respect to the center
of the cover and trimming of the edges or margins of the bound book)
are automatically adjusted upon inputting such information into the
control system, either manually or with such information being
associated with data automatically provided to the system;
The provision of such a printing and binding apparatus which may
optionally incorporate a second, book (text) page printer to increase the
rate of production of perfect bound books; and
the provision of such a printing and binding apparatus which does
not require special training for use, which is of economical construction,
which has a relatively fast production speed, and which is reliable in
operation.
Other objects will be in part apparent and in part pointed out
hereinafter.
Briefly stated, the printing and binding apparatus of a first
embodiment of this invention comprises a book page printer that prints
the text pages of the book to be bound and collates the pages to form a
book block, and a cover printer that prints the cover of the particular
book to be bound. In addition, the first embodiment of the invention
comprises a carriage receiving the book block and movable along a
workpath.
The carriage of the printing and binding apparatus of the first
embodiment is configured to hold the book block with the pages of the
book block oriented such that the width dimension of the pages of the
book block extends vertically and such that a lengthwise edge of the
book block is the lowermost horizontal edge of the book block (this
lowermost edge being referred to as the spine of the book block). The
workpath preferably has a jogging station, a milling station, an adhesive
application station, a clamping station, and optionally a trimming station
located therealong. The carriage receives the initially collated pages of
the book block from the book page (text page) printer transfer
mechanism and loosely holds the loose pages of the book block such
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that a jogging mechanism may mechanically vibrate the pages so as
allow the pages to move relative to one another in a manner such that
the edges of the pages constituting the spine of the book block are
substantially in the same horizontal plane and such that widthwise edges
of the pages are substantially in the same vertical planes.
In operation, the carriage securely grips the jogged pages and
transports the book block from the jogging station to the milling station
where a suitable tool roughs the lowermost margin of the book block so
as to insure that the spine is substantially coplanar and has a good
adhering surface. The carriage then transports the book block to the
adhesive application station where a suitable adhesive is applied to the
spine of the book block. The cover printer prints a book cover in black
and white or color and transfers the book cover to the workpath where it
is precisely positioned in the binding station of the apparatus relative to
the book block being conveyed along the workpath of the apparatus. To
increase time efficiency, this is preferably done while the book block is
being jogged and collated by the printing and binding apparatus and
while the book block receives the application of adhesive along the spine
of the book block. At the binding station, the cover of the bound book is
positioned such that the center portion of the cover is in register with and
is substantially aligned with respect to the spine of the book block with
the adhesive disposed between the spine of the book block and the
inner face of the cover. The binding station includes a clamp which
engages the cover proximate the spine and forcefully compresses the
front and back portions of the cover onto the front and back faces of the
book block to thereby adhere the center portion of the cover to the spine
of the book block, while simultaneously bonding the pages of the book
block to one another with the adhesive bonding. The carriage further
moves the bound book along the workpath to the trimming station that
has a trimming blade capable of trimming the non-spine edges of the
bound book. The trimming station has a book positioner which positions
a first edge of the book to be trimmed in a desired position with respect
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to the trimming blade such that when the trimming blade is actuated, a
predetermined amount of the cover and the book block along this first
edge is trimmed from the bound book. The trimming station further has
a book turning mechanism that turns the bound book 90 such that a
second edge of the book to be trimmed faces the trimming blade. The
book positioner moves the bound book relative to the trimming blade so
that upon actuation of the trimming blade, a predetermined amount of
the cover and the book block along this second edge is trimmed from the
book. The book turning mechanism then turns the bound book another
90 such that a third edge of the bound book to be trimmed faces the
trimming blade. Once again, the book positioner moves the bound book
relative to the trimming blade so that upon actuation of the trimming
blade, a predetermined amount of the cover and the book block along
this third edge is trimmed from the book. The trimming process
produces a perfect bound book trimmed along three edges to a
predetermined size.
While the principal advantages and features of the present
invention have been described above, a more complete and thorough
understanding and appreciation for the invention may be obtained by
referring to the drawings and the detailed description of embodiments of
the invention, which follow.
Brief Description of Drawings
Fig. 1 is top plan view of a first embodiment of a binding and
trimming apparatus of the present invention having a book page (text
page) printer, a book cover printer, and their respective transfer
mechanisms removed to better illustrate the workpath along which a
previously printed book block to be bound is transported from a jogging
station JS, to a milling station MS, to an adhesive application station AS,
to a binding station BS where the book block is bound to a cover, and
then to a trimming station TS at which margins of up to three sides of the
bound book and cover are trimmed to predetermined dimensions;
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Fig. 2 is a front side elevation view of the embodiment of the
binding and trimming apparatus of Fig. 1;
Fig. 3 is a left end elevation view taken along line 3 - 3 of Fig. 2;
Fig. 4 is a rear side elevation view of the apparatus shown in Fig.
1;
Fig. 5 is a partial end view, having a slightly larger scale than
Figs. 1-4, of the binding and trimming apparatus of Fig. 2, taken along
the line 5-5 of Fig. 2, illustrating the shear trimmer partially broken away
so as to show the nest that receives a bound book and holds the book
while the book is being trimmed along predetermined edges or margins
thereof;
Fig. 6 is a partial side elevation view of the left-hand portion of
Fig. 4 illustrating the trimming station on a slightly larger scale;
Fig. 7 is a top plan view of Fig. 6 illustrating the trimming station;
Fig. 8 is partial end view taken along line 8-8 of Fig. 6 illustrating
the book receiving nest that is movable in a vertical direction between a
raised position in which the nest receives a bound book to be trimmed
and a lowered position (as shown in Fig. 6) in which the book held in the
nest is in position to be trimmed by the shear-type trimmer;
Fig. 9 is a top plan view of Fig. 8;
Fig. 10 is a perspective view of a book block;
Fig. 11 is a plan view of a cover blank illustrating the front, back,
and center portions of the cover and further illustrating the edges or
margins of the cover to be trimmed to a predetermined size after the
book has been bound;
Fig. 12 is a schematic representation of the electrical system of
the apparatus;
Fig. 13 is a perspective view of the on demand book printing and
binding apparatus of Fig. 1 incorporating the book page printer, the book
cover printer, their respective transfer mechanisms, and the binding and
trimming apparatus shown in Figs. 1- 9 housed within a cabinet;
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Fig. 14 is a top plan view of the printing and binding apparatus of
the present invention with the book page printer and its transfer
mechanism and the book cover printer and its transfer mechanism
shown in their relative positions with the cover shown in Fig. 13
removed;
Fig. 15 is a left end elevation view similar to that of Fig. 3 but
showing the book page printer, a collator tray for receiving text pages
ejected by the book page printer, and its transfer mechanism;
Fig. 16 is a partial view of the transfer mechanism of the book
page printer viewed from the left in Fig. 15;
Fig. 17 is a view similar to that of Fig. 15 but showing the book
page printer transfer mechanism in its ejection position loading a book
block into the carriage of the printing and binding apparatus;
Fig. 18 is a schematic representation of an improvement to the
secondary jogging apparatus;
Fig. 19 is a schematic representation of the transfer mechanism
of the cover printer relative to the printing and binding apparatus;
Fig. 20 is an end view of the transfer mechanism of the cover
printer;
Fig. 21 is a top plan view of an alternative embodiment of the
printing and binding apparatus of the present invention with a second
book page printer and its transfer mechanism shown in their relative
positions;
Fig. 22 is a right end elevation view of the alternative embodiment
of the printing and binding apparatus showing the second, book page
printer in a position for initially collating a book block printed via the
second, book page printer;
Fig. 23 is a view similar to that of Fig. 22 but showing the second,
book page printer transfer mechanism in its ejection position loading a
book block into the carriage of the printing and binding apparatus;
Fig. 24 is a view similar to that of Fig. 22 but showing the second
book page printer transfer mechanism in the maintenance position; and
, .. . .... .. . ! .. ... . . . .
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Fig. 25 is a block diagram of the control system for controlling
operation of the apparatus of the present invention including control of
two page or text printers and the color cover printer;
Corresponding reference characters represent corresponding
parts throughout the various views of the drawings.
Best Mode FQr Canving Out The inverrtion
Referring now to the drawings, and In particui$r to Figs. 1- 9, a
book binding and trimming apparatus, generally as described in my U. S.
Patent 6,193,458, is shown. However, to better understand the construction
and operation of the on demand book printing, binding and trimming
apparatus of this invention, certain key parts of the above-noted book
hinding and trimming apparatus will be herein described.
As shown in F'ig. 1, a portion of a first embodiment of a printing
and binding apparatus of this invention is indicated by reference
character 1. Additional component parts of the first embodiment, a book
page printer and its book block tran fer mechanism, as well as a color
cover printer and its cover transfer mechanism are not shown in Fig. I in
order to provide an unobstructed view of the top of the binding and
trimming apparatus. The book page printer 110 and its transfer
mechanism. 112 and the book cover printer 114 and Its transfer
mechanism or conveyor 116 are shown in their reiative positions in Fig.
14, which is a view of the apparatus similar to Fig. 1: In the illustrated
embodiment of the apparatus, the book page printer 110 is a QM84032
black and white book body printer and the book cover printer 114 is a
QMS330EX color laser printer. However, these are only two examples
of printers that could be employed with the apparatus and other printers
may aiternatively be employed. In fact, because the'. manufacturers of
such printers are constantly introducing new models with better
performance and capabilities, it will be understood that such newiy
introduced printers by any manufacturer may be used with or even retro-
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fitted to the on demand book printing, binding and trimming apparatus of
the present invention. The printers and their transfer mechanisms as
shown in the drawings will be described in greater detail below.
The printing and binding apparatus 1 has a frame 3 made of
welded square steel tubes. The frame 3 has a pair of spaced horizontal
frame rails 3a, 3b extending substantially the length of the apparatus 1.
A metal cover or shroud SH may be secured to the frame 3 and is
shown in Fig. 13. The shroud has been omitted from the other drawing
figures for the sake of clarity.
A conveyor 5 is provided between the frame rails 3a, 3b for
transporting or conveying a book block BB along a workpath WP, as will
be described hereinafter. The conveyor 5 includes a carriage 7 movable
in a horizontal direction on carriage wheels CW which bear on carriage
rails 8a, 8b that are each mounted to one of the respective frame rails
3a, 3b, as best shown in Fig. 3. The carriage is power driven along the
carriage rails by means of a conveyor stepper motor Ml that drives the
carriage via a toothed timing belt and pulley arrangement, as indicated
at CB. As best shown in Fig. 4, one end of the timing belt is attached to
one end of the carriage 7 and the belt is trained around a drive pulley on
the motor Ml and around other pulleys that are journalled to the frame 3
to the other end of the belt which is attached to the other end of the
carriage. Preferably, the conveyor motor Ml is a stepper motor driven
by a control system CONT 1, as will be hereinafter described and which
is shown in Fig. 12, so that the position of the carriage (and hence the
book block carried thereby) is accurately known (i.e., to within about
0.005 inches) with respect to a reference surface of the carriage 7. In
this manner, the position of the book block is accurately known by the
control system CONT 1 as the book block is carried along the workpath
where it is bound and trimmed, as will be hereinafter discussed in detail.
In this manner, upon energization and de-energization of the motor Ml
under the control of the control system CONT 1, the carriage may be
accurately stopped at any position or work station along the workpath
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WP to accurately position the book block at a desired location. When
the carriage is at the end of the workpath, the motor M1 can be driven in
reverse so as to move the carriage 7 in a reverse direction along the
conveyor so as to return the carriage to its starting position where it can
then receive the next book block to be bound. In a variant embodiment,
the carriage can be advanced past the trimmer station to a second
printing station where the carriage receives a second book block prior to
the carriage being driven in reverse to return it to a starting position from
which the second book block can be bound and trimmed.
As shown in Fig. 10, each book block BB comprises a plurality of
pages P, which generally constitute the text pages of a book to be
bound. The number of pages making up the book block may range
between a minimum number and a maximum number of pages,
depending on the range of binding thicknesses to be accommodated by
the binding and trimming apparatus 1. In the first embodiment of the
invention, the thickness of the book block BB ranges from about'/ inch
(or less) to about 1'/2 inches (or more). This thickness range may
accommodate books from about 25 pages up to about 1000 pages (or
more), depending on the thickness of the paper used. The minimum
thickness of books to be bound by the apparatus 1 is generally
dependent on the minimum thickness of the book block capable of being
adhesive bound to a cover. Generally, book blocks with less than about
pages are not perfect bound, but in theory, a book with even a single
page could be bound by other embodiments of the present invention.
25 Typically, the pages P of the book block BB are duplex printed on
both their front and back faces and are rectangular in shape, having a
widthwise dimension and a lengthwise dimension. The pages may, for
example, range between a 5 x 7 inch rectangular format and a 8'/2 x 11
inch rectangular format, or any number of rectangular formats within the
above range. Of course, it should be understood that other formats may
be accommodated by adjusting the size of the printing and binding
apparatus. The printing and binding apparatus 1 of the first embodiment
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of the present invention automatically accommodates any book size
within the ranges of sizes thicknesses (i.e., number of pages), as is
discussed below. One edge of the book block BB is referred to as the
spine S of the book block. As contemplated, the spine of the book block
corresponds to the lowermost horizontal edge of the book block (which
is a lengthwise (major) rectangular dimension of the pages of the book
block) when the book block BB is placed in the carriage of the printing
and binding apparatus 1, as shown in Figs. 1 and 2. While the book
block BB is shown to have its longest or major dimension (i.e., its length)
as the spine of the book to be bound, those skilled in the art will
recognize that the shorter (minor) width of the book block may be used
as the spine S instead.
As seen in Figs. 13, 14, 15, and 17, the first book page (text
page) printer 110 is integrated into the book printing and binding
apparatus 1 adjacent the jogging station JS. The book page printer 110
is supported adjacent the apparatus by a support platform 118 that is
attached to the tubular frame of the apparatus by a vertically hinged
support 120. The support is hinged such that the printer can be swung
away from its operating position when the printing and binding apparatus
requires maintenance. As best seen in Figs. 15 and 17, the printer
platform 118 supports the book page printer 110 at an angled orientation
relative to the apparatus. The page ejection slot 122 of the printer is
positioned adjacent the apparatus I where a printed page of a book
being printed by the book page printer 110 will be ejected from the
printer slot 122 over the apparatus jogging station JS. The arrow 124
indicates the direction in which printed pages are ejected from the book
page printer slot 122. The operation of the book page printer 110,
including the pages of the book to be printed, is controlled by the
apparatus computer control system CONT 1 with which the book page
printer 110 communicates.
Positioned adjacent the book page printer 110 and over the
jogging station JS of the apparatus 1 is the book page printer transfer
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mechanism 112. The page transfer mechanism 112 is supported over
the jogging station JS by a support panel 128 that projects upwardly
from the frame 3 of the apparatus 1 at the left hand end of the apparatus
as viewed in Fig. 14 and by a support rod 130 that projects outwardly
over the jogging station JS from the printer hinge support 120. A shaft
132 is mounted for rotation to the support panel 128 and to the support
rod 130 and projects over the jogging station JS. As best seen in Fig.
16, the shaft 132 is angled slightly such that the end of the shaft closest
to the left hand end of the apparatus 1, as viewed in Fig. 14, will be
slightly lower than the opposite end of the shaft. Mounted on the shaft
132 for rotation therewith is a rectangular collator tray 134. The tray 134
projects out to a position adjacent the page ejection slot 122 of the book
page printer 110 where it will receive printed pages ejected from the
printer. As best seen in Fig. 15, the tray 134 on the shaft 132 angles
downwardly away from the book page printer 110 and is also angled
downwardly toward the left hand end of the apparatus as shown in Fig.
14. Mounted at the back of the tray- 134 is a box shaped bin having first
136 and second 138 side walls, a rear wall 140, and a top wall 142. The
bin receives pages ejected from the page printer 110 and holds the
pages on the tray 134 in the initial formation of the book block. A
vibrating mechanism 144 is mounted on the second side wall 138 of the
bin. Operation of the vibrating mechanism 144, which is controlled by
the control system CONT 1, provides an initial jogging and collating of
the printed pages of the book block on the tray 134 toward the back wall
140 and the second side wall 138 of the transfer mechanism 112 due to
the angled orientation of the shaft 132 and the tray 134 on the shaft.
Mounted on the back wall 140 of the tray 134 is a small
reversible, direct current clamping mechanism motor 146. The clamping
mechanism motor 146 is selectively controlled by the control system
CONT 1 to rotate a screw shaft 148 of the motor in opposite directions.
The screw shaft 148 is threaded into a clamping arm 150 at one end of
the arm. The arm 150 is mounted by a pivot pin 152 connection to the
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top wall 142 of the tray bin. The arm has a clamping pad 154 at an
opposite end of the arm from the screw shaft 148. Rotation of the
screwshaft 148 by the clamping mechanism motor 146 in one direction
will cause the arm to pivot about its pivot pin 152, thereby allowing the
clamping pad 154 to clamp down on the book block that has been
initially collated in the bin of the transfer mechanism 112. Rotation of the
screwshaft 148 in the opposite direction will cause the clamping pad 154
to pivot away from the book block, thereby releasing the book block.
Contact switches (not shown) are mounted on the clamping arm to
produce signals that indicate when a book block is clamped securely by
the arm and when the arm is moved to a position to release a book
block.
A shaft arm 156 is secured to the transfer tray shaft 132 and
projects outwardly a short distance from the shaft. An alternating current
transfer mechanism motor 158 is mounted to the frame 3 of the
apparatus 1 as shown in Figs. 15 and 17 and has a motor arm 160 that
is secured to the motor shaft and that projects outwardly from the motor
shaft. The shaft arm 156 and the motor arm 160 are interconnected by
a connecting rod 162 that is mounted to the two arms at its opposite
ends by pivot connections. Selective operation of the transfer
mechanism motor 158 will cause its shaft, the motor arm 160, and
consequently the shaft arm 156 to move through an arc segment which
causes the tray 134 to pivot between a printed page receiving position
shown in Fig. 15 and a book block depositing position shown in Fig. 17.
The motor arm 160 is preferably shorter than the shaft arm 156 such
that the tray 134 will move from the page receiving position, to the book
block depositing position, and back to the page receiving position simply
by rotating the motor arm 160 through a 360 rotation. This allows the
transfer mechanism motor 158 to be a simple, non-reversible motor.
In operation, the tray 134 of the book page printer transfer
mechanism 112 is first positioned in its page receiving position shown in
Fig. 15 by operation of the transfer mechanism motor 160 that is
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controlled by the control system CONT 1. Pages printed by the book
page printer 110 are ejected from the printer slot 122 and are collected
on the tray 134. Operation of the bin vibrating mechanism 144 causes
the printed pages to be initially jogged and collated as they are collected
into the corner of the tray defined by the back wall 140 and the second
side wall 138 of the bin. When the entire book block has been printed
and initially collated on the tray 134, the clamping mechanism motor 146
is operated causing the clamping arm 150 to close down on the book
block with the clamping pad 154 of the arm securely holding the printed
book block on the tray. The transfer mechanism motor 160 is then
operated causing the tray to move to its book block depositing position
shown in Fig. 17. In this position, the clamping mechanism motor 146 is
operated 'causing the clamping arm 150 to open and release the book
block from the tray 134 such that the book block will fall into the carriage
7 that holds the book block during further steps in the printing and
binding process of the book.
As shown in Fig. 11, each book block BB is adapted to be bound
in a suitable book cover C by a binding technique or method referred to
as perfect binding. Typically, books bound by the perfect binding
method are soft cover books. The book cover C is typically formed of a
suitable stock of heavier weight than the pages of the book block BB and
may be coated so as to have a superior finish and may be color printed.
The cover has a front face FC, a back face BC, and a center portion CP
therebetween. The width of the center portion CP of the cover C
generally corresponds to the thickness of the book block to which it is
ultimately attached. Typically, the pages P of the book block and the
cover C are somewhat oversize relative to the desired size of the
finished, bound book such that the margins of the bound book can be
trimmed to a predetermined size after the book block has been bound to
the cover to result in a perfect bound book having the desired size with
even edges along the sides or margins (preferably along three sides) of
the book. As shown in Figs. 10 and 11, the oversize margins of the
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book block BB and of the cover C are shown as trim margins, TM'!-
TM3. For example, a book having a format of any finished (trimmed)
size ranging from between about 5 x 7 Inches to just slightly less than 8
%z x 9'i inches may be printed on conventional8'/2 x 11 inch sheet stock.
The text page printers 110 and 200 will print the text on a selected area
of each page such that the text is spaced a predetermined amount from
one edge of the page (the spine) and centered along the spine. In this
manner, after the book is bound, the trim margins TMI - TM3 will be
known to the control system CONT I and thus the trim margins may be
accurately trimmed from the bound book at the trimming station TS so
as to produce a book having uniform edges and having a predetermined
finished size.
As noted, the book block BB and cover C may be pririted by any
method. However, because the printing and binding apparatus I of the
present invention is capable of instant setup for any size or format of
book to be bound (i.e., the size of the pages and the thickness of the
book) within= a predetermined range of book sizes (e.g., from 5 x 7
inches to about 8'/ x 11 inches, and any combination of rectangular
sizes within such range, and In thickness ranging from about 25 pages
to about I 00fJ pages or more), the printing and binding apparatus of the
present invention is particulatiy well-suited to print, bind, and trim a
single copy (or a small run quantity) of perfect bound book(s) printed on-
demand as described in U.S. Patent 5,465,213. In this manner, the on-
demand printing apparatus of the present invention can automatically, from
the data relating to the size and thickness of the book to be bound,
determine (calculate) the width of the center portion CP of the cover C
and the width of the trim margins TM1-TM3 so as to bind any size book
within the range of book sizes that can be accommodated by the printing
and binding apparatus 1 of this invention. The second book may be of
an entirely different size and thickness than the first book and the
printing and binding apparatus 1 will automatically accommodate this
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second book so long as the second book is also within the range of book
sizes that can be accommodated by the printing and binding apparatus.
The binding process of the printing and binding apparatus has a
sufficiently fast operational cycle such that it will finish binding and
trimming one book while a second book is being on-demand printed.
As shown in Figs. 13 and 14, the book cover printer 114 is
positioned adjacent the binding station BS of the printing and binding
apparatus 1. The book cover printer 114 is shown pulled slightly away
from the apparatus in Fig. 13 to illustrate how it can be easily separated
from the apparatus for servicing. The cover printer 114 is shown in its
operative position relative to the apparatus in Fig. 14. The cover printer
114 has a slot 166 on the top of the printer where color printed book
covers are ejected from the printer. Mounted on the top of the cover
printer is the cover printer transfer mechanism 116 that projects
outwardly from the printer to a position adjacent the binding station BS of
the printing and binding apparatus 1.
The cover transfer mechanism 116 is comprised of a pair of C-
shaped channels 168, 170 having openings that mutually oppose each
other and extend along the length of the apparatus from positions over
the printer 114 to positions adjacent the binding station BS of the
apparatus. A plurality of cross bars 172 extend between the two
channels 168, 170 forming the frame of the cover transfer mechanism
116. An additional plurality of bars 174 extend between pairs of the
cross bars 172 rigidifying the frame and providing a sliding surface for
the cover to be printed by the cover printer 114. A pivot rod 176 extends
across an intermediate portion of the frame and has a plurality of pawls
178 secured to the rod. The pivot rod 176 is connected. to a switch 180
that controls the operation of the cover transfer mechanism 116 as will
be explained.
As shown in Figs. 14, 19, and 20, two pairs of roller shafts 182,
184 are mounted for rotation to the channels 168, 170 of the frame on
opposite sides of the pivot rod 176. Each of the shafts of the pairs are
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positioned above and below each other. Each of the pairs of shafts 182,
184 has three pairs of mutually contacting rollers 186, 188 mounted to
the shafts for rotation with the shafts. The upper shafts of each pair are
operatively connected together by a chain and sprocket connection 190
shown in Fig. 14. The chain and sprocket connection 190 and the
mutual engagement between the roller pairs 186, 188 provide a driving
arrangement between the rollers where, when the rollers on the upper
shafts rotate in a clockwise direction, the rollers on the lower shafts
rotate in a counter clockwise direction and vice versa. A reversible
motor (not shown) is controlled by the control system CONT 1 and is
operatively connected to the chain and sprocket connection 190 to drive
the rotation of the upper and lower rollers in opposite directions of
rotation. The motor (not shown) is also operatively connected with the
pivot rod switch 180 to control the motor's direction of rotation, and thus
the direction of rotation of the rollers 186, 188.
When the book cover printer 114 and its transfer mechanism 116
are operated, as each book cover is printed by the printer, the book
cover is ejected from the top of the printer in the direction indicated by
the arrow 192 shown in Fig. 19. The cover C being ejected from the
printer contacts the plurality of pawls 178 and causes the pawls to move
from their first position shown in solid lines in Fig. 19 to their second
position shown in dashed lines in Fig. 19. The movement of the pawls to
their second position activates the pivot rod switch 180, which in turn,
controls the motor of the cover transfer mechanism 116 to rotate the
upper rollers 186 of each pair of rollers to rotate in the clockwise
direction and the lower rollers 188 of each pair of rollers to rotate in the
counter clockwise direction as viewed in Fig. 19. The cover being
ejected from the cover printer 114 is received between the pairs of
rollers shown to the left in Fig. 19 and the rotation of the rollers
transports the cover to the left as viewed in Fig. 19 between the opposed
pair of channels 168, 170 and over the sliding bars 174 of the transfer
mechanism frame. This movement of the cover continues until it is
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completely ejected from the cover printer 114 and moves past the
plurality of pawls 178, causing the pawls 178 to move from their second
position back to their first position shown in solid lines in Fig. 19. This
movement of the pawls causes the pivot rod switch 180 to control the
transfer mechanism motor (not shown) to reverse its rotation. The
reverse rotation of the motor causes the upper rollers 186 of the pairs of
rollers to now rotate in the counter clockwise direction and their mating
lower rollers 188 to rotate in the clockwise direction. This, in turn,
causes the pairs of rollers 186, 188 to transfer the cover to the right as
viewed in Fig. 19 between the pairs of rollers and over the pawls 178 to
the binding station BS of the apparatus. The rollers 186, 188 of the
transfer mechanism 116 transfer the cover over the clamp members
35a, 35b with an edge of the cover sliding along the positioning pins 36
until the leading edge of the cover comes in contact with the stop switch
196 indicating the proper position of the cover over the center of the
binding clamp 38. Alternatively, when only one size of cover stock is
used to print the covers of all sizes of books, the positioning pins and the
stop switch can be eliminated and replaced by a simple bin that is
centrally positioned with respect to the binding clamps. In either
manner, the cover printer 114 and its associated transfer mechanism
116 automatically operate to provide a color printed cover to the printing
and binding apparatus 1 where it is ready to be secured to the book
block by the apparatus.
Regardless of how the book block BB and cover C are printed,
the book block BB is loaded in the carriage 7 which is movable along the
conveyor 5 in a horizontal direction along the workpath WP. As will be
described in detail hereinafter, the carriage 7 is substantially centered on
the workpath WP and has a carriage clamping mechanism 9, which is
selectively actuated to firmly hold the pages P of the book block relative
to one another. This clamping mechanism 9 comprises vertical
clamping members 11a, 11 b which, upon actuation of the clamping
mechanism, are preferably self-centering such that the book block BB,
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regardless of its thickness, is centered with respect to the workpath WP
as it is held within the carriage 7. The self-centering drive of the
clamping members 11 a, 11 b is driven by an electric motor M2. The
motor M2 drives the clamping members toward each other via a suitable
self-centering gear drive (not shown) such that they firmly grip the book
block BB and such that when the motor M2 stalls or stops, the clamping
members exert a sufficient gripping force on the book block so as to
firmly hold the pages relative to one another as the book block is
transported to the various stations along the workpath WP during the
various operations that are preformed on the book block, as will be
hereinafter described. When the book block is clamped, the clamping
members 11 a, 11 b grip the front and back faces of the book block BB in
a manner such that the lower margin adjacent the spine of the book
block extends below the clamping members. The spine S of the book
block preferably extends approximately 2.0 cm. below the clamping
members when clamped.
As shown in Figs. 1, 2, and 4, the carriage 7 and the book block
BB carried thereby are shown in a first station, referred to as a jogging
station JS, at which location the book block is deposited in the carriage
7, but is not clamped. In the jogging station JS, the pages of the book
block are mechanically vibrated or jogged so as to allow the pages to
move relative to one another such that the bottom most edges of all of
the pages of the book block bear on a horizontal surface 13 and the
leading, trailing, and upper edges of the pages are substantially aligned
with one another. As previously stated, the lower lengthwise dimension
of the book block, referred to as the spine S of the book block, rests on
the surface 13 of the jogging station JS. The jogging operation is carried
out by vibrating the book block in the carriage by an electro-mechanical
vibrating mechanism 15 (as shown in Fig. 2), which has a vibrating
magnetic coil (solenoid) 17 connected to the surface 13 by resilient arms
19. The magnetic vibrating coil is energized by a suitable power supply
(not shown) under the control of the control system CONT 1. Preferably,
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during the jogging operation, the carriage clamp 9 is positioned in such
manner as to loosely hold the pages P of the book block in vertical
positions relative to one another such that they may move relative to one
another during the jogging operation to permit the pages to align with
one another. During the jogging operation, the pages of the book block
are preferably vibrated in such manner that the pages move rearwardly
relative to the carriage 7 such that the trailing edges of the pages of the
book block contact a vertical surface 21 of the carriage. The vertical
surface 21 of the carriage 7 thus provides an accurate reference position
for the trailing edge of the book block that is later used to positively
position the book block relative to the components of the apparatus as
the book block is bound and trimmed.
One arrangement for accomplishing this jogging of the book block
is shown schematically in Fig. 18. Fig. 18 shows the carriage 7 mounted
on a vibrating device comprised of an upper angled block 300 and a
lower angled block 302 with the vibrating mechanism 304 mounted
between the two blocks. With the angled blocks 300, 302 above and
below the vibrating mechanism 304, operation of the mechanism is split
into two, perpendicular force components with one component directed
upwardly and the other directed horizontally to the left as shown in Fig.
18. Thus, operation of the vibrating mechanism 304 will jog and collate
the pages of the book block on the bottom surface 13 of the jogging
station JS and against the left vertical surface 21 of the station.
Upon completion of the jogging operation (which may only take a
second or so), the carriage clamp motor M2 is energized so at to actuate
the clamp 9 to firmly clamp the pages of the book block together and to
firmly hold the book block BB in a fixed position relative to the carriage 7
as the carriage is moved along the workpath WP. The thickness of the
book block BB being bound and the clamping pressure exerted by the
clamp members 11 a, 11 b is accommodated by energizing motor M2 to
close the clamp and to allow the motor M2 to stall upon the clamp
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member firmly engaging the book block and exerting a clamping force
thereagainst.
The control system CONT 1, upon being supplied with the size of
the book block and cover of the book being bound, can then calculate
the position of the leading edge of the book block relative to the carriage
by reference to the vertical carriage surface 21. Thus, both the trailing
and leading edges of the book block can be accurately located relative
to each station of the printing and binding apparatus as well as the
trimmer as the carriage is moved along the workpath from one station to
the next.
Additionally, the horizontal plate 13 of the jogging station serves
as a reference surface for establishing the elevation of the spine S of the
book block as the latter is transported along the workpath WP. As noted
above, the carriage 7 is moved along the workpath WP by the stepping
motor Ml via the timing belt and pulley arrangement CB such that the
position of the carriage (and hence the position of the book block carried
thereby) may be accurately controlled at any point along the workpath to
an accuracy of within about 0.005 inches or about 0.127 mm.
The carriage 7 and the book block BB carried thereby are moved
by the conveyor 5 from the jogging station JS to a second station along
the workpath WP. This second station is a milling station MS at which a
rotary milling or spine grooving head 23 mills or otherwise removes
material from the lowermost edge of each of the pages (i.e., the spine S)
of the book block to thereby roughen the surface of the spine to better
bond the adhesive to thp spine and to insure that the spine is coplanar.
The milling station MS is provided with a vacuum dust or debris collector
27, driven by a motor M3. The inlet opening for the dust collector is
shown at 29 in Fig. 1. The milling head 23 is rotary driven by a motor
M4 at high speed and has a milling blade 31 (as shown best in Fig. 2)
which engages the spine of the book block as the latter is conveyed over
the milling head by the carriage 7. It should be understood that the
milling operation is only intended to remove only a minimal amount of
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material from the spine S of the book block, to roughen the surface of
the spine and create a good adhesive gripping surface on the spine.
The milling blade 31 is a single blade carried on the rapidly rotating
milling head, configured to roughen and cut shallow grooves in the spine
as the carriage moves the book block thereover. These grooves hold a
supply of adhesive and facilitate the spine of the book block being firmly
adhered to the center portion CP of the cover. The milling station
utilized in the preferred embodiment of the printing and binding
apparatus can be commercially acquired from Martin Yale Industries,
Inc. of Wabash, Indiana.
Downstream of the milling station MS along the workpath WP is
next located an adhesive application station AS. As shown, this
adhesive application station includes a hot melt adhesive bath 31 (as
shown in Fig. 1) in which a quantity of a suitable hot melt adhesive, of
the type which is well known in the book binding art, is heated to a liquid
state. One such adhesive that has worked well in conjunction with the
system and method of this invention is a hot melt adhesive commercially
available from Capital Adhesives of Mooresville, Indiana, recommended
by the manufacturer for binding books. However, any suitable hot melt
or cold melt adhesive may be used in accordance with this invention.
The adhesive application station AS further has an adhesive
applicator roller 33 which is, partially immersed in the liquid hot melt
adhesive and which is rotary driven by a motor M5 such that the roller
picks up a coating of the liquid hot melt adhesive on its cylindrical face.
The upper portion of roller 33 is positioned to be generally tangent to the
spine of the book block BB as the book block is conveyed by the
carriage 7 along the workpath WP over the roller 33. Thus, as the spine
of the book block is conveyed over the roller 33, a quantity of hot melt
adhesive is applied to the spine of the book block. The roller 33 is rotary
driven by the motor M5 at approximately the same speed as that of the
carriage 7 moving along the workpath WP so as to pick up molten
adhesive from the bath 34 and lay down a substantially continuous
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coating of the liquid hot melt adhesive on the spine S of the book block
as the latter is conveyed over the roller. The roller motor M5 is
energized and de-energized by a micro-switch (not shown) tripped by
movement of the carriage 7 as it approaches and leaves the adhesive
station. The hot melt bath and roller are commercially available. It
should be understood that the bath 31 is provided with suitable heaters
so as to heat the adhesive to a desired temperature and is further
provided with a thermostat control system to maintain the adhesive in
the bath at a desired temperature.
While the apparatus described herein is shown to utilize a hot
melt adhesive, those skilled in the art will recognize that a cold (room
temperature) adhesive could be used as well.
The book block BB is conveyed by the carriage 7 from the
adhesive application station AS to the next work station, which is the
binding station BS. At the binding station the binding clamp 35 is
provided. The binding clamp is preferably of the type that is
commercially available. The binding clamp includes a pair of self-
centering, power operated clamp members 35a, 35b, driven by a motor
M6, that are disposed on opposite sides of the book block. The clamp
members 35a, 35b are driven between their open and closed positions
by the motor M6 by means of a suitable gear train (not shown). As
shown in Fig. 1, the clamp members 35a, 35b are in their open position
with their inner edges spaced apart a distance sufficient to
accommodate the thickness of the book block BB to be bound to a cover
C.
Referring to Fig. 2, it can be seen that the clamp members 35a,
35b are positioned slightly above the bottom surface of the jogging
station JS but below the carriage 7 such that the clamp members are
disposed to engage the side faces of the book block below the level of
the carriage clamp members 11 a, 11 b, and just above the level of spine
S of the book block. As provided, one lateral side of the binding clamp is
mounted by a hinge to the rail 3a and is selectively movable between a
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lowered position in which the clamp members 35a, 35b are positioned
below the level of the spine S of the book block as the carriage 7 moves
the book block (with the adhesive applied to the spine) into position over
the binding clamp 35 assembly, and a raised position where the book
block spine 5 engages against the binding clamp 38 and is positioned
between the clamp members 35a, 35b. The clamp members 35a, 35b
are provided with cover positioning pins 36 which accurately locate a
cover C relative to the book block BB to be bound therein. In this
manner, with the cover installed on the clamping members 35a, 35b, the
center portion CP of the cover may be disposed over the opening
between the clamping members 35a, 35b and positioned substantially
centered with respect to the spine of the book block.
When the carriage 7 with the book block therein is stopped at the
binding station BS, the book block is positioned above the cover C with
the spine S of the book block over the center portion CP of the cover.
With the book block BB in such position, it will be understood that the
book block is substantially in register with the center portion of cover C
and that the book block is substantially centered in heightwise relation
with the cover. The book block is transported from the adhesive
application station to the binding station in such a short time that the
adhesive substantially does not appreciably cool or otherwise begin to
set up before the binding operation begins. With the book block
substantially correctly positioned with respect to the cover (i.e., the
center of the spine S of the book block is centered with respect to the
cover both laterally and longitudinally), a combination hydraulic
pump/electric motor PM4 is energized so as to pressurize a fluid cylinder
37 to effect the raising of the clamp assembly 35 from its lowered
position to a raised binding position in which the clamp assembly 35 is
substantially horizontal. As the clamp is raised, a surface 38 of the
clamp between the clamp members 35a, 35b is moved into engagement
with the center portion CP of the cover from below the outer face of the
center portion of the cover C so as to raise the cover and to force it into
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adhesive engagement with the adhesive applied to the spine S of the
book block. The clamp members 35a, 35b are then power driven toward
each other by means of a motor M6 which acts through a self-centering
mechanism so as to insure that the clamp members 35a, 35b
substantially simultaneously engage the outer surface of the cover of the
book immediately above the level of spine S. As the clamp members
35a, 35b close on the cover C and the book block BB, the motor M6
stalls, thus insuring that sufficient clamping force has been applied to
properly bind the book.
As the clamp members 35a, 35b clamp on the cover of the book
block, the cover stretches around the spine and the lower margins of the
book block BB proximate the spine S to insure that the cover tightly
conforms to the spine of the book block, preferably without the formation
of wrinkles in the center portion CP of the cover C. While it has not been
found necessary to do so in all cases, for some cover stock materials
which are thicker than conventional cover stock material, the cover C
may be scored along either side of the center portion CP of the cover in
the manner described in U.S. Patent No. 6,142,721 which is herein
incorporated by reference. The clamp members 35a, 35b hold a
clamping force on the front and back face of the cover of the book being
bound just above the level of the spine S for only a few seconds to allow
the adhesive to properly set (i.e., cool), thereby binding the book block to
the inner face of the center portion of the cover. The outer surfaces of
the clamp members 35a, 35b may be coated with a suitable low
friction/non-stick material such as a Teflon tape to insure that cover C
does not adhere to the clamp members and to insure that any excess
hot melt adhesive may be readily cleaned from the clamp members. It
should be understood that the spine S of the book block is not
necessarily in a tight compressive relation with the cover, after the
binding clamp 35 has been moved fully to its raised position, but that
there may be a desired gap (e.g., a few mm) between the bottom face of
spine S and the inner face of the center portion CP of the cover so as to
.. . . .~ . .. ... ...... . . . .. . . . , .., . . _ .. .. .. . . . . . .
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insure that a,layer of adhesive remains between the spine and the cover
so as to result in the satisfactory binding of the book block to the cover.
It should also be understood that if the spine were tightly forced onto the
inner face of the cover, excessive amounts of the still liquid (or otherwise
flowable) adhesive may be forced from between the spine and the cover
so as to result in a weakened binding of the book. Furthermore, it
should be understood that the transverse grooves (not shown, but which
may, for example, be about 1/8 inch wide, 0.020 inches deep, and on
about 3/8 inch centers) which are optionally formed in the spine S of the
book block by the milling knife 31 act as a reservoir for holding an extra
amount of the adhesive and to present additional surface area for the
adhesive boncting of the pages to the cover and to one another. Yet
further, it should be understood that, with the pages of the book block
BB held tightly by the carriage clamp members 11 a, 11 b at the binding
statiion and with the cover C disposed on the upper face of the binding
clamp assembly 35 (as positioned by locating pins. 36), the upward
movement of the binding clamp assembly 35 causes the cover, to splay
outwardly relative to the boqk block with the front and back cover FC
and BC, respectively, being in nearly horizontal position beneath the
carriage 7.
Yet further, it should be understood that the hot melt adhesive, as
above described, may be omitted and replaced with aroom temperature
adhesive, such as that described in U.S. Patent No. 6,142,721. In such
instance, rather than applying a coating of a hot melt adhesive to the spine
S of the book block BB (as above described), a suitable quantity of the room
temperature, solid adhesive may be adhered to the inner face of the center
portion of the cover C or to the spine S of the book block as the book block
is conveyed along the workpath WP. In the event that such room
temperature adhesive is used, the adhesive station AS, heretofore
described, is replaced with the adhesive application station, as described in
the above noted U.S. Patent No. 6, 142, 721. Furthermore
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the binding station BS, as described above, is replaced with the
ultrasonic adhesive activation system described in the above-noted
patent. In such ultrasonic adhesive activation systems, an ultrasonic
horn (tool), as described in the above-noted patent, is brought into
working engagement with the lower surface of the center portion CP of
the cover C and the tool is caused to resonant to thereby transmit
ultrasonic energy from the tool through the thickness of the cover so as
to activate or melt the adhesive. The ultrasonic energy aids in forcefully
driving the now activated or liquefied adhesive into adhesive
engagement with pages comprising the book block BB. In this manner,
the ultrasonic energy forces the adhesive vertically a short distance
(e.g., a few hundredths of an inch) between the lowermost edges of the
pages of the book block adjacent the spine S to imbed the edges of the
pages of the book block into the adhesive and to insure that the inner
face of the center portion of the cover is adhered to the spine of the book
block. It should be noted that the time required for such ultrasonic
energy to activate the adhesive may be very short (a fraction of a
second), depending on the thickness and height of the book being
bound. Upon removal of the ultrasonic energy, the adhesive will
substantially instantaneously cool, thus allowing the bound book to be
quickly released from the clamping members 35a, 35b. In accordance
with this invention, the printing and binding apparatus I may be readily
converted between use of hot melt adhesives and room temperature
adhesives which must be ultrasonically activated. In order to readily
accomplish this changeover, the adhesive application station AS using
hot melt adhesive (as herein described) may be removed from the frame
3 as a unit and replaced with the room temperature adhesive applicator
and ultrasonic adhesive activation unit, as described in the above-noted
patent.
Within the broader aspects of this invention, the adhesive
application station may apply the adhesive directly to spine S of the book
block BB. Alternatively, the adhesive may be applied first to a central or
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selected area of cover C. The term "application of adhesive so as to be
disposed between the spine and the cover upon binding of the book", or
similar words, is intended to mean either applying the adhesive directly
to spine S or directly to a designated area of the cover C.
As noted above, the cover C and the pages P constituting the
book block BB are oftentimes printed on oversize stock which needs to
be trimmed along three (3) edges or trim margins TM 1, TM2 and/or TM3
(i.e., along the top, outer, and bottom margins) of the bound book so as
to produce a bound book of a precise, predetermined size with uniform
top, bottom, and outer edges. The cover stock from which the cover C
of the on-demand printed book is produced may be of a size such as to
allow a wide range of book thicknesses to be printed using the same
stock size for the cover. To facilitate the use of a common cover stock
size, the width of the cover center portion CP is adjustable to
accommodate books of a wide range of thicknesses and each graphic of
each cover can be printed substantially centered with respect to the
stock cover size, such that no mechanical adjustments are necessary to
print books of varying thicknesses.
In accordance with one aspect of the printing and binding
apparatus 1 of the present invention, the carriage 7 further transports the
now bound book from the binding stations BS to another work station,
referred to as the trim station TS, along the workpath WP. In the
manner as will be described, one, two, or three edges of the bound book
(i.e., the book block BB and the cover C) are trimmed (i.e., the above-
described trim margins TM are removed) at the trimming station TS to
provide the bound book with a precise, predetermined size having neat
and uniform edges. Referring to Fig. 2, as the bound book is
transported by the carriage 7 from the binding station BS to the trimming
station TS, the cover is bonded to the spine of the book block, but the
cover is splayed into a partially open position (i.e., the cover does not lie
flat on the book block) and the carriage clamping members 11 a, 11 b are
maintained in clamping engagement with the front and back faces of the
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book block. Further, the spine of the book is disposed at the lower
horizontal edge of the book and the trailing edge of the book block
remains in engagement with the vertical wall 21 of the carriage 7 thereby
accurately maintaining the position of the book relative to the carriage.
In this manner and since the control system CONT 1"knows" the
desired final (predetermined) size of the finished book, the size of the
stock used for the pages P of the book block BB, and the size of the
stock used to print the cover C, the control system has sufficient
information to calculate the trim margins TM along the top, bottom, and
outer edges of the book so as to result in a finished, trimmed book of a
desired size.
As the carriage 7 moves along the workpath WP to the trimming
station TS, the book clamp motor M2 is energized so as to open the
carriage clamp members 11 a, 11 b and thereby release the bound book
B, allowing the book to drop vertically downwardly into a trimming nest,
as generally indicated at 41. After the book has been released and
dropped into the nest 41, the carriage 7 is advanced along the workpath
WP so that the vertical reference surface 21 of the carriage again
engages the trailing edge of the book block and nudges the book in the
nest 41 in a forward direction (i.e., toward the right-hand end of the
apparatus 1, as shown in Fig. 1), thereby accurately positioning the book
in the nest 41 relative to a trimming knife (as will be hereinafter
described) so that the trim margins TM may be accurately trimmed from
the book to give the book its predetermined dimensions. With the book
properly positioned in the nest 41, the book is positioned with its spine
constituting its lower edge, with its pages vertical, and with one edge to
be trimmed disposed toward the trimmer. The front and back faces FC,
BC of the cover C are disposed against the front and back pages of the
book block such that the book is in its normally closed position.
The nest 41 of the trimming station TS is mounted on a vertically
movable nest elevator 43 that may be selectively moved in the vertical
direction. The elevator is moved along a vertical track 45 on track rollers
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47 by a power screw drive 49 which includes a vertical drive screw 51
journalled in bearings 53 mounted to the frame 3 of the printing and
binding apparatus. The drive screw is rotary driven by an electric
stepper motor M7 through a timing belt and pulley drive, as indicated at
55. In this manner, the nest 41 is moved to its raised position (not
shown) at which location it receives the bound (but not yet trimmed)
book B from the carriage 7. With the book B received in and properly
positioned relative to the nest 41, the stepper motor M7 is energized so
as to rotate the drive screw 51 which lowers the nest 41 from its raised
to its lowered trimming positions (as shown in Fig. 2).
The nest 41 includes a book clamp 57, as best 'shown in Figs. 5,
7, and 8, for holding the bound book B while one or more edges thereof
are trimmed. The details of the book clamp 57 and the nest 41 will be
more fully described hereinafter. However, the book clamp 57 includes
an indexing mechanism, as generally indicated at 99 (which is also
described hereinafter), that operates to rotate the book B held in the nest
41 through various angles (or through any desired angle) from a first
position in which a first edge or trim margin TMI of the book B is
trimmed, to a second in which the book is rotated to a set position, for
example rotated 90 such that a second edge or trim margin TM2 of the
book is in position such that it may be trimmed, and then to a third
position in which the book is rotated to another set position, for example
rotated an additional 90 such that a third edge or trim margin TM3 of
the book may be trimmed. Finally, book clamp 57 may be retracted or
opened to release the trimmed book B.
As generally indicated at 59, a book shear or trimmer is provided
which may be adjustably moved into operating relation with a book held
in the nest 41 for trimming one, two, or three sides or edges of the book.
Preferably, the trimmer 59 is a knife shear of sufficient length to trim the
lengthwise dimension of the largest book B to be bound and trimmed by
the apparatus 1 of the present invention. The trimmer 59 is vertically
mounted on a trim carriage 61 which is mounted for horizontal
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movement toward and away from an edge of the book B held in the nest
41 such that the horizontal position of the trimmer (and more particularly
the vertical plane of the blade of the trimmer) relative to the edge of the
book being trimmed determines the amount of the margin of the book B
to be trimmed. Of course, the horizontal position of the trim carriage 61
(and hence the position of the trimmer 59) is under the control of the
control system CONT 1, as will be explained.
As best shown in Figs. 6 and 7, the trimmer 59 comprises a
trimmer frame 62 in which a guillotine-type shear blade 63 having a
shear edge 64 (as shown in Fig. 7) is mounted to move between a fully
open position and a closed trimming position. The trimmer further
comprises an anvil 65 against which the book B in the area to be
trimmed rests and against which the blade edge 64 cuts through the
upper face of the cover C, the pages P of the book block BB, and
through the other face of the cover to trim an edge or margin of the
bound book B. The trimmer further has a book clamp 67 which is
operable independently of the trimming blade 63 for firmly holding the
book relative to the trimming blade adjacent the trim line (i.e., the line
along which the blade 63 will trim the edge of the book upon closing of
the trim blade 63) to insure that the trim blade uniformly trims the edge
of the book being trimmed.
Movement of the trim blade 63 between its open and closed
positions is power operated by means of a fluid cylinder, as indicated at
69 (see Figure5). Further, the clamp 67 is power driven by another fluid
cylinder 71. Each of these fluid cylinders is preferably hydraulic, but
those skilled in the art will recognize that pneumatic cylinders or other
devices may be used. Each of the fluid cylinders 69, 71 is supplied
hydraulic fluid under pressure from a dedicated unitary hydraulic
pump/electric motor (not shown). Such pumps may be driven in forward
or reverse directions to reverse the pressure supplied to the cylinders
69, 71 so as to reverse their direction of movement. Thus, opening and
closing of the shear blade and the shear clamp may be controlled
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(initiated) merely by reversing the operation of the pumps without the
need for any expensive hydraulic valves or the like. Of course, those
skilled in the art will recognize that many other acrangements for
supplying hydraulic fluid under pressure to the fluid cylinders 69 and 71
may be used and that pneumatic, eiectromechanical, andlor other
means could be used in place of the fluid cylinders themselves.
As noted, the trimmer 59 Is mounted on the trim carriage 61 for
movement in the horizontal dfrection toward and away from an edge of
the book B being trimmed as the book is held in the nest 41. More
specifically, the trim carriage 61 Is mounted on track rollers 73 which roll
on a trim carriage track 75 that is rigidly mounted to the frame 3 for
movement of the trimmer between a retracted position (as shown in Fig.
6) where the trimmer will be clear of the rnaximum size book that can be
trimmed. In the retracted position, the book can be rotated In the
apparatus into a trimming position as ft is held in the nest 41 for
presenting another edge or margin of the book to the trimmer for being
trimmed. In the trimming position, the plane of the shear blade 63 is
accurately positioned with respect to a margin of the book B to be
trimmed. The trim carrlage 61 is power driven by a power drive 77 for
movement between its retracted and trimming positions. The power
drive 77 is shown to comprise an electric stepper motor M8 which drives
a drive screw 79 by means of a belt and pulley arrangement 81. The
drive screw 79 is joumailed with respect to the trim track 75 by means of
bearings 83. Under the control of the control system CONT I of the
present Invention, the stepper= motor M8 is controlled so as to accurately
position (e.g., to w(dhin 0.005 inches) the cut.ting plane of the shear
knife 63 relative to the margin of the book B to be trimmed such that a
predetermined trim margin TM Is removed from the book B along the
vertical edge of the book presented to the trim blade.
The trimmer 59 described above is the trimmer described in my U.S.
Patent 6,193,458. It will be understood, however, that while such a trimmer
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works well in this instance, a trimmer, as disclosed in my U.S. Patent
6,928,914, may be used as well. In particular, it will be understood the blade
and actuation system of U.S. Patent 6,928,914 may be used in place of the
blade 63 and blade actuation system, as above.
As shown best in Fig. 7, the book clamp 57 carried by the nest 41
comprises a-fluid piston/cyiinder actuator 85 having a book pressing
platen 87 on its inner end for pressing against one face of the book B
deposited within the nest 41, The fluid cyiinder 85 is powered by a
unitary pumpleiectric motor (not shown) similar to the above described
pump/electric motors used to supply fluid pressure to the cylinders 69,
71 described above. The pressing platen 87 Is journalled on the rod of
the cylinder 85 by means of a bearing 89 so as to readily permit rotation
of the book B with respect to' the cylinder as the book B is held in
clamped refation- with the platen 87 when the book is in the nest 41 so as
to permit a second and then a third margin of the book to be rotated Into
position for bping trimmed by the blade 63. The nest 41 includes a lower
reference surface 91 for engagement with the spine S of the book B as
the book is deposited within the nest. The nest further has a wall 93
extending upwardiy from the surface 91 which bears against a vertical
face of the bound book B. This wall 93 is mounted on a rotary shaft 95
that Is mounted In bearings 97 carried by an elevator 43. As shown In
Fig. 8, upon, pressurization of the cylinder 85, platen 87 is forcefully
moved inwardly toward the book B held in the nest 41 to thereby firmly
grip the book between the platen 87 and the verticai wall 93 which in
turn is rotatably mounted on the shaft 95 which is carried by the bearings
97. In this manner, the book B is firmly held In place within the nest 41,
thereby enabling positioning of the blade 63 reiative to the known
position of the book in the book nest to enable a predetermined trim
margin TM1 TM3 to be trimmed from each of three respective margins
or sides of the book B.
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Preferably, the book B is positioned in the nest 41 such that the
geometric center of the finished book is coaxial with the centerline of the
book clamp cylinder 85 and the shaft 95 such that, as the book is
rotated, the book will rotate about the axis of the finished book (i.e., the
center of the book as trimmed).
As shown best in Figs. 6 and 7, the index drive 99 is mounted on
the elevator 43 for indexing the shaft in increments of 90 so as to rotate
the book B held within the nest 41 through a predetermined angle (e.g.,
90 ) about the horizontal axis of the shaft 95 to present a second and
then a third edge of the book B for being trimmed by the blade 63. More
specifically, the index drive is a stepper motor M9 connected to the shaft
95 by means of a belt 103 and pulley arrangement. Upon energization
of the stepper motor M9 for a predetermined number of counts by the
control system CONT 1, the shaft 95 (and hence the book B) rotates a
90 such that another edge or margin of the book B is rotated to assume
a vertical position where a predetermined trim margin for that edge or
side of the book B may be trimmed by the trimmer 61. It should be
understood that other arrangements for indexing the book B may be
used. For example, a hydraulically driven index mechanism may be
used to rotate the book through angles of 90 or through other desired
angles. For example, the book could be rotated through 180 between
trimming of the top and bottom margins of the book without the trimming
blade being horizontally repositioned. In addition, multiple trimming
blades could be used to trim the book margins simultaneously.
Referring to Fig. 6, as shown within the phantom line circle, a
range of sizes of books B held by the nest 41 is depicted that can be
accommodated by the trimming station TS of the present invention. As
shown, both the smallest and largest sizes of the books B
accommodated by the apparatus of this invention is shown with the
spine S of such books B bearing on the upper face of the nest surface
91, thereby properly positioning the book in heightwise orientation
relative to the shear blade 63. The phantom line circle depicts the swing
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of the largest size book as the book is rotated from the first position to
the second and then the third positions.
With the book positioned within nest 41 in the first position such
that the book's leading vertical edge and its trim margin TM1 are
disposed toward the shear 59, the control system CONT I operates to
energize stepper motor M8 an amount so as to move shear trimmer 59
horizontally from its retracted position (as shown in Fig. 6) to a
predetermined trimming position in which the vertical cutting plane of the
trimmer is oriented such that the trimmer will shear the trim margin TM1
from the book. With the shear 59 in this first trimming position, the pump
PM2 is energized so as to close the shear clamp 67 on the book to firmly
hold the book while the trim margin TM1 is sheared from the book.
Then, the shear pump PM1 is energized so as to actuate the cylinder 69
to forcefully move the blade 63 from its open position to its closed
position so as to cut the desired trim margin TM1 from the book. After
the shearing operation is complete, the pump motors PM1, PM 2 are
energized in a reverse direction so as to open the clamp and move the
shear blade to its open position.
After trimming of the first trim margin TM1, the stepper motor M8
is energized so as to horizontally move the trim carriage 61 back to its
retracted position from its cutting position. After the shear 59 is clear of
the book circle, the stepper motor M9 is energized so as to index the
nest 41 (and hence the book held therein) 90 about the horizontal axis
of the shaft 95 to dispose a second edge or trim margin TM2 of the book
in a vertical position. The control system CONT 1 is provided with
information so as to calculate the shear plane of the shear 59 in relation
to the book, as discussed above, so,that the second trim margin TM2
may be trimmed from the book. With the book rotated to this second
position, the stepper motor M8 is energized to move the trim carriage 61
in the horizontal direction toward the book so that the shear plane of the
blade 63 is positioned where the shear 59 can remove the second trim
margin TM2 from the book. Again, pump PM2 is energized to actuate
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the shear clamp 67 and then the shear pump PM1 is energized so as to
trim the second trim margin TM2 from the book. Once again, the pump
motors PM1, PM 2 are energized so as to open the clamp and move the
shear blade into its open position and the stepper motor M8 is energized
so as to horizontally move the trim carriage 61 clear of the book. Finally,
the book is indexed through another 90 angle so as to position a third
edge or trim margin TM3 of the book in a vertical position disposed
toward the trim blade 63. In the manner heretofore described, the shear
carriage is moved inwardly toward the book and the vertical plane of the
shear blade is positioned so as to trim the third trim margin TM3 from the
book, thereby forming a book having three trimmed edges and an
accurate, predetermined size. After the trimming is complete, the shear
carriage is moved to its retracted position where it is clear of the book
and the nest clamp cylinder is retracted to thereby release the book.
It should be noted that it may not always be required to return the
trimmer 59 to its retracted position after trimming of each edge of the
book and that the trim carriage may be maintained in substantially its
trimming position, moving only a minimal distance while the book is
rotated from one trimming position to another. By not having to retract
and advance the trimmer fully between its trim and retracted positions
when trimming each edge of the book, the time required for trimming the
book may be reduced. Furthermore, by moving the trimmer only a
minimal amount, as needed during the rotation of the book, the book can
remain positioned between the shear clamp 67 of the trimming carriage
61, albeit without the shear clamp firmly grasping the book, as the book
is rotated. This prevents the opposite faces of the book cover from
naturally splaying apart and where they could possibly fail to reenter the
shear clamp 67.
An alternative embodiment of the printing and binding apparatus
of the invention is shown in Figs. 21-24. The alternative embodiment of
the printing and binding apparatus incorporates a second, book page
printer assembly 200 attached to the printing and binding apparatus 1 at
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a location along workpath WP separate from the location of the first text
page printer assembly 110. For example, the second text page printer
assembly 200 may be located at the opposite end of the workpath WP
from the first described book page printer assembly 110. In operation,
the second, book page printer assembly 200 functions similar to the first
book page printer assembly and is configured to print and initially collate
the pages of a book block and to load them into the carriage 7 in
substantially the same manner a the first book page printer assembly
110. Use of the second, book page printer assembly 200 increases the
production rate of perfect bound books produced by the printing and
binding apparatus I by effectively cutting in half the time required to print
the pages of the book blocks.
The second, book printer assembly 200 comprises a printer 202
and a transfer mechanism 204. The printer 202 of the second, book
printer assembly 200 is preferably a black and white printer that is
identical to the printer 110 of the first, book page printer assembly
described above. It should be understood, however, that the printer 202
of the second, book page printer assembly 200, could be any type of
printer, including a color printer if so desired, and need not be identical
to the printer 110 of the first, book page printer assembly. The second
printer 202 is mounted to the frame 3 of the printing and binding
apparatus 1 adjacent the trimming station TS at the opposite end of the
workpath WP from the printer 110 of the first, book page printer
assembly. Like the first, book page printer assembly, the printer 202 of
the second, book page printer assembly 200 is preferably mounted to
the printing and binding apparatus 1 by a support platform 206 that is
attached to the frame 3 of the printing and binding apparatus by a
vertically hinged support member 208. In general, the printer 202 of the
second, book page printer assembly 200 functions identically to the
printer of the first, book page printer assembly.
The transfer mechanism 204 of the second, book page printer
assembly 200 comprises a rectangular tray 210 and a support bracket
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212. The tray 210 is preferably a mirror image of the tray of the first,
book page printer assembly and includes identical features such as a
box shaped bin having first 214 and second 216 side walls, a rear wall
218, and a top wall 220, a vibrating mechanism 222 for initial jogging
and collating of the printed pages of the book block, and a screw driven
clamping arm 224. A shaft 226 is mounted to the support bracket 212
for rotation about the shaft's axis. The tray 210 is mounted on the shaft
for rotation with the shaft. Like a mirror image of the shaft 132 of the
first, book page printer assembly, the left most end 228 of the shaft 226
of the second, book page printer assembly is oriented slightly above the
opposite right end 230 of the shaft such that the shaft and tray 210 are
angled slightly from the horizontal.
Unlike the transfer mechanism 112 of the first, book page printer
assembly, the support bracket 212 of the second, transfer mechanism
204 is constructed with a C-shaped portion 232 of the bracket that
supports the opposite ends of the tray shaft 226. The C-shaped portion
232 is mounted to the frame 3 of the printing and binding apparatus I for
pivoting movement about a vertical axis defined by a main support
member 234 of the support bracket. This pivoting connection allows the
C-shaped portion 232 of the bracket 212, along with the tray 210
mounted thereto, to swing between an operational position, as shown in
Fig. 21-23, and a maintenance position, as shown in Fig. 24. In the
maintenance position the transfer mechanism 204 is easily accessed for
servicing and the trimming station TM beneath the transfer mechanism
is also more easily accessed for servicing. A locking mechanism 236 is
provided for releasably securing the C-shaped portion 232 of the bracket
212 in the operational position.
Due to the pivoting movement of the tray 210 and the C-shaped
portion 232 of the support bracket 212 with respect to the printing and
binding apparatus 1, the rotation of the tray shaft 226 with respect to the
C-shaped portion of the support bracket is driven by an alternating
current tray shaft drive motor 238 that is mounted directly to the C-
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shaped portion of the support bracket such that it can pivot therewith.
When the C-shaped portion 232 of the support bracket 212 is in the
operational position, the tray shaft drive motor 238 can be operated by
the control system CONT 1 to selectively rotate the shaft, together with
the tray 210, between a printed page receiving position shown in Fig. 22
and a book block depositing position shown in Fig. 23.
In operation, the transfer mechanism 204 of the second, book
page printer assembly 200 operates in a similar manner to the transfer
mechanism 112 of the first, book page printer assembly. Thus, the
transfer mechanism 204 receives pages from the printer 202 of the
second, book page printer assembly 200 with the tray 210 in the printed
page receiving position, initially jogs and collates the printed pages of a
book block, clamps the printed book block on the tray, rotates the tray to
its book block depositing position, and releases the book block to allow
the book block to fall into the carriage 7, in the same manner as
described above in reference to the first, book page printer assembly.
Unlike the transfer mechanism 112 of the first, book page printer
assembly, the transfer mechanism 204 of the second, book page printer
assembly rotates the tray 210 to its book block depositing position and
releases the book block into the carriage 7 when the carriage is at the
opposite end of the workpath WP, adjacent the trimming station TS.
Just prior to this point, the carriage 7 will have deposited a bound book
into the nest 41 of the trimming station TS and the carriage is therefore
empty. Under the control of controller CONT 1, the carriage is moved
beyond trimming station TS to a position below transfer mechanism 204
to receive the book block printed by the second printer 200. Then, after
the book block is received in the carriage, the carriage is returned to the
opposite end of the workpath WP so as to convey the second book block
to the jogging station JS, to the milling station MS, to the adhesive
application station AS, to the binding station BS, and thence to the
trimming station TS in a manner similar to that described in regard to the
book block printed by the first printer 110. Of course, while these
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operations are being carried out on the second book block, printer 110
may be printing another book block.
A horizontal positioning plate 240 is mounted to the printer
binding apparatus 1 in a position aligned with the tray of the second
transfer mechanism 204 and just beneath the carriage 7 when the
carriage is positioned beneath the transfer mechanism 204 of the
second, book page printer assembly 200 as shown in Figs. 22-24.
When a book block is deposited into the carriage 7 from the transfer
mechanism 204 of the second, book page printer assembly 200, the
spine of the book block is supported on the positioning plate 240 and
then the clamping members 11a, 11b of the carriage 7 are moved
together to firmly hold the book block. The positioning plate can also be
provided with vertically extending sides positioned outside and below the
clamping members 11 a, 11 b of the carriage 7 to prevent pages of the
book block from slipping off of the positioning plate. The positioning
plate 240 is at an elevation above that of the horizontal plate 13 of the
jogging station JS such that a book block deposited into the carriage 7
by the second, book page printer assembly 200 is positioned higher in
the carriage than a book block deposited into the carriage by the first,
book page printer assembly. Thus, the positioning plate 240 serves to
establish the vertical orientation of the book block as the book block is
moved by the carriage 7 back along the workpath WP to the jogging
station JS at the opposite end of the workpath. Positioning the book
block higher in the carriage 7 prevents the book block from contacting
any components of the various work stations as it is brought to the
jogging station JS.
Once the carriage 7 arrives at the jogging station JS with the book
block printed by the second, book page printer assembly 200, the
clamping members 11 a, 11 b of the carriage 7 are released to allow the
book block to drop onto the horizontal surface 13 of the jogging station
JS. From this point, the pages of the book block.are jogged and the
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book binding process proceeds in the same manner as it would if printed
by the first book page printer assembly as described above.
Thus, by incorporating the second, book page printer assembly
200 in the additional embodiment of the printing and binding apparatus
of the invention, the production rate of perfect bound books can be
increased by alternating the feeding of the carriage with a book block
printed by either of the first and second, book page printer assemblies.
The increased production rate should be apparent in situations where
the printing of a book block requires more time than it takes the carriage
7 to move along the work path from the jogging station JS to the
opposite end of the work path and then return to the jogging station
during the production of a perfect bound book. This is often the case
when the books being bound have large numbers of pages.
Incorporating the second, book page printer assembly 200 in the
additional embodiment of the printing and binding apparatus also allows
the printing and binding apparatus to continue production of perfect
bound books when either of the printers of the first and second, book
page printer assemblies is being serviced.
As mentioned above, the second, book page printer assembly
200 is positioned adjacent the trimming station TS which periodically
requires maintenance. To perform such maintenance, it is helpful to
have access to the trimming station TS from above. This is why the C-
shaped portion 232 of the support bracket 212 is pivotable about the
main support member 234 of the support bracket between the
operational position and the maintenance position. As best shown in
Fig. 21, the main support member 234 of the support bracket 212 is
positioned adjacent the rear and right side of the C-shaped bracket 232.
By releasing the locking mechanism 236, the C-shaped portion 232 of
the support bracket 212 and the tray 210 can be pivoted about the main
support member 234 into the maintenance position as shown in Fig. 24.
With the C-shaped portion 232 of the support bracket 212 and the tray
210 in the maintenance position, the top of the trimming station TS can
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be easily accessed for maintenance. Finally, when such maintenance is
complete, the C-shaped portion 232 of the support bracket 212 and the
tray 210 can be quickly pivoted back into the operational position and
the printing and binding apparatus returned to production.
As noted, the binding and trimming apparatus 1, as shown in
Figs. 1- 9, is controlled by a programmable controller CONT 1. CONT
1 is preferably a programmable controller, such as an AT6400 controller,
as described in the aforementioned U. S. Patent 6,193,458 and as
illustrated in Fig. 12 thereof. The controller CONT 1 for the printing,
binding and trimming apparatus, as shown in Figs. 14 - 25, in turn
controls operation of the black and white printer 110 via a controller
CONT 2 and of operation of black and white printer 200 via a controller
CONT 3. Operation of color printer 114 is controlled by a fourth
controller CONT 4. For example, controllers CONT 2 - 4 may be model
RPC-150 programmable controllers commercially available from Remote
,Processing Corporation, 7975 E. Harvard Avenue, Denver, Colorado
80231.
As previously noted, the apparatus of this invention is intended for
printing, binding and trimming perfect bound books on demand. That is,
such on demand printed books are stored in a digital library in a variety
of digital formats. For example, the test pages of the books may be
scanned and stored in a bit mapped format, or they stored in a PDF or
other widely used format. The covers for the books are also stored in
the digital library. Such covers may also be stored in a variety of
formats. The digital library is typically stored on a so-called book server
computer (not shown) and may be controlled by a book director
computer program, the essential details of which are disclosed below.
As described in the above-noted U. S. Patent 5,465,213, the book server
may be located proximate the apparatus of this invention or may be
located remotely and connected over a wide area network, such as the
Internet. Persons may access the system to order a book to be printed
on demand in a variety of ways. One preferred way would be to allow
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an Internet connection such that a customer could access the book
server remotely, view the books in the digital library, and upon choosing
a book, ordering the book and commanding the apparatus of the present
invention to print, bind and trim the selected book.
The control logic for operating a printing, binder, trimmer
apparatus, as shown in Fig. 21, will be understood by one of ordinary
skill in the art from the following listing of the basic programming steps:
1. CONT 1 determines the number of book block printers 110
or 200 running on the machine.
2. CONT I signals (by placing a control file) the book director
program on a book server, which black and white book
block printer 110 or 200 is ready for a book block file (i.e.,
the text pages) and if two printers are present, toggles a
logical variable to signal the book director program to the
second printer for the next book. (And then back to the first
printer for the following book and so on.)
3. The book director program sends a pre-defined book
"package" consisting of a book block printing script or text
with the printer designated by 2 to the print spooler of the
selected printer 110 or 200, a cover printing script with the
cover printer 114 designated to the print spooler and a
control file containing the book finish parameters (e.g.,
number of pages, paper thickness, any vertical offset
between the cover and the book block, and finish trim
dimensions).
4. CONT 1, having determined which black and white book
block printer is to receive the next book block, positions the
carriage 7 proximate to and monitors port #23 of that
printer 110, 200 via a tcp/ip connection for a job complete
message at that port.
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5. Upon receiving the job complete message at the monitored
port, controller CONT 1 moves the carriage 7 fully into
position at a respective printer 110, 200 to receive the
book block BB. As the carriage moves into position, a
switch is closed causing the book block tray controller
associated with that printer to clamp rotate and then
release the book block into the carriage. Upon releasing
the book block, the book block tray controller notifies
CONT 1 that the block is in place.
6. As the cover exits cover printer 114, a signal is generated
to. signal the cover controller CONT 4 that the cover is
within cover transport mechanism 116 and the cover
controller is then able to deliver the printed cover to the
binding station BS.
7. CONT 1 then monitors the cover printer transfer controller
CONT 4 for a signal that it has placed the cover into place
in the binder station BS.
8. Upon notification that a book block BB is in place within
carriage 7 and that the cover is in place at the binding
station BS, CONT 1 then moves carriage 7 to the jogging
station JS and reads the control file sent in 3.
9. Using the dimensions T1 - T5 incorporated in the control
file, as above described, the trim margins TMI - TM3 are
determined.
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10. The desired position of the cover C at the binding station
BS are then determined such that that cover is centered
with respect to book block spine S. The cover may be
centered with respect to the spine S of the book block BB
by energizing stepper motor M1100 to drive rolls 186 if
forward or rearward direction so as to accurately located
the portion of cover C which is to be bound to spine S of its
respective book block. It will also be understood that the
cover may be located with respect to the spine of its book
block by, upon printing of the cover, centering the material
printed on the cover with respect to the cover stock. In this
manner, the cover may be accurately positioned by
bringing the leading edge of the cover C into engagement
with a fixed stop.
11. With carriage 7 positioned at jogging station JS, the
jogging station is energized and deenergized for a time
sufficient to jog or vibrate pages P (about 1- 3 seconds) so
as to align the pages of the book block.
12. During the jogging operation, the trailing edge of book
block BB is insured to be in contact with vertical carriage
wall 21 thus accurately establishing the fore to aft position
of the book block in carriage 7.
13. With the book block BB properly positioned within the
carriage, carriage clamp motor M2 is energized so as to
close carriage clamps 11 a, 11 b.
14. Wait 5 seconds, and then energize motors M3 - M5.
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15. Energize Carriage Stepper Motor Ml to drive carriage 7
from Jogging Station JS to Mill Station MS. As the
carriage approaches Mill Station MS, the mill head 31 is
energized so as to roughen the spine of the book block as
the latter is conveyed past the mill station.
16. As the book block BB is conveyed over adhesive
application station AS, the spine of the book block has a
suitable amount of hot melt adhesive applied thereto.
17. Deenergize Carriage Stepper motor Ml so as to stop
carriage 7 at
binding station BS with book block BB positioned over
center CP of cover C.
18. Energize pump PM4 to raise binding clamp 35.
19. Energize clamp motor M6 to clamp cover on book block.
This clamp is maintained for a time sufficient for the setting
of adhesive A to bind the spine of the book block BB to the
inner surface of the conditioned cover C.
20. Energize clamp motor M6 to release book.
21. Reverse operation of pump PM4 to lower binding clamp
35.
22. Energize carriage stepper motor Ml to convey carriage
from binding station BS to trim station TS.
23. Energize nest elevator motor M6 to raise nest elevator.
24. Energize carriage clamp motor M2 to drop book.
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25. Energize carriage stepper motor Ml to nudge book to
predetermined position within nest 41 such that first edge
of book is accurately position with respect to nest 41.
26. Energize pump PM3 to actuate nest clamp 57.
27. Energize nest elevator stepper motor to lower nest to
predetermined elevation.
28. Energize trim carriage 61 stepper motor M9 to move
trimmer 59 toward first edge of book to be trimmed (T3).
29. Deenergize motor M9 to stop trimmer 59 so as to trim first
trim margin TM1 from book.
30. Energize Pump PM2 to close shear clamp 67.
31. Energize Pump PM1 to close trimmer blade 64.
32. Reverse operation of Pump PM1 to open trimmer blade 64.
33. Reverse operation of Pump PM 2 to open shear clamp 67.
34. Energize trimmer carriage stepper motor M9 to move
trimmer carriage clear of book.
35. Energize book indexing stepper motor M9 to rotate book in
nest 90 so as to position a second edge of book to be
trimmed.
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36. Energize trim carriage 61 stepper motor M9 to move
trimmer 59 toward second edge of book to be trimmed.
37. Deenergize motor M9 to stop trimmer 59 so as to trim
second trim margin TMI from book.
38. Energize Pump PM2 to close shear clamp 67.
39. Energize Pump PM1 to close trimmer blade and to trim
second edge.
40. Reverse operation of Pump PM1 to open trimmer blade 63.
41. Reverse operation of Pump PM 2 to open shear clamp 67.
42. Energize trimmer carriage stepper motor M9 to move
trimmer carriage clear of book.
43. Energize book indexing stepper motor M9 to rotate book in
nest 41 90 so as to orient third edge of book to be
trimmed toward trimmer.
44. Energize trim carriage 61 stepper motor M9 to move
trimmer 59 toward third edge of book to be trimmed.
45. Deenergize motor M9 to stop trimmer 59 so as to trim third
trim margin TM1 from book so as to trim book to final
height (T5).
46. Energize Pump PM2 to close shear clamp 67.
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47. Energize Pump PM1 to close trimmer blade and to trim
third edge.
48. Reverse operation of Pump PM1 to open trimmer blade.
49. Reverse operation of Pump PM 2 to open shear clamp 67.
50. Energize trimmer carriage stepper motor M9 to move
trimmer carriage clear of book
51. Energize Pump PM to open book clamp 57 and to release
book.
52. Upon CONT 1 determining that the book block for the first
book to be printed has been loaded into the carriage,
CONT I may signal the book director program that printer
110 is ready to receive another book "package" such that
the text pages of a third book may be sent to the print
spool of printer 110. In this manner, printer 110 can begin
printing the third book while printer 200 is still printing the
text pages of the second book.
53. Likewise, upon CONT 1 determining that the book block for
the second book to be printed has been loaded in the
carriage, CONT 1 may signal the book director program
that printer 200 is ready to receive another book "package"
such that the text pages of a fourth book may be sent to
the print spool of printer 200. In this manner, printer 200
may be printing the text pages of the fourth book while
printer 110 is still printing the text pages of the third book.
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The above steps complete the printing of the book block BB and
of the cover C, the laminating of the cover C, the binding of the book
block to the double laminated cover C, and the trimming of a first book.
It will be understood that while the first book is being so printed,
laminated, bound and trimmed, a second book may be substantially
simultaneously be printed by the second text printer 200. Depending on
the number of pages in the books being printed, the printing of the text
pages of the book block typically determines the length of time
necessary to print and bind a book with the apparatus of this invention.
Thus, by providing two text page printers, the throughput of the
apparatus can be significantly increased.
While the disclosure herein describes the use of sheet fed text
page printers 110 and 200, it will be understood that in certain
applications web fed printers may be used. In such case, after the text
pages are printed on a web of paper, the text pages are cut from the
web and are accumulated so as to form the book blocks BB, as above
described, and then the books are bound and trimmed in the manner
described.
While the present invention has been described by reference to
specific embodiments, it should be understood that modifications and
variations of the invention may be constructed without departing from the
scope of the invention defined in the following claims.
