Abstract:
This invention relates to a method and apparatus for producing a pillowless booklet by flattening the spine of the booklet.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    1. Field of the Invention  
           [0002]    This invention relates to a method and apparatus for producing a pillowless booklet by flattening the spine of the booklet.  
           [0003]    2. Description of the Related Art  
           [0004]    Prior to the present invention, as set forth in general terms above and more specifically below, it is known, in the booklet making art to employ opposing rollers to form the booklet. Exemplary of such prior art are U.S. Pat. No. 5,377,965 (&#39;965) to B. P. Mandel et al., entitled “Automatic On-line Signature Booklets Finisher for Electronic Printers,” U.S. Pat. No. 6,276,677 (&#39;677) to H. Hommochi et al., entitled “Sheet Bundle Folding Apparatus with Movable Push-in Member,” and U.S. Pat. No. 6,354,059 (&#39;059) to K. Yoshie et al., entitled “Sheet Finisher and Image Forming Apparatus Therein.” While the devices of the &#39;965, &#39;677, and &#39;059 references disclose various apparatus for forcing a flat sheet or sheet stack between opposing rollers, none of these references teach or suggest the use of an apparatus for flattening of the booklet spine in order to eliminate a raised or “pillow” condition at the spine. Consequently, a more advantageous system, then, would be provided if a booklet could be produced from a flat sheet stack such that the spine of the booklet was flattened in order to eliminate any pillow conditions at the spine.  
           [0005]    It is apparent from the above that there exists a need in the art for an apparatus that is capable of creating a booklet, but which at the same time reduces the pillow condition of the spine by flattening the spine. It is a purpose of this invention to fulfill this and other needs in the art in a manner more apparent to the skilled artisan once given the following disclosure.  
         SUMMARY OF THE INVENTION  
         [0006]    Generally speaking, an embodiment of this invention fulfills these needs by providing a method for creating a pillowless booklet, wherein the method is comprised of steps of: accumulating a desired number of sheets for the booklet; fastening the sheets together; folding the fastened sheets to form a booklet spine edge; and flattening the spine edge in order to substantially eliminate any pillows located adjacent to the spine edge.  
           [0007]    In certain preferred embodiments, a stapling device and stapler anvil are used to fasten the sheets together. Also, a crease wire, clamping jaws, and crease rollers are used to fold the fastened seats in order to form the booklet spine edge. Finally, a V-shaped spine form roller is used to flatten the spine edge.  
           [0008]    In another further preferred embodiment, substantially any raised areas or “pillowing” located adjacent to the booklet spine are eliminated through the use of the V-shaped spine form roller.  
           [0009]    The preferred method for creating a booklet, according to various embodiments of the present invention, offers the following advantages: ease-of-use; substantial elimination of spine pillowing; good stability; good durability; excellent booklet creating characteristics; and good economy. In fact, in many of the preferred embodiments, these factors of ease-of-use, substantial elimination of spine pillowing, and excellent booklet creating characteristics are optimized to an extent that is considerably higher than heretofore achieved in prior, known booklet creating methods.  
           [0010]    The above and other features of the present invention, which will become more apparent as the description proceeds, are best understood by considering the following detailed description in conjunction with the accompanying drawings, wherein like characters represent like parts throughout the several views and in which: 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0011]    [0011]FIG. 1 is a front schematic illustration of an apparatus for creating a pillowless booklet, according to one embodiment of the present invention;  
         [0012]    [0012]FIG. 2 is a cross-sectional view of the apparatus for creating a pillowless booklet as shown in FIG. 1, according to one embodiment of the present invention;  
         [0013]    [0013]FIG. 3 is a front schematic illustration of the apparatus for creating a pillowless booklet, illustrating the sheet accumulation, according to another embodiment of the present invention;  
         [0014]    [0014]FIG. 4 is a front schematic illustration of the apparatus for creating a pillowless booklet, illustrating the sheet trailing edge buckle, according to another embodiment of the present invention;  
         [0015]    [0015]FIG. 5 is a front schematic illustration of the apparatus for creating a pillowless booklet, illustrating a full booklet sheet count, according to another embodiment of the present invention;  
         [0016]    [0016]FIG. 6 is a front schematic illustration of the apparatus for creating a pillowless booklet, illustrating the fastening operation, according to another embodiment of the present invention;  
         [0017]    [0017]FIG. 7 is a front schematic illustration of the apparatus for creating a pillowless booklet, illustrating the fastened bundle handoff operation, according to another embodiment of the present invention;  
         [0018]    [0018]FIG. 8 is a front schematic illustration of the apparatus for creating a pillowless booklet, illustrating the bundle crease wire/fastener alignment, according to another embodiment of the present invention;  
         [0019]    [0019]FIG. 9 is a front schematic illustration of the apparatus for creating a pillowless booklet, illustrating the bundle crease operation, according to another embodiment of the present invention;  
         [0020]    [0020]FIG. 10 is a front schematic illustration of the apparatus for creating a pillowless booklet, illustrating the spine flattening operation, according to another embodiment of the present invention; and  
         [0021]    [0021]FIG. 11 is a front schematic illustration of the apparatus for creating a pillowless booklet, illustrating the booklet ejection operation. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0022]    With reference first to FIG. 1, there is illustrated one preferred embodiment for use of the concepts of this invention. FIG. 1 shows apparatus  2  for creating a pillowless booklet. Apparatus  2  includes, in part, frame  4 , bundle clamp  5 , suspension  6 , lower bundle plane  8 , drive rollers  10 , sheet diverter  12 , bundle clamp  14 , hand-off rollers  16 , fastener  18 , stapler anvil  20 , anvil drive gear  22 , bundle diverter  23 , hand-off rollers  24 , upper bundle plane  26 , crease wire  28 , jaw centering arm  29 , crease rollers  30 , clamping jaws  32 , carriage centering rollers  34 , carriage guide rail  36 , spine form roller  38 , spine form roller tensioner  39 , carriage drive screw  40 , and drive nut  42 .  
         [0023]    With respect to apparatus  2 , frame  4 , preferably, is constructed of any suitable, durable, rigid material. Bundle clamp  5 , preferably, is constructed of any suitable, durable, rigid material. Suspension  6 , preferably, is constructed so as to adequately provide suspension between frame  4  and the remainder of apparatus  2 . Lower bundle plane  8 , preferably, is constructed of any suitable, durable material that is capable of allowing media (element  3  in FIG. 3) to be held upon lower bundle plane  8  and traverse along lower bundle plane  8 . Drive rollers  10 , preferably, are any suitable rollers that can introduce media on to sheet diverter  12 . Sheet diverter  12 , preferably, is constructed of any suitable, durable material. Bundle clamp  14 , preferably, is constructed of any suitable, durable, rigid material. Hand-off rollers  16 , preferably, are any suitable rollers that can introduce the bundle into bundle diverter  23 . Fastener  18 , preferably, is any suitable fastening device, such as a stapler, that is capable of fastening the sheets of the bundle together. Stapler anvil  20 , preferably, is constructed of any suitable, durable, rigid material. Anvil drive gear  22 , preferably, can be any suitable gear that is capable of moving stapler anvil  20  and crease wire  28  up-and-down. Hand-off rollers  24 , preferably, are any suitable rollers that can introduce the bundle on to upper bundle plane  26 . Upper bundle plane  26 , preferably, is constructed of any suitable, durable material that is capable of allowing the bundle to be held upon upper bundle plane  26  and traverse along upper bundle plane  26 . Crease wire  28 , preferably, is constructed of any suitable, durable, rigid material that is capable of pushing the bundle into jaw centering arm  29 , crease rollers  30 , clamping jaws  32 , and spine form roller  38 . Jaw centering arm  29 , preferably, is constructed of any suitable, durable, rigid material that is capable of allowing clamping jaw  32  to traverse along its length. Crease rollers  30 , preferably, are any suitable rollers that can introduce the bundle into clamping jaws  32  and spine form roller  38 . Clamping jaws  32 , preferably, are constructed of any suitable, durable, rigid material that is capable of clamping the bundle in order to retain the spine of the bundle. Carriage centering rollers  34 , preferably, are any suitable rollers that are capable of traversing spine form roller  38  along the spine of the bundle. Carriage guide rail  36 , preferably, is constructed of any suitable, durable, rigid material that is capable of allowing carriage-centering rollers  34  to traverse along its length. Spine form roller  38 , preferably, is any suitable V-shaped roller that is capable of traversing along the spine of the bundle in order to flatten the spine. Carriage drive screw  40  and drive nut  42 , preferably, can be any conventional drive screw and drive nut that are capable of driving spine form roller  38  along the spine of the bundle.  
         [0024]    [0024]FIG. 2 is a cross sectional view of apparatus  2 , as illustrated in FIG. 1. FIG. 2 more clearly shows how the various elements interact with each other.  
         [0025]    [0025]FIG. 3 shows the introduction of media  3  into apparatus  2 . It is to be understood that media  3  can be any suitable media upon which printing or other similar types of imaging can be placed. As shown in FIG. 3, bundle clamp  5  is conventionally moved to a downward or closed position to allow media  3  to come into contact with drive rollers  10 . In this manner, sheet diverter  12  causes sheets of media  3  to accumulate along lower bundle plane  8 .  
         [0026]    As shown in FIG. 4, as a new sheet of media  3  is placed upon bundle  50 , the sheet of media  3  is traversed along bundle  50 . The various sheets of media  3  of bundle  50  are pre-cut prior to being introduced into apparatus  2 . In this manner, when the spine of bundle  50  is formed and flattened, the various media sheets of bundle  50  will align to form a straightedge, thereby resembling a booklet. Consequently, the various sheets of media  3  of bundle  50  must be placed upon bundle  50 , as shown in FIG. 4, in order to produce a “stairstep” effect between the adjacent sheets of media  3  of bundle  50 .  
         [0027]    This is accomplished through the use of bundle clamp  14  and drive rollers  10 . As a sheet of media  3  is introduced on to bundle  50 , the leading sheet edge of media  3  is conventionally monitored so that when leading sheet edge of media  3  reaches a desired point along bundle  50 , bundle clamp  14  is lowered or closed on to the sheet of media  3  and drive rollers  10  creates a trailing edge buckle that causes the trailing end of the sheet of media  3  to position itself at the other end (trailing end) of bundle  50 .  
         [0028]    As shown in FIG. 5, after the desired number of sheets of media  3  are accumulated, in order to form bundle  50 , bundle clamps  5  and  14  are conventionally lowered on to bundle  50  in order to hold bundle  50  in place.  
         [0029]    As shown in FIG. 6, stapler anvil  20  is conventionally lowered by anvil drive gear  22  on to bundle  50  in order to fasten the sheets of media  3  of bundle  50  into place through the use of fastener  18 . Also, bundle clamps  5  and  14  are conventionally raised.  
         [0030]    As shown in FIG. 7, after bundle  50  has been fastened, hand-off rollers  16  interact with bundle  50  in order to cause bundle  50  to traverse along bundle diverter  23  and interact with hand-off rollers  24 .  
         [0031]    As shown in FIG. 8, hand-off rollers  24  traverse fastened bundle  50  along upper bundle plane  26  and conventionally centers the area where bundle  50  was fastened over crease wire  28 . It must also be noted that once bundle  50  has been transferred to upper bundle plane  26 , another sheet of media  3  can be introduced on to lower bundle plane  8  in order to begin the formation of another bundle  50 .  
         [0032]    As shown in FIG. 9, crease wire  28  is conventionally raised by anvil drive gear  22  such that spine  52  in bundle  50  is formed between crease rollers  30 .  
         [0033]    As shown in FIG. 10, crease wire  28  and crease rollers  30  cause bundle  50  and spine  52  to traverse through clamping jaws  32  and interact with spine form roller  28 . This manner, clamping jaws  32  are caused to clamp down on bundle  50  and, more particularly, spine  52  in order to hold spine  52  in place to create a spine edge. After clamping jaws  32  have clamped down on bundle  50  and spine  52 , V-shaped spine form roller  28  is traversed along the length of the edge of spine  52  through the use of carriage drive screw  40 , drive nut  42 , carriage-centering rollers  34 , and guide rail  36  in order to flatten spine  52 . Tensioners  39  are utilized in order to keep spine form roller  38  centered along spine  52  as spine form roller  38  flattens spine  52 . In this manner, substantially any raised areas or “pillowing” located along spine  52  is eliminated.  
         [0034]    As shown in FIG. 11, after booklet  100  has been formed and conventionally ejected from apparatus  2 , another fastened bundle  50  is traversed from lower bundle plane  8  to upper bundle plane  26  so that another booklet  100  can be formed through the flattened of spine  52 . It is to be understood that the present invention can be embodied in any computer-readable medium for use by or in connection with an instruction execution system such as a computer/processor based system or other system that can fetch or obtain the logic from the computer-readable medium and execute instructions contained therein. A “computer-readable medium” can be any medium that contains, stores, or maintains programming for use by or in connection with the instruction execution system. The computer-readable medium can comprise any one of many physical media such as, for example, electronic, magnetic, optical, electromagnetic, infrared, or semiconductor media. More specific examples of a suitable computer-readable medium would include, but are not limited to, a portable magnetic computer diskette such as floppy diskettes or hard drives, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory, or a portable compact disc.  
         [0035]    Once given the above disclosure, many other features, modifications or improvements will become apparent to the skilled artisan. Such features, modifications or improvements are, therefore, considered to be a part of this invention, the scope of which is to be determined by the following claims.