Abstract:
The present disclosure relates to a trimmer block pad, a trimmer, and a process of trimming. The process includes inserting a book into a trimmer, positioning a trimmer block pad to abut the book, the trimmer block comprising a first non-square exterior corner and a second non-square exterior corner, and trimming a portion of the book. The positioning of the trimmer block pad applies a distributed force to the book.

Description:
FIELD OF THE INVENTION 
     The present invention is directed to book making systems and methods. More specifically, the present invention is directed to book making systems and methods including a block pad. 
     BACKGROUND OF THE INVENTION 
     Trimming of books is often automated and done at high speeds with high precision. Three-knife trimmers trim pages within a book to predetermined specifications. Known systems involve several layers of pads used for applying a force to the pages of the book during the trimming process. These layers are generally made of metal, wood, or cardboard. 
     When the knives cut through the pages of the book to trim them, these layers provide a template or profile for the cutting. Known systems suffer from the drawback that the layers of cardboard compress due to chemicals (for example, solvents and/or silicone spray) and other materials applied in liquid form to aid in the cutting process. The compression can be inconsistent (for example, based upon inconsistent exposure to chemicals), resulting in a non-uniform force being applied to the book or portions of the book while being positioned for trimming. This non-uniform force can result in chip-outs occurring on the book. In the past, splitter knives have been used to score the spine of books to reduce the number of chip-outs. 
     Likewise, chip-outs can result from unevenly and/or focused force being applied to the spine. To avoid this, known systems may be adjusted to apply a reduced force to the spine of the book while it is positioned for trimming. This reduced force may not have enough force to depress the spine, may undesirably adjust the angle of the profile, and/or may reduce the precision of the trimming. 
     What is needed is a trimmer block pad, trimmer, and method of trimming capable of reliably and consistently trimming books without forming chip-outs and capable of repeated use in the presence of chemicals. 
     SUMMARY OF THE INVENTION 
     One aspect of the present invention includes an apparatus including a trimmer block pad for forming a book. The trimmer block pad includes a first substantially square exterior corner connected by a first elongate exterior portion to a second substantially square exterior corner, a first non-square exterior corner connected by a second elongate exterior portion to the first substantially square exterior corner, and a second non-square exterior corner connected by a third elongate exterior portion to the second substantially square exterior corner. The first non-square exterior corner and the second non-square exterior corner are configured to apply a distributed force to the book. The first, second, and third elongate exterior portions are sized to define a trimmed portion of the book. 
     Another aspect of the present invention includes a trimmer block pad for forming a book. The trimmer block pad includes a first exterior corner connected by a first elongate portion to a second exterior corner, a third exterior corner connected by a second elongate portion to the first exterior corner, and a fourth exterior corner connected by a third elongate portion to the second exterior corner. The first, second, and third elongate portions are sized to define a trimmed portion of the book. The third exterior corner and the fourth exterior corner are configured to provide a distributed force to the book. The trimmer block pad comprises a thermoplastic material. 
     Another aspect of the present disclosure includes a process of forming a book. The process includes inserting the book into a trimmer, positioning a trimmer block pad to abut the book (the trimmer block comprising a first non-square exterior corner and a second non-square exterior corner), and trimming a portion of the book. The positioning of the trimmer block pad applies a distributed force to the book. 
     An advantage of the present disclosure includes reusability of block pads during a book trimming process. 
     Another advantage of the present disclosure includes chemical resistance of block pads used during a book trimming process. 
     Another advantage of the present disclosure includes the ability to apply a distributed force from a block pad to a book during a book trimming process. 
     Another advantage of the present disclosure includes the reduction or elimination of chip-outs during a book trimming process. 
     Another advantage of the present disclosure includes the reduction or elimination of using splitter knives during a book trimming process. 
     Another advantage of the present disclosure includes utilizing recyclable, recycled, or otherwise environmentally friendly materials. 
     Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows a side view of a pressing block arrangement for a trimmer system including a trimmer block pad according to an exemplary embodiment of the disclosure. 
         FIG. 2  shows an exploded perspective view of a pressing block for a trimmer system including a trimmer block pad according to an exemplary embodiment of the disclosure. 
         FIG. 3  shows a top view of a trimmer block pad for pressing a block of a trimmer system according to an exemplary embodiment of the disclosure. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Provided is a trimmer block pad, a trimmer, and a method of trimming for book making systems and methods. 
     Embodiments of the present disclosure can include reusability of block pads during a book trimming process, include chemical resistance of block pads used during a book trimming process, include the ability to apply a distributed or substantially uniform force from a block pad to a book during a book trimming process, include the ability to apply a force to a book from a block pad during a book trimming process, include the reduction or elimination of chip-outs during a book trimming process, and/or include the reduction or elimination of using splitter knives during a book trimming process. 
       FIG. 1  shows a portion of an exemplary trimmer system  100  including a pressing block arrangement  102  having a block pad  104  in accordance with exemplary embodiments disclosed herein. The system can otherwise be any suitable trimming system, and more specifically can be any three-knife trimming system as is known in the art. In one embodiment, the system  100  is used for a perfect-binding process as is understood by those skilled in the art. In another embodiment, the system  100  is used for a saddle-stitching process as is understood by those skilled in the art. 
     Referring to  FIGS. 1 and 2 , the pressing block arrangement  102  includes the block pad  104 , a first plate  106  secured to the block pad  104 , a second plate  108  secured to the first plate  106 , and a pad holder  110  secured to the second plate  108 . The pad holder  110  can be any suitable pad holder. The pad holder  110  is configured for being positioned/urged toward a book  101  to apply pressure to the book  101  from the block pad  104 . As used herein, the term “book” includes any bound volume. For example, a book can be a soft-cover book, a hard-cover book, a magazine, a journal, etc. The side view of  FIG. 1  shows a view of the pressing block arrangement  102  with a spine  401  of the book  101  toward the front. The exploded perspective view of  FIG. 2  shows the pressing block arrangement  102  rotated  180  degrees so that the spine  401  of the book  101  would be positioned toward the rear. 
     The pad holder  110  can be configured for specific sizes and/or machines. The second plate  108  can be a metal plate (for example, steel) and/or can be configured for specific sizes and/or machines. 
     The first plate  106  can be secured with the second plate  108  by any suitable fastening or adhering mechanism. The first plate  106  can be a wood plate and/or can be configured for specific sizes and/or machines. In one embodiment, the first plate  106  is secured with the second plate  108  by mechanical fastening through countersinking to bore out holes (not shown) and pounding drive-in nuts  202  into the holes. In one embodiment, the first plate  106  includes a first elongate portion  204 , a second elongate portion  206 , and a third elongate portion  208 . A first plate profile (not shown) formed by the first elongate portion  204 , the second elongate portion  206 , and the third elongate portion  208  substantially equals a profile (not shown) formed of the book  101  produced by the system  100 , the profile of the book  101  being defined by edges of pages cut by the system  100 . 
     The block pad  104  can be secured to the first plate  106  by any suitable fastening or adhering mechanism. In one embodiment, the block pad  104  is secured to the first plate  106  by an adhesive (for example, a tape adhesive or glue). The block pad  104  can be of any suitable material. In one embodiment, the material for the block pad  104  is selected to provide resistance to moisture (the moisture can include silicone spray, water, lubricant, solvent, combinations thereof, etc.). In another embodiment, the material for the block pad  104  is selected to provide solvent resistance and easy cleaning. The material of the block pad  104  can be solid and/or can include or be a thermoplastic such as high density polyethylene, acrylonitrile butadiene styrene, acrylic, celluloid, cellulose acetate, cycloolefin copolymer, ethylene-vinyl acetate, ethylene vinyl alcohol, fluoroplastics, ionomers, liquid crystal polymer, polyacetal, polyacrylates, polyacrylonitrile, polyamide, polyamide-imide, polyaryletherketone, polybutadiene, polybutylene, polybutylene terephthalate, polycaprolactone, polychlorotrifluoroethylene, polyethylene terephthalate, polycyclohexylene dimethylene terephthalate, polycarbonate, polyhydroxyalkanoates, polyketone, polyester, low density polyethylene, polyetheretherketone, polyetherketoneketone, polyetherimide, polyethersulfone, polyethylenechlorinates, polyimide, polylactic acid, polymethylpentene, polyphenylene oxide, polyphenylene sulfide, polyphthalamide, polypropylene, polystyrene, polysulfone, polytrimethylene terephthalate, polyurethane, polyvinyl acetate, polyvinyl chloride, polyvinylidene chloride, styrene-acrylonitrile, or combinations thereof. The material of the block pad  104  can be substantially devoid of cardboard, other bio-degradable materials, cellulosic materials, thermoset materials, and/or layered materials. For example, the material of the block pad  104  can be substantially devoid of polyester fiberglass, vulcanized rubber, phenol-formaldehyde resin, urea-formaldehyde, melamine resin, epoxy resin, polyimides, cyanate esters, polycyanurates, or combinations thereof. 
     In one embodiment, the block pad  104  can be sized larger than the profile of the book  101 . In this embodiment, the block pad  104  is cut to size by one or more knives  103  (see  FIG. 1 ) in the system  100  after being secured as part of the pressing block arrangement  200 . 
     The block pad  104  includes a profile  400  (see  FIG. 3 ). The profile  400  is a top view of the block pad  104  showing a top surface  301  (see  FIG. 2 ) of the block pad  104 . A bottom surface (not shown) contacts the book  101  when the block pad  104  is positioned by the pressing block arrangement  200 . The profile  400  includes a first substantially square exterior corner  302  connected by a first elongate portion  304  to a second substantially square exterior corner  306 , a first non-square exterior corner  308  connected by a second elongate portion  310  to the first substantially square exterior corner  302 , and a second non-square exterior corner  312  connected by a third elongate portion  314  to the second substantially square exterior corner  306 . The first elongate portion  304 , the second elongate portion  310 , and the third elongate portion  314  can define a fore edge of the book  101 . The fore edge can be at least a predetermined length and be at least a predetermined distance from the spine  401  of the book  101 . 
     The block pad  104  includes a predetermined thickness T between the top surface  301  and the bottom surface. The predetermined thickness T can be any suitable thickness. For example, the predetermined thickness T can be based upon specific machine specifications. In one embodiment, the predetermined thickness T is about ¼ inch, ½ inch, or ¾ inch. In another embodiment, the predetermined thickness T can be modified by shaving, sanding, cutting, or otherwise removing a portion of the block pad  104 . The predetermined thickness T can be substantially equal throughout the block pad  104  or can be substantially equal along the first substantially square exterior corner  302 , the first elongate portion  304 , the second substantially square exterior corner  306 , the first non-square exterior corner  308 , the second elongate portion  310 , the second non-square exterior corner  312 , and/or the third elongate portion  314 . In this embodiment, the substantially equal predetermined thickness T forms a substantially square edge along the first substantially square exterior corner  302 , the first elongate portion  304 , the second substantially square exterior corner  306 , the first non-square exterior corner  308 , the second elongate portion  310 , the second non-square exterior corner  312 , and/or the third elongate portion  314 . It is desirable that the profile  400  is arranged to apply a distributed and/or substantially uniform amount of force against the book  101  when the pressing block arrangement  102  is positioned/urged to secure the book  101  for trimming. 
     Referring to  FIG. 2 , in one embodiment, one or more portions of the block pad can include a curved or radius edge  316  (for example, a beveled edge). The curved or radius edge  316  can be in an interior region  318  (for example, an opening) of the block pad  104 . The curved or radius edge  316  in the interior region  318  can be positioned on the bottom surface (not shown) and oriented downward to abut the book  101 . 
       FIG. 3  shows the profile  400  of the block pad  104 , which can form the profile for the book  101  to be formed by a three-knife trimmer (i.e., the top, bottom and fore edge of the pages of the finished book). As shown in  FIG. 3 , prior to being cut, the book  101  (shown pre-trimmed in  FIG. 3 ) can be larger than the profile  400 . Likewise, the block pad  104  can extend beyond all or a portion of the spine  401  of the book  101 . The first elongate portion  304  can be sized to correspond to a portion of the book  101  to be trimmed (for example, a desired length of a fore edge of the book  101 ). For example, in a book having pages that are about 8½ inches by about 11 inches, the first elongate portion  304  can be about 11 inches. The second elongate portion  310  and the third elongate portion  314  can be substantially equal in length but longer than the portion of the book  101  to be trimmed (for example, pages of the book). For example, in the book having pages that are about 8½ inches by about 11 inches, the second elongate portion  310  can be about 8¾ inches and the third elongate portion  314  can be about 8¾ inches. Additionally or alternatively, the first non-square exterior corner  308  and/or the second non-square exterior corner  312  can extend beyond the portion of the book  101  to be trimmed. 
     The second elongate portion  310  and the third elongate portion  314  can be exactly parallel or substantially parallel. As such, the first elongate portion  304  can be exactly perpendicular or substantially perpendicular to the second elongate portion  310  and/or the third elongate portion  314 . The interior region  318  can include a first interior corner  402  connected by a first interior elongate portion  404  to a second interior corner  406 . The first interior elongate portion  404  can be smaller than and parallel to the first elongate portion  304 . The first interior elongate portion  404  can include the radius edge  316  (see  FIG. 2 ). A second interior elongate portion  408  can extend from the first interior corner  402  and a third interior elongate portion  410  can extend from the second interior corner  406 . The second interior elongate portion  408  and/or the third interior elongate portion  410  can be smaller than and parallel to the second elongate portion  310  and/or the third elongate portion  314 . The second interior elongate portion  408  and/or the third interior elongate portion  410  can include the radius edge  316 . 
     The non-square exterior corners  308 ,  312  cannot be 90 degree angles. In one embodiment, the non-square exterior corners  308 ,  312  are each less than 90 degrees (for example, about a 75 degree angle) (see angle α of  FIG. 3 ). The non-square exterior corners  308 ,  312  can prevent the spine  401  from crushing during the trimming process. For example, if the non-square exterior corners  308 ,  312  are less than 90 degree angles, then the non-square exterior corners  308 ,  312  extend beyond the spine  401  during the trimming process thereby distributing force over a greater portion of the spine  401 . In this embodiment, the outermost portions of the block pad  104  extend inward toward the interior region  318  along a first non-parallel elongate portion  412  and a second non-parallel elongate portion  416 , respectively. 
     The first non-parallel elongate portion  412  extends from the first non-square exterior corner  308  toward the interior region  318  and a first interior region corner  414 . The first non-parallel elongate portion  412  is not parallel to the first elongate portion  304  and/or is not perpendicular to the second elongate portion  310 . Likewise, the second non-parallel elongate portion  416  extends from the second non-square exterior corner  312  toward the interior region  318  and a second interior region corner  418 . The second non-parallel elongate portion  416  is not parallel to the first elongate portion  304  and/or is not perpendicular to the third elongate portion  314 . 
     Applying force to the book  101  during the trimming process by using the block pad  104  has resulted in substantial improvements in trimming operation. For example, use of the block pad  104  in trimming processes has permitted the trimming process to be executed without the use of splitter knives frequently and traditionally used for scoring the back of a book to reduce chip-out problems. 
     While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.