Patent Application
20140375044
This application claims priority to Italian Application No. TO2013A000516 filed Jun. 24, 2013, and entitled “Process and system for the production of books with digital printing from a continuous paper strip, and respective book”, the content of which is incorporated herein by reference in its entirety.
The present invention relates to improvements to a process for the production of books from a continuous paper strip with digital printing, a system for its implementation and book formed in accordance with that process.
More specifically, the invention relates to a process for the production of books from a continuous paper strip with digital printing, a system for its implementation and a book formed in accordance with the process of the invention. The paper strip defines book sections in sequence, each book section is associated to a book and includes a number of signature groups, and each signature group is formed with a given number of basic sheets of the book.
Typically, a book comprises a plurality of sheets with printed pages, stacked on one another and which constitute a block book, and a cover bounded with the block book. In manufacturing systems for books “on demand”, the printing is performed on both sides of a continuous paper strip and defines book sections in sequence. Each book section is associated to a book and is different from the preceding and the following section in the case of books with different titles. The paper strip is of origin for basic sheets of the block book, which are separated by transversal cuts and, possibly, by longitudinal cuts and are processed individually in operations of stacking and preparation of the block books, subsequently trimmed. The above mentioned manufacturing systems allow to process customer orders quickly and efficiently, with fidelity to the original editing of the books but, ceteris paribus, the operating speed of the system is negatively affected by the number of transversal cuts on the continuous strip.
According to an editorial technique by signatures and specific editing, the basic sheets of a book are derived from “signatures” obtained, by folding, from respective signature sheets. By way of example, a signature in 8° corresponds to a transversal fold in a half of a signature sheet, followed by a longitudinal fold. A signature in 12° corresponds to a transversal fold in a half of a signature sheet, followed by two zig-zag longitudinal folds. Signatures in 16° and in 24° can be obtained with a second fold. In the lines of the folds, the sheets of the books are then separated in a trimming step. This technique by “signatures” allows to obtain book blocks with ease and a number of loose sheets reduced with respect to the number of sheets required to form the same basic block with basic sheets cut individually.
The technique by signatures can be applied to produce books, specifically, but not exclusively “books on demand” with printing on a continuous paper strip. The paper strip maintains the configuration of book sections arranged in sequence: each book section is constituted by signature sheets, each formed with a predetermined number of basic sheets, while the number of signature sheets depends on the number of pages in the book. The transversal cuts required for the basic sheets are reduced, resulting in a greater speed of the system.
In particular, the continuous paper strip is processed by a book manufacturing system, which includes a transversal cutting equipment for cutting the strip and separating the basic sheets, in groups, as signature sheets and a transversal folding equipment for transversally folding the separated signature sheets. A longitudinal folding equipment folds longitudinally the previously folded signature sheets, forming respective signatures and a stacking and gluing device stacks then the signatures, forming a basic book block for subsequent treatments.
For manufacturing books “on demand” by signatures of the above defined type, and fidelity to the original editing of the printed pages, the last signature of the book block, and the finished book can be constituted by a large number of blank pages. This, in addition to constitute a waste of paper, is not considered favorably by the editorial market.
On the other hand, the formation of signature sheets with a smaller number of basic sheets, for example by forming the signatures only with a row of flanked basic sheets, would increase the number of transversal cuts, giving rise to a consequent reduction of the operating speed of the system.
An object of the present invention is to provide a process and a system for the manufacturing of books, in particular but not exclusively “books on demand”, with printing on a continuous paper strip and signatures which, without cost increase or reduction of productivity and maintaining the original editing of the pages, reduce or cancel the number of paper devoid of print in the last signature of the book.
In accordance with this object, the process for the production of books with digital printing of the above defined type comprises steps: a) identifying in said book section sheet sections formed by side by side basic sheets, separable from the strip through a single cut, and a reduced signature group including a number of sheet sections having at least a page with text and/or figures, for a book in which the part regarding a last signature group has at least a sheet section devoid of text and/or figures; b) actuating the transversal cutting equipment for cutting the strip so as to separate, with respect to the last signature group, as reduced signature sheet, the sheet section or the sheet sections having at least a page with text and/or figures; c) processing the reduced signature sheet by actuating the transversal folding equipment limited to the sheet sections having at least a page with text and/or figures or skipping the actuation of the transversal folding equipment for a single sheet section; d) actuating the longitudinal folding equipment, for longitudinal folding the reduced signature sheet, as signature with reduced number of sheets; and e) stacking the signature with reduced number of sheets on the other signatures for completing the basic book block.
According to another object, the production system of the invention comprises a control program of a system for the manufacturing of books comprising a perforating equipment, a transversal cutting equipment, a transversal folding equipment and a longitudinal folding equipment, such as: a) identifying in the book section sheet sections formed by side by side basic sheets, separable from the strip through a single cut and defining a reduced signature group for a book in which the part regarding a last signature group has at least a sheet section devoid of text and/or figures; b) actuating the perforating equipment for perforating the signature groups and, if present, the reduced signature group in the parts provided for the folds of the signatures; c) actuating the transversal cutting equipment for cutting the strip so as to separate, with respect to the last signature group, as reduced signature sheet, the sheet section or the sheet sections having at least a page with text and/or figures; d) processing the reduced signature sheet by actuating the transversal folding equipment limited to the sheet sections having at least a page with text and/or figures or skipping the actuation of the transversal folding equipment for a single sheet section; e) actuating the longitudinal folding equipment, for longitudinal folding the reduced signature sheet as signature with reduced number of sheets; and f) stacking the signature with reduced number of sheets on the other signatures for completing the basic book block.
In accordance with a further object, a book produced by a system for manufacturing books with print on both the sides of a paper strip and organized by book sections and sheet sections comprises a number (SBN-1) of signatures each one formed with a given number (SSN) of basic sheets and an end signature with a reduced number of sheets when the part of the book sections regarding the last signature has at least a sheet section without pages with text and/or figures.
The characteristics of the invention will become clear from the following description, given purely by way of non-limiting example, with reference to the appended drawings in which:
In summary, the book manufacturing system 21 comprises an unwinding and printing station 24 and other kinematic components including a perforating and cutting station 25, a dynamic signature forming station 26 and a collecting and pre-assembling station 27. The system 21 operates on the basis of information on the books to be printed, supplied from a database, and a program 28 comprising parts of coordination and control for the stations 24, 25, 26 and 27.
The continuous paper strip 23 is wrapped in coil and defines a longitudinal axis corresponding, as not limiting example, to the longitudinal axes of the signature sheets, after their separation. The unwinding and printing station 24 includes an unwinder 29 for unwinding the strip 23 and a printing equipment 31. The unwinder 29 and the printing equipment 31 are aligned with the longitudinal axis of the strip 23 and operate with a substantially continuous feed of the strip along a direction of advancement “X”. The printing equipment 31 is of a high-speed type and provides for digitally printing text and figures of the books to be manufactured on the two sides of the strip 23.
In extreme synthesis, the program 28 controls the printing equipment 31 so as to define book sections 32, which are arranged in sequence along the longitudinal axis of the strip and contain the data of the text and figures of the books to be manufactured. Each book section 32 is associated to a specific book 22 and includes a number SBN of signature groups 33 in which each signature group is formed by a given number SSN of basic sheets 34 with printed text and/or figures on the two sides of the paper strip 23. Each book section 32 also identifies sheet sections 35 formed by flanked basic sheets, which can be separated with a single cut from the continuous strip 23.
Each book section 32 defines a start area indicated with “St”. The program 28 provides to the printing on the area “St” of optically readable codes, which include, inter alia, information regarding the start of the book section and the number of the respective sheets. Moreover, in association with the sheets, the program causes the printing of synchronization bars and codes with information regarding the sequential number of the sheets, and the positions of the perforations, the cuts and the folds for the execution of the signatures. The codes are readable by suitable code readers of the various equipments of the system for providing information for the executions of the respective operative functions.
The book manufacturing system 21 can operate, however, without departing from the scope of the invention, with treatment programs of information having a centralized organization of the data or with codes different from what was previously summarized.
Downstream from the printing equipment 31, the system 21 includes a deflecting device 36, a buffering device 37 and a loop device 38. The deflecting device 36 deflects of 90°, along a direction “Y”, the paper strip 23 emerging from the printing equipment 31 along the axis “X”. In turn, the buffering device 37 and the loop device 38 have function of compensation, with accumulation, for different instantaneous speeds of the strip between the printing equipment 31 and the other kinematic components of the system 21.
The perforating and cutting station 25 comprises a dynamic perforating equipment 39 and a transversal cutting equipment 41. The perforating equipment 39 perforates the strip 23 in the longitudinal direction and in the transversal direction along weakening lines of the basic sheets 34 provided for the folds, for making easy the folding of the sheets in the steps of formation of the signatures. In particular, the equipment 39 performs a transversal perforation to facilitate the folding of the signature sheet perpendicular to the longitudinal axis and one or more longitudinal perforations to facilitate a fold or more folds of the signature sheet parallel to the longitudinal axis.
The perforating equipment 39 is, for example, of the type described in the Italian Patent IT 1.344.097 of Tecnau Srl, with setting of the transversal perforation pitch depending on the format of the book. The perforations are effected on the fly while the paper strip is in continuous motion. For the longitudinal perforations, the equipment 39 comprises a plurality of pairs of perforating discs. The discs are arranged transversally to the strip 23, in positions associated with the possible lines of longitudinal folds on the signature sheets, and are selectively actuatable for executing the respective perforations.
The cutting equipment 41 cuts transversely the paper strip 23, by separating the signature groups 33 sheets with more sheet sections, as signature sheets 42. The equipment 41 can provide a guillotine blade, of width suitable for the wider paper strips, and in which the strip is temporarily arrested at the moment of the cutting. A loop device 43, downstream of the perforating equipment 39, compensates for the differences in speed of the strip 23 between the perforating equipment 39 and the cutting equipment 41.
The signature forming station 26 comprises a first folding equipment, identified as a transversal folding equipment 46, an aligning and direction changing device 49 and a second folding equipment, identified as longitudinal folding equipment 47. The folding equipments 46 and 47 receive the signature sheets 42, flat or folded in overlapping, and execute controlled folds parallel to a leading edge of an entering sheet.
The aligning and direction changing device 49 aligns a leading edge of the signature sheets 42 emerging from the folding equipment 46, with abutment on a contrast surface perpendicular to the direction “Y” and deflects of 90° the direction of advance, indicated with “Z”, of the signature sheets 42. Therefore, the transversal folding equipment 46 folds transversally the signature sheets 42 with respect to the axis of the strip 23 and the direction of movement “Y”. The longitudinal folding equipment 47 folds the sheets 42 emerging from the equipment 46 transversally to the direction of movement “Z”, but longitudinally with respect to the axis of the strip 23, forming respective signatures 48.
The collecting and pre-assembling station 27 comprises a collecting and transferring device 51 with conveyor belt, where the signatures 48 are collected and transported with partial overlap (as fish scales), and a stacking and gluing device 52 for stacking the signatures and forming a basic book block 53. At the end of the stacking, the device 52 provides to apply a layer of glue on a binding edge 54 of the basic book block 53, with stabilizing function for subsequent operations. There is also provided a conveyor belt 56, from which an operator can extract the stabilized book blocks for manual treatments, or access to a book binder. In these steps, external to the present invention, the basic book block 53 is bound to the cover and trimmed on the other edges, with separation of the sheets still joined by the folds of the signatures.
The above described manufacturing system 21 has a substantially “C” shaped plain layout, but it should be clear that the book manufacturing system of the invention can assume different configurations, for example an “L” shaped layout, by modifying or eliminating the deflecting device 36.
The perforating equipment 39, the cutting equipment 41, the folding equipments 46 and 47 and the stacking and gluing device 52 operate on the continuous paper strip 23 or on sheets separated and/or folded, on control of the program 28 and on the basis of information obtained from the codes read from the strip 23 or from a database of the system 21.
In accordance with the invention, the manufacturing system 21 operates with an optimization program 58, which is integrated with the program 28 for controlling the printing equipment 31, the perforating and cutting station 25 and the signature forming station 26 so as to reduce or avoid the number of sheets devoid of texts and/or figures in the signatures of the book 22 to be manufactured. To this end, the program 58 checks in each book section 32 the existence of incompleteness if the last signature group has sheet sections 35 devoid of texts and/or figures, which would result in a final signature with one or more sheet sections 35 with blank pages. In the case of incompleteness, the program 58 controls the printing equipment 31, by setting an identification code 59 of a reduced signature group in the book section 32.
By way of example, for signatures providing a single transversal fold for each signature, the program 58 checks if the number of basic sheets 34 devoid of texts and/or figures in the last signature group is SSN/2 or less, which would result in a final signature having SSN/2 or more blank pages. The identification code is functional to the last signature having a number SSN/2 of basic sheets 34, which is a half of the given number of basic sheets SSN. On the basis of the identification code, the perforating equipment 39 skips the transversal perforation, while the cutting equipment 41 cuts the continuous strip 23 so as to separate the halved signature group as halved signature sheet.
Then, the program 58 processes the halved signature sheet by skipping the actuation of the transversal folding equipment 46. On the contrary, the program actuates the longitudinal folding equipment 47 for the longitudinal folding of the halved signature sheet, as a signature with halved number of sheets and proceeds with the stacking of the signature with halved number of sheets on the previously stacked signatures to complete the basic book block 53 and following treatments.
With reference to the
The transversal folding equipment 46 executes the transversal folds only on the signature sheets 42, while the longitudinal folding equipment 47 is provided for executing two longitudinal folds both on the signature sheets 42 with six basic sheets transversally folded, and on possible, unfolded, halved signature sheet 62.
In the
The perforating equipment 39 is provided for executing a longitudinal perforation 79 both on the signature groups 74 and the halved signature group 78. The transversal folding equipment 46 executes the transversal fold only on the signature sheets 77, while the longitudinal folding equipment 47 is provided for executing a longitudinal fold both on the signature sheets 77 with four basic sheets transversally folded and forming respective signatures 82, and on the possible, unfolded, halved signature sheet 81 with two basic sheets and forming a signature with halved number of sheets 83.
The process for the production of the books 72 is similar to that described for the book 22. After the longitudinal perforation, the separation, the crossing of the equipment 46 and the longitudinal fold, the program 58 also processes the signature with halved number of sheets 83 as the other signatures 82, proceeding with the stacking of the signature 83 on the previously stacked signatures 82, forming a basic book block 84 and applying a layer of glue on a binding edge 86 of the basic book block 84, in preparation of following treatments.
Suitably, the system for manufacturing 21 can also operate for manufacturing books with different signatures from a common continuous strip.
In the
In the perforating equipment 39, the pairs of longitudinal perforating disks are selected and actuated on control of the program 58 for defining the longitudinal perforations 64 and 66 or 79. For the signature groups 33 with six basic sheets, the program selects the two pairs of disks positioned transversally in the positions provided for the perforations 64 and 66. For signature groups with four basic sheets 74, the program 58 selects individually the pair of disks of the transversal position provided for the execution of the perforation 79.
The transversal folding equipment 46 and the longitudinal folding equipment 47 can be of a “buckle chute folder” type including input rollers and more folding pockets (elements not shown in the figures), which can be selected by suitable deflectors controlled by the program 58 for executing folds of the signature sheets in the requested positions. Moreover, the transversal folding equipment 46 can be set up for causing the halved signature sheets to transit without folds.
The system 21 (
By elaborating the information of the database, the program 58 identifies, in each book section, sheet sections formed by the basic sheets, in which each sheet section is separable from the continuous strip with a single cut. For a book in which the last signature group has at least a sheet section without pages with texts and/or figures, the program defines a reduced signature group, including a number of sheet sections having at least a page with texts and/or figures. Hence, the program causes the printing in the book section of a respective code of incompleteness for the processing of the reduced signature groups.
With reference to the
In the case of incompleteness, the program 58 defines in the book section 91, 93, as last signature group, a reduced signature group 98, 99 including a number of sheet sections 96, 97 with at least a page of text and/or figures. Thus, the reduced signature groups 98 and 99 can be formed from one to three sheet sections 96, 97 and the program makes print in the book section 91, 93 a respective code of incompleteness, of identification of these features.
For the book section 91, 93, the perforating equipment 39 selects the longitudinal perforation disks for defining the longitudinal perforations 64 and 66 or the single longitudinal perforation 79 for the weakening lines on the signature groups 92 and 94 and on the reduced signature groups 98 and 99. On the contrary, the transversal perforations are limited only to the weakening lines provided for the folds of the signatures. In turn, the cutting equipment 41 separates from the continuous strip 87 the signature groups 92 and 94 as signature sheets 101 and 102 with twelve and, respectively, eight basic sheets for books in 24° and in 16°, while the reduced signature groups 98, 99 are separated as reduced signature sheets 103 and 104 from one to three sheet sections 96, 97, from three to nine basic sheets 34 and from two to six basic sheets 76.
The transversal folding equipment 46 executes only the complete transversal folds on the signature sheets 101 and 102, while it executes one or two transversal folds on the reduced signature sheets 103 and 104 with two or three sheet sections 96, 97 or, respectively, skipping the transversal folds in the case of reduced signature sheets constituted by a single sheet section 96, 97.
After the passage through the transversal folding equipment 46 and the change of direction, the longitudinal folding equipment 47 executes two longitudinal folds or a single longitudinal fold on the signature sheets 101 or 102, forming respective signatures 107 and 108. In a similar way, the equipment 46, executes two longitudinal folds or a longitudinal fold on the reduced signature sheets 103 or 104, either folded or unfolded, if present, forming respective signatures with reduced number of basic sheets 109 and 111.
Thereafter, the program 58 proceeds as for the books having signatures with a single transversal fold, by collecting and stacking the signatures 107 and 108 and the signatures with reduced number of sheets 109 and 111 to complete basic book blocks represented with 112 and 113.
With the above mentioned structures or functionally similar structures, the manufacturing system 21 can produce, with different formats and from a same continuous strip, books “on demand” having different signatures and maintaining the limitation on the number of white pages in the last signature. It is performed without mechanical changes on the system and without any arrest between a book and another. Thus, for instance, the system 21 can fulfill orders, in sequence and without intervention of operators, for a book with signatures in 8° or in 16° and height of 8″, for a book with signatures in 8° or in 16° and height of 9″ and for a book with signatures in 12° or in 24° and height of 9″.
The process for the production of books with digital printing and technique by signatures, represented with 116 in
Extracting, from the database of the system 21, the information on the book to be manufactured, block 117, with the data on the format of the book, association of the data to be printed of the book with the book section 32, 73, 89, 91. The block 117 also provides the definition of the number SBN of signature groups 33, 74, 93, 94 of the book section so that each signature group 33, 74, 93, 94 is formed by a number SSN, of six, four, twelve or eight basic sheets 34, 76 and the definition of the sheet sections 96, 97 formed by basic sheets separable from the strip with a single cut.
Checking, in a decision box 118, the condition of incompleteness on the last signature group 33, 74, 93, 94. In case of incompleteness, the program 58 defines in a block 119, as last element of the book section 32, 73, a halved signature group 59, 78 or, respectively, a reduced signature group 98, 99 with at least a page of text and/or figures. Namely the halved signature group 59, 78 having a half of the basic sheets 34, 76 and the reduced signature group 98, 99 having ⅓ or ⅔ of sheet sections 96, 97.
In a block 121, the program activates the printing equipment 31, for printing texts and/or figures in the pages of the book section 32, 73, 89, 91, the control codes for the other components of the system and the code of incompleteness in the case of existence of the halved signature group 59, 78 or the reduced signature group 98, 99.
In a decision box 122, the program 58 checks the condition of incompleteness of the signature group to be perforated. In a negative case, the program executes the longitudinal perforations 64 and 66 or the single longitudinal perforation 79 and the transversal perforation or perforations, block 123 in dependence on the typology of signature and the format of the book 22 or 72. In presence of incompleteness, block 124, the equipment 39 executes the longitudinal perforations or the single longitudinal perforation on the halved signature group 59, 78 or the reduced signature group 98, 99 and skips the transversal perforation, not necessary, or limiting the perforations to the parts required for the folds.
In a decision box 126, the program 58 checks the condition of incompleteness of the signature sheet or the signature sheet halved or of the signature sheet reduced in transit. In negative case, block 127, the program 58 activates the cutting equipment 41 for separating from the strip 23 the signature sheet 42, 77, 101, 102 and proceeds with the activation of the transversal folding equipment for one or more folds, block 128.
If, decision box 126, the condition of incompleteness of the signature group is recognized, the program activates the cutting equipment 41, block 129, for separating from the continuous strip 23 the halved signature sheet 62, 78 or the reduced signature sheet 103, 104 and proceeds by skipping the activation of the transversal folding equipment 46 or executing a reduced number of folds, block 131.
The signature sheet or the halved signature sheet or the reduced signature sheet emerging from the transversal folding equipment 46, folded or unfolded, is aligned by the aligning and direction changing device 49, block 132, and transferred into the longitudinal folding equipment 47 for the longitudinal fold and the formation of the signatures 48, 77, 107, 108 or the signatures with halved number of sheets 63, 83, or the signatures with reduced number of sheets 109, 111, block 133.
The procedure of production continues with the collection and the stacking of the signatures in the collecting and transferring device 51 and in the stacking and gluing device 52, block 134, with formation of the basic book block 53, 84, 112, 113. Thereafter, the basic book block is shifted into the conveyer belt 56, block 136, for the following treatments of binding with the cover and trilateral cuts for separating of the edges with elimination of the folds and equalization of the edges in the book.
Naturally, the principle of the invention remaining the same, the embodiments and the details of construction can broadly be varied with respect to what has been described and illustrated, by way of non-limitative example, without by this departing from the ambit of the present invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| TO2013A000516 | Jun 2013 | IT | national |
