Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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. BOOR BINDING PROCB~8
BAC~GROUND OF THE INVENTION
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: 1. Field of the Invention
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This invention relates generally to book binding, and
more particularly to a process which bonds both coated and
;l 5 uncoated signatures using low temperature glues.
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2. Description of the Related Art
Nodern book binding processes which mass produce bound
books or catalogues are essentially fully automated, with
the exception of minor human handling requirements. Large
10 printing machines print information onto large paper webs
which are cut and folded to form signatures. Since a
finished book may require several signatures, the
~` signatures are stacked or compiled to form a book block.
`~ Typically, fork lifts or automatically guided vehicles
15 transport the signatures from the printing machine to a
signature compilation machine where operators load the
signatures into appropriate stacking stations. The
signature compilation machine sequentially stacks the
proper signatures on top of one another to form a plurality ~ ~-
20 of identical signature blocks.
Once the signature blocks have been formed the
signatures in each block must be bound together by a
~ suitable process. One popular process binds the ~ignatures
-~ with a layer of primer adhesive. Prior to the application
~ 25 of primer adhesive, however, one edge of each signature
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block is cut to form a spine or backbone surface acceptable
for the receiving the primer adhesive. This cutting
operation is performed by passing each consecutive
signature block through a saw which is aligned to cut off a
portion of the block. Typically, the surface of the cut
backbone surface is also roughened by passing each
signature block by a rotating "rougher" blade. Roughening
yields an absorptive surface which maximizes the adhesion
properties of the primer adhesive.
`~ 10 The primer adhesive is usually applied to each
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suitably prepared backbone by brushing, spraying or rolling
until the primer adhesive coats and penetrates the
roughened backbone. ~he primer adhesive is then set, i.e.,
at least the top layer of adhesive is dried, by air drying
or by subjecting the backbone to a heat source. Once the -
primer adhesive is set, a cover adhesive is applied in a `-
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similar fashion to the backbone of each signature block.
Book covers are brought into register with the cover
adhesive on the backbones, and the adhesive binds the book
; 20 covers to the respective signature blocks. The covered
signature blocks are then automatically trimmed, and the
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~; finished books are ready for packaging and shipment.
While the~above-described process seems simple~and
straight-forward, many factors influence the quality of
~ 25 books produced by similar automated processes. One
``~' particular problem concerns the incompatibility of
~; different types of adhesives and the effectiveness of
~ ~ adhesives on different types of paper.
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For instance, telephone directories and catalogs,
heretofore, have been made almost exclusively w1th uncoated
paper products. Animal glues adhere quite well to uncoated
paper stock, so animal glues are used for both the primer
and cover adhesives in the process described above. Books
bound with animal glues have excellent repulping value,
and, thus, paper mills pay a premium price for paper
shavings which contain only animal glue adhesives. Animal
l glues are usually applied at low temperatures (under
;l 10 150F), so there animal glue is generally safe to handle
and apply. However, animal glues can be undesirably
affected by humidity and temperature, and books bound with
~;~ animal glue tend to display a limited life. Moreover,
animal glues do not adhere well to coated paper ~tock, and,
~` 15 therefore, are usually not used in any process where coated
`;~ stock must be bound. If animal glue is used to bind coated
`~ paper, the life of the booX is severely limited to no more
than a few months assuming occasional use of the book.
~ One gluing process which generally follows the steps
;~; 20 of the above-described process uses an emulsion primer glue
to bond the signatures together and a hot melt cover glue
to bond the cover to the signature block. These glues
adhere very well to both coated and uncoated paper stock~,
and produce high quality, long-lasting books. However,
paper shavings which contain hot melt glue have very low ;~
repulping value, and emulsion and hot melt glues are more
expensive than animal glues. Hot melt glues are also
applied at temperatures of about 350F, and, therefore, are
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more hazardous to handle and apply than animal glues.
Furthermore, the drying of the emulsion primer layer limits
the production rate because the hot melt cover glue cannot
be effecti~ely applied until the layer of emulsion primer
glue is dry. In an effort to increase throughput using
this type of process, gas dryers are used to dry the
emulsion layer. Unfortunately, the use of gas dryers
` create fire concerns.
' Another type of gluing process, which is similar to
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the process previously described, uses only a single -~
; application of glue to bind the signatures together and to
,~ bind the covers to the signature blocks. This process is
referred to as a "one shot hot melt" process. A layer of
~`1 hot melt glue is applied to the backbone of the signature
~j 15 blocks using a glue pot, for instance. Then, before the
hot melt adhesive is allowed to dry, the book cover is
adhered to the backbone. While this process creates a
durable book using any type of paper stock, it also suffers
~` from many of the disadvantages discussed in the previous
;~~ ~20 paragraph.
Advertisers are increasingly using catalogs and
telephone directories to promote their goods and services.
Since glossy, coated paper captures the attention oP
consumers better than uncoated paper, coated inserts and
signatures are currently being included in the signature
blocks of books which previously used only uncoated paper.
Therefore, it is desirable to provide a book binding
process which effectively binds coated and uncoated paper
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together, while retaining the advantages of low temperature
glues, such as animal glues and cold emulsion glues.
However, as set forth above, animal glue does not
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adhere w~ll to coated paper stock. Cold emulsion adhesive
does adhere to coated stock to provide a sufficient bond,
and paper shavings having cold emulsion adhesive thereon
have a good repulping value. Unfortunately, animal glue
does not adhere to cold emulsion adhesive, so attempts to
; use a cold emulsion primer adhesive with an animal glue
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cover adhesive have proven futile.
The present invention is directed to overcoming one or
more of the problems as set forth above.
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8UMMARY OF TH~ INVENTION
It is the primary object of the present invention to
provide a book binding process which effectively binds both
coated and uncoated paper stock.
It is an important object of the present invention to -
;~ provide a book binding process in accordance with the
primary objective which does not use hot melt adhssives.
It is another object of the present invention to
provide a book binding process which yields paper shavings
having good rèpulping value.
It is yet another object of the present invention to
provide a book binding process which does not use a heater
to dry the adhesives.
It is still another object of the present invention to
provide a book binding process which uses only low
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temperature glues.
It is a further object of the present invention to
provide a book binding process which produces long-lasting,
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~` high quality books.
In accordance with the present invention, a method of
applying adhesives to the backbone of a book block is ~ ;
provided which allows a cold emulsion primer adhesive to be
; used with an animal glue cover adhesive. First, the
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backbone of a book block is roughened to form a backbone
- 10 surface suitable for the application of adhesivee. Next,
the backbone surface is transversely slashed, and a
coating of primer adhesive, preferably cold emulsion
adhesive, is appliQd to the backbone surface for binding
pages in the book block together. Then, substantially all
of the primer adhesive is removed from the backbone
surface, preferably by passing the surface by at least one
scraper. Once the backbone surface is clean, a cover
adhesive, preferably animal glue, is applied to the
backbone surface for binding a cover to the backbone
surface of the book block.
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BRIBF DE8CRIPTION OF T~E DRA~ING8
Other objects and advantages of the invention wiIl
become apparent upon reading the following detailed ;;
description and upon reference to the drawings in which:
` 25 Fig. 1 is a flow diagram describing the book binding
process of the present invention;
Fig. 2 is a diagrammatic illustration of the book
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binding apparatus of the present invention;
; Fig. 3 is a perspective view of a book block;
Fig. 4 is a perspective view of the primer glue pot
and scrapers of the present invention; and
Fig. 5 is a perspective view of the cover glue pot of
the present invention.
While the invention is susceptible to various
~, modifications and alternative forms, specific embodiments
~,'; thereof have been shown by way of example in the drawings
and will be described in detail herein. It should be
understood, however, that it is not intended to limit the
~;~ invention to the particular forms disclosed, but on the
contrary, the intention is to cover all modifications,
equivalents, and alternatives falling within the spirit and -~
scope of the invention as defined by the appended claims.
DESCRIPTION OF TH~ PREFERRED EM~ODIM~N~
Refer initially to Fig. l which illustrates a book
binding process using a flowchart l0, and to Fig. 2 which -
~;; diaqrammatically illustrates a book binding apparatus l00.
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The process, and apparatus which performs the process,
will be discussedlbeginning with the stacking of printed
and folded signatures. Since a finished book may require
several signatures, the signatures are stacked or compiled
`~ to form a signature block a6 set forth in step 12. A
~5 signature compilation portion 102 of the apparatus l00
sequentially stacks the proper signatures, one top of
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another, to form a plurality of identical signature blocks.
The stacking operation is performed by loading the
appropriate signatures into their respective receptacles
104a-d, and feeding the signatures one at a time onto a
; 5 conveyor 106. First, a signature in receptacle 104a is
feed onto the conveyor 106. As the conveyor 106 moves the
signature to receptacle 104b, a signature from receptacle
104b is fed onto the top of the signature deposited by
receptacle 104a, and another signature from receptacle 104a
is fed onto the conveyor 106. When the two stacked
` signatures move to receptacle 104c, a signature from
receptacle 104c is fed onto the top of the first two
signatures, a signature from receptacle 104b is fed onto
the second signature deposited by receptacle 104a, and
`~ 15 receptacle 104a feeds another ignature onto the conveyor ~ ~-
`~ 106. This sequential stacking operation continues until
the requisite number of signature have been stacked to form
a signature block. While only four receptacles ars
illustrated, clearly a fewer or greater number may be used ~;
depending on the number of signatures required to form each
signature block.
Once the signature blocks have been formed, in the
next step 14, the sig~atures in each block are aligned for
~` further processing. Since further processing requires thatthe alignment of the signatures within each block be
maintained, the aligned signature blocks are transferred to
~` a clamping conveyor 108 (Fig. 2.). Spring actuated clamps
; 110 on the conveyor 108 grip each signature at about point
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A for transport through various processing apparatus which
will form the signature block into a finished book.
As illustrated in Fig. 3 and in accordance with step
16, one edge of each signature block 40 is cut to form a
spine or backbone surface 42. This cutting operation is
performed by passing each consecutive signature block 40
through at least one saw 112 which is aligned to cut off a
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portion of the block 40. Preferably, three Comstock and
Wescott ten-toothed dustless saws are consecutively aligned
`I 10 for making a proper cut in each signature blocX. The first
~i two saws are right handed and the last saw is left handed
to insure an even cut.
Next, as set forth in step 18 of the flowchart 10, the
surface of the cut backbone surface is roughened by passing
each signature block by a rotating "rougher~ blade 114.
Roughening yields an absorptive surface acceptable for the -
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receiving a coating of primer adhesive and which maximizes
the adhesion properties of the primer adhesive. -
Preferably, two Comstock and Wescott rouqher spindles are
located directly after the third saw. The rougher spindles
have 72 teeth with a 1 to 5 tooth angle, and the spindles
rotate at about 3000 r.p.m.
When the signature blocks contain coated stock, it i8
also preferable to transversely "slash" the backbone of the
signature block before applying a primer adhesive.
Slashing produces grooves 43 which run from the first
signature to the last signature in the block 40. Since
coated stock does not absorb glue as readily as uncoated
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; stock, the transverse grooves 43 provide a path into which
glue seeps so that coated stock can be securely bound
together. Therefore, step 20 is performed by a slasher
114, which is preferably mounted on the second rougher
spindle. If the coated stock is in the middle portion of
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; the signature block, two slasher teeth are mounted near the
; center of the radius of each rougher. However, i~ the
coated stock is on one of the ends of the cignature block,
two additional slasher teeth are mounted at the outer
radius of the rougher.
To clean the backbone 42 before the application of a
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primer adhesive, one or more brushes 116 are located after
the rougher/slasher 114. The backbone cleaning step 22
removes paper dust so that the dust will not contaminate
~; 15 the primer adhesive. Preferably, the conveyor 110 moves
the signature blocks into contact with a straight brush and
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~ ~ a rotary brush. The dust removed by the brushes is
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withdrawn from the apparatus by a vacuum.
~ Next, as set forth in step 24, a primer adhesive is
; 20 applied to each suitably prepared backbone by paesing each
backbone through a glue pot 118, as shown in Fig. 4. The
primer adhesive is a polyvinyl acetate co-polymer emulsion
adhesive, such as WB-~791 which may be purchased from the
H.B. Fuller Company, 2400 Energy Park Drive, St. Paul,
Minnesota 55108. The primer adhesive is applied at
ambient temperature, and preferably has a low viscosity of
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~; about 500 centipoise. The glue pot 118 is a straight wheel
pot which preferably includes three glue-applying stainless
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steel wheels 120,122,124, as shown in detail in Figs. 4 and
5.
The three glue-applying stainless steel wheels
120,122,124 rotate clockwise as shown by the arrows on the
wheels in Fig. 4. The direction of book travel is shown by
the arrow 125, so the upper surface of each of th¢ wheels
120,122,124 is rotating in the same direction as book
travel. The lower surface of each wheel 120,122,124 is
immersed in a bath of the cold emulsion primer adhesive
which is held within a vat 126. As the wheels rotate
through the glue bath, glue becomes attached to the wheels.
Doctor blades 128,130,132 remove glue from their respective
wheels 120,122,124 so that a predetermined thickness of
glue remains on the wheels. Signature blocks which pass
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over the glue-covered wheels 120,122,124 contact a portion
of the glue on each wheel, thus transferring a portion of
the glue to the backbone of the signature blocks. Three
glue-applying wheels are used to accurately control the
`~ amount of glue being applied to the backbones of the
passing signature blocks.
Since the use of cold emulsion adhesives and animal
glue do not reduce the value of paper shavings produced
during;book binding processes, animal glue will be usèd to
attach covers to each signature block bound by the cold
emulsion adhesive. However, animal glue does not bond to
cold emulsion adhesives. Therefore, in accordance with
steps 26 and 28, substantially all of the cold emulsion
adhesive applied to the backbone is removed prior to the
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application of the animal cover glue.
A spinner wheel 134 removes a portion of the cold
emulsion adhesive as the backbone of each signature block
passes over the spinner wheel 134. The spinner wheel 134
is located in the glue pot 118 downstream from the three
glue-applying wheels 120,122,124. Unlike the glue-applying
wheels, the spinner wheel 134 is not immersed in the glue
bath. Instead the spinner wheel 134 rotates in the
opposite direction from the wheels 120,122,124, and removes
a portion of the cold emulsion adhesive from the backbone
of each signature block. A doctor blade 136 removes the
cold emulsion adhesive from the spinner wheel 134, and
directs the removed adhesive down into the glue bath.
; To effectively remove the remaining cold emulsion -`
adhesive from the backbone of each signature block at least
one scraper 119 is positioned downstream from said spinner
wheel 134. Preferably, a straight-bladed scraper 138
removes the majority of cold emulsion adhesive from the ~-
backbone of each passing signature block. The straight-
bladed scraper 138 is adjusted so that the blade of the
scraper just contacts the backbone of each passing
signature block. The contact should be sufficient for
removing the glùeibut should not damage the bacXbone.
Advantageously, straight-bladed scraper 138 is positioned
above a container ~not shown) so that the removed adhesive
drips off of the scraper and into to the container.
Downstream from the straight-bladed scraper 138, at
least one "tucker" scraper 140 removes cold emulsion
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adhesive from the sides of the signature block near the
backbone. The tucker scraper 140 includes two metal fins
140a,140b which are angled in the direction of book travel,
one on each side of the passing signature blocks. Since
there is very little adhesive on the sides of the signature
block, adhesive removed from the sides also falls into the
container.
To ensure that substantially all of the cold emulsion
adhesive is removed from the backbone of each signature
block, a V-shaped scraper 142 is positioned downstream from
the tucker scraper 140. The V-shaped scraper 142 contacts
the backbone of each passing signature block, and removes
most of any remaining glue from each backbone.
To prevent the backbones of the signature blocks from
flaring out during the scraping operations, a pair of side
rails or "wings" 144a,144b are positioned on each side of
the passing signature blocks. The side wings 144a,144b
slightly compress the signatures within each block together
as the signature blocks pass between them. Preferably, the
side wings are positioned above at least the spinner wheel
134 and the straight-bladed scraper 138, because these
mechanisms tend to promote flaring of the backbone. The
wings are not as useful above the tucker scraper 140~and
the V-shaped scraper 142, because these scrapers tend to
compress the signatures in each block together.
After the cold emulsion primer adhesive has been
removed from the backbone of each signature block, the
conveyor 108 moves the consecutive signature blocks to a
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cover glue pot 146, as set forth in step 30. The cover
glue is an animal glue, such as WB-1481 which may be
purchased from the H.B. Fuller Company, 2400 Energy Park
Drive, St. Paul, Minnesota 55108. The cover glue is
applied at about 130F to about 160F, and preferably has a
viscosity of about 20,000 centipoise to about 40,000
centipoise. The desired viscosity of the animal glue
depends on the thickness of the signature block. It has
been found that glue having a viscosity of about 20,000
centipoise works well for thin blocks of about 1/4 inches
to about 1/2 inches in thickness, while glue having a
higher viscosity of about 30,000 centipoise produces a
stronger bond for thicker signature blocks.
The glue pot 146 is a straight wheel pot which
preferably includes two glue-applying stainless steel
wheels 148,150, as shown in detail in Fig. 5. The two
glue-applying stainless steel wheels 148,150 rotate
~ clockwise as shown by the arrows on the wheels. The
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direction of book travel is shown by the arrow 152, so the
upper surface of each of the wheels 148,150 is rotating in
` the same direction as book travel. The lower surface of
each wheel 148,150 is immersed in a bath of animal glue
which is held within a vat 154. As the wheels rotate
through the glue bath, glue becomes attached to the wheels. A~
Doctor blades 156,158 remove glue from their respective
wheels 148,150 so that a predetermined thickness of glue
remains on the wheels. Signature blocks which pass over
the glue-covered wheels 148,150 contact a portion of the
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glue on each wheel, thus transferring a portion of the glue
to the backbone of the signature blocks.
A pair of wings 160,162 cooperates with the first
wheel 148 in ordPr to apply a glue bead to the edges o~
each passing backbone, and also guide each successive
signature block into the cover glue pot 146. A groove
164,166 in each respective wing 160,162 causes glue on the
rotating wheel 148 to form a raised ridge. The ridges of
glue are spaced apart from one another by about the -
thickness of the signature blocks which are being
processed. As each signature block passes over the wheel
148, the ridge of glue is applied to the edgcs of the
backbone. The ridge of glue forms a glue bead which
effectively bonds the edges of each backbone to an applied
cover.
The second glue-applying wheel 150 carries a greater
thickness of animal glue than does the first wheel 148. A
portion of the glue is applied to the entire backbone
surface of each signature block as it passes over the wheel
; 20 150 and contacts the glue.
A spinner wheel 163 removes a portion of the animal
glue from the backbone of each signature block as the
backbone of each signature block passes over the spinner
wheel 163. The spinner wheel 163 is located in the glue
pot 146 downstream from the two glue-applying wheels
148,150. Unlike the glue-applying wheels, the spinner
wheel 163 is not immersed in the glue bath. Instead the
spinner wheel 163 rotates in the opposite direction from - ;
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the wheels 148,150, and removes a portion of the animal
glue from the backbone of each signature block to ensure
that there is a predetermined thickness of glue on the
backbone of each signature block. A doctor blade 165
removes the excess animal glue from the spinner wheel 163,
and directs the removed glue down into the glue bath or
into a container.
Next, in accordance with step 32, the signature blocks
are passed over a heater 168 which partially dries the
applied cover glue. Usually, the heater is only used when
the cover glue has been applied in an environment having a
high humidity.
The final step 34 of the gluing process brings the
covers into register with the cover adhesive on the
backbones, and the adhesive binds the book covers to the
respective signature blocks. This step is carried out by a
~; cover applicator 170 which is downline from the heater 168.
The covered signature blocks are then automatically
trimmed, and the finished books are ready for packaging and
~ 20 shipment.
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