Abstract:
A binding machine for binding together punched sheets of paper includes means for temporarily retaining a wire binding element, to allow punched sheets to be hung thereon, and means for closing the retained wire binding element so that the closed points come into the vicinity of the open roots, in which the wire binding element retaining means includes a flap and finger plate having projections or fingers. The flap is mounted for pivoted movement such that the plate is pivoted away from an equilibrium position by insertion of the binding element but returns to the equilibrium position thereafter, thus retaining the wire binding element in a generally horizontal orientation between the flaps and the fingers.

Description:
FIELD OF THE INVENTION 
     The present invention relates to a machine for binding together a number of sheets of paper by means of wire binding elements. 
     BACKGROUND OF THE INVENTION 
     A wire binding element is manufactured from a length of deformable material such as wire bent into a series of hairpin shaped prongs on which punched sheets are hung, the machine then closing the generally C shaped binding element into a ring shape, thus bringing the closed ends or points of the prongs close to the open ends or roots. The sections of wire between the roots are referred to as blunts. This wire binding element will hereinafter be referred to as a wire binding element of the kind set forth. 
     There are several different machines of this type currently available, some of which also include means for punching holes in the sheets prior to binding. However, existing machine designs are generally difficult to operate and may require considerable manual dexterity, particularly in loading the binding element and in removing the bound document from the machine. Such existing machines also include manual means for closing the wire binding element as well as a manually operated adjustment mechanism to enable different sizes of binding element to be used, but such existing manual adjustment mechanisms are vague and time consuming to set up. 
     There is thus a need for a machine which is simpler to operate and provides a more definite adjustment mechanism allowing straightforward selection of the appropriate setting for the particular size of binding element being used. 
     It is therefore the aim of the present invention to provide an improved binding machine which overcomes these and other disadvantages of existing machine designs. 
     SUMMARY OF THE INVENTION 
     According to a first aspect of the present invention there is provided a binding machine for binding together a number of punched sheets of paper, the machine including: 
     means for temporarily retaining a wire binding element of the kind set forth so as to allow punched sheets to be hung thereon, 
     means for closing the retained wire binding element so that the closed points come into the vicinity of the open roots, 
     wherein the means for retaining the wire binding element includes a flap and finger plate comprising a number of projections or fingers, the flap being mounted for pivotal movement such that the plate is pivoted away from its equilibrium position by insertion of the binding element but returns to its equilibrium position thereafter, thus retaining the wire binding element in a generally horizontal orientation between the flap and the fingers. 
     The closing means may be powered by a drive mechanism, or alternatively it may be manual. 
     Preferably, the fingers are resiliently deformable. This assists in the release of the bound document as will be described hereinafter. 
     Preferably, the position of the flap is adjustable with respect to the closing means. This enables different sizes of wire binding elements to be utilised in the machine according to the number of pages to be bound. 
     Conveniently, the closing means comprises a base plate having an edge portion facing a closing surface, these two components being mounted for relative movement towards and away from each other whereby a wire binding element held therebetween is closed. 
     The closing surface preferably comprises a pivoting arm, movable between an inoperative up position and an operative down position. In the preferred embodiment the baseplate is arranged for to and fro movement relative to the pivoting arm. 
     The position of the flap relative to the base plate is preferably adjusted (for different wire sizes) by means of a cam and cam follower arrangement. Conveniently this is driven by a stepper motor. 
     The degree of to and fro movement of the base plate relative to the closing surface is conveniently adjusted simultaneously with the flap position adjustment, by means of a second cam the edge of which engages a limit switch at the end of the stroke, the length of the stroke thus being determined by the degree of rotation of the second cam. 
     According to a second aspect of the present invention there is provided a binding machine for binding together a number of punched sheets of paper, the machine including: 
     means for temporarily retaining a wire binding element of the kind set forth so as to allow punched sheets to be hung thereon, 
     means for closing the retained wire binding element so that the closed points come into the vicinity of the open roots, 
     wherein upon completion of closure of the wire binding element the bound document is automatically released from the machine. 
     Preferably, this is achieved by means of a pivoting flap co-operating with a finger plate comprising a number of resiliently deformable projections or fingers so as to temporarily retain the binding element therebetween. By manufacturing the flap from a resiliently deformable material, the retained wire itself can be pushed against the flap from the inside, thereby flexing the flap outwardly and releasing the closed binding element from the machine. 
     Preferably the pivot axis of the flap is positioned forwardly of the flap, whereby outward flexing of the flap will cause the flap lower edge to lift slightly, opening a gap between the fingers and the flap into which the closed binding element is released. Preferably, the pivot axis of the flap is on the flap centre line when releasing and in front when loading. 
     According to a third aspect of the present invention there is provided a binding machine for binding together a number of punched sheets of paper, the machine including: 
     means for temporarily retaining a wire binding element of the kind set forth so as to allow punched sheets to be hung thereon, 
     means for closing the retained wire binding element so that the closed points come into the vicinity of the open roots, 
     wherein the machine also includes means for punching holes in sheets of paper, said punching means and said means for closing the retained wire binding element both being activated by a single drive mechanism. 
     Preferably, said single drive mechanism comprises a drive cam and associated drive cam shaft, rotation of which drives the closing means and the punching means simultaneously and in opposite directions. 
     Conveniently, the punching means comprises a die with a row of holes therein and a co-operating row of headed punch pins, each adapted to be received within a corresponding hole in the die, the paper being inserted within the die. 
     Preferably, the punching means includes means for selectively disabling the punching of one or more holes, to accommodate different sizes of paper, eg A5 instead of the more usual A4. Conveniently, this is achieved by means of a solenoid operated pin disable mechanism. 
     Preferably, the machine includes a storage container, located underneath the die, into which the confetti generated by the punching operation falls. 
     Conventionally, such storage containers are in the form of a shallow tray which needs to be frequently emptied to avoid the confetti, which tends to build up in conical piles underneath each hole, from clogging the mechanism. 
     In the present invention the container is deeper and is generally A shaped, the top being truncated to form a relatively narrow opening which widens out towards the base, allowing for a much greater storage capacity and hence reducing the need for emptying. 
     According to a fourth aspect of the present invention there is provided a binding machine for binding together a number of punched sheets of paper, the machine including: 
     means for temporarily retaining a wire binding element of the kind set forth so as to allow punched sheets to be hung thereon, 
     means for closing the retained wire binding element so that the closed points come into the vicinity of the open roots, 
     wherein the machine includes an adjustment mechanism for adjusting the degree of closure to suit the size of binding element being employed, said adjustment mechanism comprising an adjustment cam. 
     Preferably, the adjustment cam is rotated by means of a stepper drive. 
     In the fifth aspect of the invention there is provided a machine incorporating all of above defined four aspects of the invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     An embodiment of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: 
     FIG. 1 is an exploded drawing of the binding machine in accordance with the present invention, 
     FIG. 2 is a drawing of the control system, 
     FIG. 3 illustrates the A5 punch pin sub-assembly, 
     FIGS. 4 and 5 illustrate the position of the A5 sub-assembly during punching operation for A4 paper, 
     FIGS. 6,  7  and  8  illustrate the disengagement of the A5 punch pin for A5 punching, 
     FIGS. 8A and 9 are both vertical section through the machine, 
     FIGS. 10 and 11 illustrate the general arrangement of the machine, 
     FIG. 11A illustrates the A5 punch pin disengagement mechanism, 
     FIG. 12 illustrates the guard in the up position, 
     FIG. 13 illustrates movement of the guard into the down position, 
     FIG. 14 illustrates the placement of the paper, 
     FIG. 15 illustrates the punching operation, 
     FIGS. 16 through 21 illustrate the adjustment mechanism, 
     FIG. 22 illustrates the wire loading mechanism, 
     FIG. 23 illustrates paper loading, 
     FIGS. 24 and 25 illustrate commencement of the closing operation, 
     FIGS. 26 and 27 illustrate release of the bound document, and 
     FIG. 28 illustrates the return of the closer to its original position, ready for re-loading. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to the drawings, a machine  50  according to the present invention comprises a binding element hanging and closure mechanism  18 , 12  at the front end and a punching mechanism  25 , 27 , 28  at the rear end, which are both powered from a central drive shaft  24  and associated cam  11  with eccentric end  24   a,  mounted intermediate the two mechanisms. 
     A guard  35  acts as both safety shield and machine enables, revealing control console  36  when pivoted downwards. As shown in FIG. 12, the guard  35  is in the up position, in which power is isolated from the drive assembly and the control console  36  is shielded under the main cover  39 , thus inhibiting operation of the machine. 
     As shown in FIG. 13, the guard  35  is moved manually into the down position, which movement in turn moves the closer arm  12  into the down position—the over centre action of the guard spring  37  and the weight of the guard  35  together act to hold the closer arm  12  in position when the operator releases the guard  35 . 
     A deep, A-shaped open-topped confetti storage container  31  is located towards the rear of the machine, underneath the punching mechanism. 
     The main binding operation and the machine components associated therewith will now be described in detail. 
     The main parts of the hanging/closure mechanism comprise a pivoting flap  18  mounted for pivotal movement about pivot axis  18   a  (see FIG.  22 ). As a wire binding element  52  of the kind set forth is offered up to the machine and pushed by the operator against the flap  18 , the latter pivots inwardly, and since the pivot axis  18   a  is a short distance in front of the flap  18 , the lower edge of the flap is lifted up. The wire element  52  is then slid down the front face of the flap  18  until the individual fingers in the finger plate  5  engage with the blunts in the binding element  52 , the blunts resting on the fingers such that contact between the binding element and the pivoting flap is broken, allowing the flap to pivot under gravity back to its original, equilibrium position. Thus, when the operator releases the binding element it is retained between finger plate  5  and pivoting flap  18 . This is shown in FIG. 23, in which position pre-punched paper sheets  60  are hung on the binding element  52 . 
     As shown in FIG. 24, with the paper hung on the binding element  52  which is itself held between flap  18  and finger plate  5 , the closer arm  12  is pivoted downwardly, by moving the guard  35  manually downwards and towards the operator (thus revealing control console  36  and allowing power-up of the machine) until the inner angle of the closer arm engages with the stop  13 . Then, as shown in FIG. 25, the base plate  1  along with all its attachments is pushed, in the direction shown by the large arrow, by activation of the main closing cam  11  , towards the inner face  12   a  of the closer arm  12 . In this position the closer arm locking pin  14  is above the angle on the closer arm  12 , thus restricting any angular movement and effectively locking the closer arm in the down position. 
     The actual closing of wire binding element  52  is illustrated in FIG.  26 . The opposed faces  12   a  of closer arm  12  and  1   a  of base plate  1 , having been roughened by sand blasting or similar procedure, such that the element  52  is gripped between the two faces. As base plate  1  continues to be driven towards closer arm face  12   a,  the element  52  is closed, the wire tips tracing the loci shown in FIG. 26 b.  During this closing movement, the wire tips retained between the flap  18  and finger plate  5  move forward and engage the inner surface of flap  18 , pushing the edge of flap  18  outwardly as shown in FIG. 26 a.  As the flap  18  is now flexing about a pivot axis on its centre line, rather than pivoting about pivot axis  18   a  located forwardly of its centre, as occurred during wire loading, the lower edge of the flap  18  rises relative to the wire until the wire is released. This automatic releasing of the binding element  52  is assisted by the deflection of the resiliently deformable fingers of finger plate  5 . 
     Completion of the closing stroke occurs when cam  10  hits limit switch  20 , whereupon the drive to the drive cam  11  is reversed, allowing the base plate to return to its original position in the direction shown by arrow A in FIG. 27, by means of base plate return springs  22 . Pages  60  bound by closed element  52  are thereby automatically released from the machine, in the direction of arrow B. 
     The closer arm  12  is then allowed to return to the up position as shown in FIG. 28, under the action of springs  38 , ready for the next binding operation. 
     The operation of the punching mechanism, located at the other end of the machine (i.e the end furthest away from the operator) will now be described in detail, with reference in particular to FIGS. 12 to  15 . 
     In this position, the control console  36  is exposed and power is connected to the main drive assembly, as has been previously described. After selecting the appropriate wire/bind setting from console  36  (the adjustment mechanism is described in detail hereinafter), paper is dropped into the punch die  28 , using the paper support  40  (see FIG.  14 ). Once the paper is in position in the die  28 , two button type switches located at each end of the console  36  are pressed simultaneously (necessitating two handed operation to avoid possibility of inserting fingers into machine during punching), thereby activating the main drive which in turn rotates cam shaft  24 . During such rotation, the eccentric end  24   a  of cam shaft  24  locates within a slot  25   a  in the punch drive plate  25 , such that when the cam shaft rotates the plate  25  moves in a linear motion which pushes the punch pins  27  through the die  28  and the paper  62  therein (see FIG.  15 ). When the cam  10  hits the limit switch  20  the drive is reversed until the plates  1  and  25  resume their original position. 
     For normal A4 punching all the pins  27  will be utilised, but for A5 punching it is necessary to inhibit the operation of one of the pins (to avoid a partial hole being punched right at the edge of the paper). For this purpose an A5 punch pin disengagement mechanism is provided, the structure and operation of which is illustrated in FIGS. 3 through 8. 
     At least one of the pins  27  is provided with a recess into which the pin is pushed by contact with the paper, but the pin is normally prevented (during A4 operation) from entering this recess by means of solenoid plunger  32 . As shown in FIG. 3, the punch pin return finger spring  42  is in tension, pulling the punch pin return finger  41  to a position which allows the solenoid plunger  32  to pass through a slot running along its length. The solenoid is de-energised and the solenoid return spring assembly  43  in tension, thereby pulling the solenoid plunger  32  through the punch pin return finger  41  into the opposing hole, making a rigid face behind the pin  27 . In this position, when the punch drive plate  25  is activated the assembly pushes the punch pin  27  through the paper, as shown in FIG.  4 . 
     However, when the A5 disable solenoid is energised, the plunger  32  is retracted into its housing  32   a,  thus removing the main support from behind the punch pin (see FIG.  6 ). In this position, activation of the punch drive plate  25  pushes the pin  27  towards the paper, and when contact is made the paper resistance pushes the punch pin return finger  41  back into its slot, against the action of the punch pin return finger spring  42  which stops the hole from being punched (see FIG.  7 ). As the punch drive plate  25  retracts, the punch pin return finger  41  pushes against the head of punch pin  27 , pushing it back into the die  28 . Upon completion of the stroke, the punch pin return finger is back in its original position in which it can accept the A5 disable solenoid plunger  32 . 
     Next, the adjustment mechanism will be described in detail, with reference to FIGS. 16 through 21. The machine is adapted to accept all binding element sizes from small ones used to bind calendars and the like, to large ones suitable for binding documents over 25 mm thick. It is important to adjust the machine to the correct wire setting in order to allow the binding element  52  to sit horizontally when loaded in the machine, and this is achieved by positioning the retaining flap  18  with respect to the base plate  1 . The retaining flap pivot  18   a  is attached to upper plate  4  and this upper plate  4  is moved relative to base plate  1  to effect the flap position adjustment. Rotation of the wire size adjustment cam  9  puts a force on the upper plate adjustment stop block  7 . Stop block  7  is attached to upper plate  4  and so rotation of cam  9  is translated into movement of upper plate  4  (and hence pivot axis  18   a ) relative to base plate  1 . 
     The cam  9  is rotated by use of a stepper motor  21  located in the base plate  1 , the stepper motor being activated from the main unit controller. This is shown schematically in FIG. 2, comprising keypad  36   a  and controller with inputs  36   b  through  36   m  and outputs  36   n  through  36   t  as follows: 
     Inputs 
       36   b —Wire size select 
       36   c —wire size fine adjust 
       36   d —A5 pin disable 
       36   e —Close/bind 
       36   f —Close/bind 
       36   g —Enter 
       36   h —Reset 
       36   i —Wire size cam datum switch 
       36   j —System datum switch 
       36   k —Binder travel switch 
       36   l —Safety switches 
       36   m —system on relay 
     Outputs 
       36   n —wire size display 
       36   o —alarm condition display/buzzer 
       36   p —A5 pin disable indicator 
       36   q —A5 pin disable relay 
       36   r —wire size cam stepper motor 
       36   s —main drive contactor (forward) 
       36   t —main drive contactor (reverse) 
     The operator enters the wire size on a keypad on console  36 , this in turn rotates the cam  9  via the stepper motor  21  until cam  9  is in the correct position for the selected wire size setting (as measured from cam datum pin  9   a )—the smaller the wire size the larger the closing stroke as measured by the distance travelled by base plate  1  towards closer arm surface  12   a.    
     The shaft of the stepper motor  21  extends downwardly from the bottom of the motor, where closing travel adjustment cam  10  is mounted for rotation with the motor shaft, thereby giving the required setting. Whatever the setting, the drive is reversed when cam  10  hits limit switch  20 , automatically releasing the bound document and returning the base plate  1  and all its attachments to the original position, as described above. FIGS. 18 and 19 illustrate the positions of cams  9  and  10  when set for the largest wire size (i.e shortest stroke), and FIGS. 20 and 21 show the positions of these items when set for the smallest wire size (longest stroke). 
     Whilst it is anticipated that the machine according to the present invention will mainly be used for punching and binding in two, separate operations the unique arrangement of the punching and binding mechanisms whereby both are activated simultaneously with a single drive mechanism means that for small wire sizes at least, simultaneous punching and binding is possible. It is believed that this capability for simultaneous punching and binding is both novel and inventive, as it allows for much faster operation in a mass production situation—the operator can thus bind the previously punched document at the same time as punching the next set of pages to be bound, speeding up the process considerably. 
     Text Associated with the Figures 
     FIG.  3 —A5 punch pin sub assembly 
     FIG.  4 —A4 punch pin engaged; stage no.  1   
     1. The punch pin return finger spring ( 42 ) is in tension and pulls the punch pin return finger ( 41 ) to a position that allows the plunger in item No.  32  to pass through the slot that runs along its length. 
     2. The A5 disenable solenoid ( 32 ) is de-energised and the A5 disenable solenoid return spring assy ( 43 ) is in tension therefore pulling the plunger through the punch pin return finger into the opposing hole thus making a rigid face behind the A5 pin. 
     FIG.  5 —A4 punch pin engaged; stage no.  2   
     1. When the punch drive plate ( 25 ) is activated the assembly pushes the punch pin ( 27 ) through the paper. 
     FIG.  6 —A5 punch pin disengaged; stage no.  1   
     1. The A5 disenable solenoid ( 32 ) is energised and the plunger is retracted into its housing thus removing the main support from behind the punch pin. 
     FIG.  7 —A5 punch pin disengaged; stage no.  2   
     1. When the punch plate ( 25 ) is activated the punch pin ( 27 ) is pushed towards the paper, when contact is made the paper resistance pushes the punch pin return finger ( 41 ) back into its slot against the pressure of the punch pin return finger spring ( 42 ) thus stopping the A5 hole being punched. 
     FIG.  8 —A5 punch pin disengaged; stage no.  3   
     1. As the punch drive plate ( 25 ) retracts the punch pin finger ( 41 ) pushes against the head of the punch pin ( 27 ) pushing it back into the die ( 28 ). 
     2. When the stroke is complete the punch pin return finger is back in its original position that can accept the A5 disenable solenoid plunger. 
     FIG.  12 —M/C off; stage no.  1   
     1. The guard is in the upper position which isolates power from the drive and shields the control console ( 36 ) under the main cover ( 39 ) inhibiting any machine operation. 
     FIG.  13 —Guard placement; stage no.  2   
     1. The guard ( 35 ) is manually moved into its closed position, this in turn moves the closer bracket ( 12 ) into position. 
     2. The over centre action of the guard spring ( 37 ) and the guard weight hold the closer bracket in position when the guard is released. 
     3. The control console ( 36 ) is now visible and power is made available to the main drive. 
     4. The “smallest wire/bind” setting is selected from the control console. 
     FIG.  14 —Paper placement; stage no.  3   
     1. Paper is dropped in the die (item  28 ) using the paper support ( 40 ) as a guide. 
     FIG.  15 —punching; stage no.  4   
     1. When two button type switches are located at either end of the control console ( 36 ) are pressed simultaneously the main drive is activated which rotates the cam shaft ( 24 ). 
     2. The eccentric end of the cam shaft locates within a slot in the punch drive plate ( 25 ), when the cam shaft rotates the plate moves in a linear motion and pushes the punch pins ( 27 ) through the die ( 28 ) and the paper. 
     3. When the cam ( 10 ) hits limit switch ( 20 ) the drive is reversed until the original position is reached. 
     FIGS.  16  &amp;  17 —system adjustment 
     The system is designed to accept all wire sizes from small wires used on calendars to large wires used for binding documents over 25 mm thick. The correct setting will allow the wire to sit horizontal when loaded. This is achieved by positioning the wire retaining flap assy ( 18 ) relative to the base plate ( 1 ). The retaining flap assembly pivot is attached to the upper plate ( 4 ) and it is this upper plate that is moved relative to the base plate. When the wire size adjustment cam ( 9 ) is rotated it puts a force on the upper plate adjustment stop block ( 7 ) which is attached to the upper plate this moves the upper plate relative to the base plate. The cam is moved by the use of a stepper motor ( 21 ) that is located in the base plate. The stepper motos is actuated from the unit controller. The operator will enter the wire size on a keypad and this will in turn revolve the cam to its correct position. The stroke of the closer will vary depending in the size of the wire. The small wire will have the longest closing stroke and the largest wire the shortest. From the extended shaft from the bottom of the stepper motor there is the closing travel adjustment cam ( 10 ) this rotates together with the upper cam to give the required setting. When the base plate and all its attachments are moving and closing the wire the process is terminated when the cam hits a limit switch ( 20 ) which reverses the closing drive thus releasing the completed bound book and returning the base plate and all its attachments to its home position. 
     FIGS.  18  &amp;  19 —system adjustment; longest wire 
     FIGS.  20  &amp;  21 —system adjustment; smallest wire Stage no.  1   
     FIG.  22 —wire hanging; stage no.  1   
     1. The wire is picked up by the operator and offered up to the hanging mechanism. 
     2. The wire is then pushed against the wire retaining flap assy ( 18 ), this in turn pivots backwards and as the pivot point is a distance in front of the flap face lifts the lower edge of the flap up. 
     3. The wire is slid down the flap face and the fingers in the finger plate ( 5 ) mate with the large loops in the wire. 
     4. When the wire larger loops almost touch the finger plate contact is lost between the wire and the flap assy this results in the flap pivoting back to its original position due to gravity. 
     5. The wire is released by the operator and is retained between the finger plate and flap assy. 
     FIG.  23 —paper loading; stage no.  2   
     1. Bundles of pre-punched paper are pushed over the tips of the wire and released so that they hang down. 
     FIG.  24 —closer positioning 
     1. The closer arm is spring loaded in the upper position. 
     2. The operator pulls the closer into the lower position until the inner angle hits the stop ( 13 ). 
     FIG.  25 —closing start 
     1. The main closing cam is activated ( 11 ) which pushes the base plate ( 1 ) and all its attachments toward the face of the closer bracket ( 12 ). 
     2. The closer locking pin is now above the angle on the closer bracket thus restricting any angular movement and locks the closer bracket in position. 
     FIG.  26 —wire release 
     1. The closing surfaces of the base plate ( 1 ) and the closer bracket ( 12 ) are sand blasted so they are rough. 
     2. When the wire is gripped by the moving base plate it is held rigid. 
     3. When pressure is applied and the wire is crimped the tips of the wire follow the path shown. 
     4. The wire tip that is being restrained by the flap ( 18 ) moves forward and deflects the flap and as the pivot point of the flap is now on the flap centre line and not in front as when it was pushed in the other direction, the lower edge of the flap will rise relative to the wire until the wire is released. 
     5. The fingers that are on the finger plate ( 5 ) will also deflect thus aiding the release of the wire. 
     FIG.  27 —stroke complete 
     1. When the closing travel cam ( 10 ) hits the closing travel limit ( 20 ) the drive to the main drive cam ( 11 ) is reversed allowing the base plate to return to its original position by the means of the base plate return springs ( 22 ). 
     2. The completed is naturally automatically released. 
     FIG.  28 —load 
     1. The spring loaded closer bracket is allowed to return to its original position ready for the next load.