Patent Publication Number: US-6338603-B1

Title: Process and a machine for the manufacture of covers for books and the like, and covers produced thereby

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to a process for the manufacture of covers for books and the like. 
     BRIEF SUMMARY OF THE INVENTION. 
     The process according to the invention is characterized in that it comprises the operations of: 
     arranging a plurality of sheets of card or the like, having overall dimensions which are greater than those of the covers to be produced and having a central aperture with a substantially elongate rectangular shape and dimensions which are greater than those of the spines of the covers to be produced; 
     feeding these sheets in series to a conveyer which can entrain and guide this series of sheets in a direction parallel with the aperture, supporting these sheets such that a central portion of the lower face around this aperture is left free; 
     applying a first layer of adhesive to a central strip of the lower face of each sheet about the central aperture; 
     applying to this first layer of adhesive a portion of a flexible strip which is wider than the apertures in these sheets; 
     applying a second layer of adhesive to a central strip of the lower face of the portion of the flexible strip applied to each sheet; 
     applying to this strip of adhesive a strip of card or the like which is narrower than the apertures in the sheets; 
     then shearing the ends of each sheet along lines which are parallel with one another and are perpendicular to and intersect the central aperture. 
     According to a further characteristic of the process, the flexible strip portions and the strips of card or the like are produced as a result of strips of flexible material and of card or the like, respectively, being cut transversely, the strips being wider than the length of the spine of the cover to be produced. 
     Advantageously, these flexible strip portions and strips of card or the like are applied to the sheets with a rotational movement in a plane which is substantially at right angles to that of the sheets, such that, at the moment when these strip portions or strips are applied, their speed is substantially equal to the advance speed of the sheets. 
     The invention also relates to an automatic machine for producing covers for books and the like. 
     A further subject of the invention is the covers for books and the like produced with the process or machine defined above. 
     Further characteristics and advantages of the invention will become clear from the following detailed description, given with reference to the appended drawings, provided purely by way of non-limiting example. 
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a diagrammatic illustration in plan view (viewed from above) of an automatic machine for producing covers for books in accordance with the invention; 
     FIGS. 2 a  to  2   h  are plan views of the lower or internal face of semifinished products obtained in the successive stations of the automatic machine of FIG. 1; 
     FIG. 3 is a side view, partially in section, of an adhesive applicator device comprised in the machine of FIG. 1; and 
     FIGS. 4 and 5 are partial perspective views showing, in two different operating states, a station for the cutting and application of portions of a flexible strip to a sheet of card, comprised in the machine of FIG.  1 . 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     With reference to FIG. 1, an automatic machine for producing covers for books and the like according to the invention comprises a sheet feeding machine  1  of known type, such as, for example, a so-called feeder produced and marketed by the TEKGRAF company or by the MULLER MARTINI company. This machine comprises a loader  2  in which is disposed a stack of rectangular sheets  3  of card or the like. By means of devices with suction cups or the like, for example, the feeding machine  1 , operating in known manner, takes the sheets from the loader  3  and deposits them in series on a conveyer  4 . In the embodiment illustrated, the conveyer  4  comprises two chains  5  which run in the direction of the arrow F between two stationary side walls or guides  6 . Connected to the chains  5  are entrainment members  7  which engage one side of a sheet  3  of card deposited on the chains of the machine  1 . 
     The upwardly turned upper face of the sheets  3  of card or the like is the face corresponding, in the final cover, to the outer surface of the cover, or to the so-called first and fourth (faces) of the cover. 
     As shown in FIG.  1  and FIG. 2 a , each sheet  3  of card deposited on the chains  5  has a central aperture  8  of a substantially elongate rectangular shape. The dimensions of this aperture are greater than those of the spine of the cover to be produced. 
     A first gluing station, generally indicated  9  in FIG. 1, is provided along the chain conveyer  4 , downstream of the feeding machine  1 . 
     In the embodiment illustrated in FIG. 3, the gluing station  9  comprises a container  10  in the form of a tank, disposed below the chain conveyer  4  and containing a liquid adhesive  11 , for example a cold-type vinyl adhesive. The lower part of a wheel or roller  12  rotatably mounted on a shaft  13  is immersed in the adhesive  11 , and its upper part extends between the chains  5  of the conveyer  4 , adjacent the path of the sheets  3  of card or the like. As a result of the rotation (controlled by a motor which is not illustrated) according to the arrow F 1  of FIG. 3, the lateral cylindrical surface of the wheel or roller  12  transfers a layer of adhesive and applies it to a central strip of the lower face of the sheets  3  transported by the chains  5 , about the central aperture  8 . In FIGS. 1 and 2 b , the central strip of the lower face, provided with adhesive, of each sheet  3  is indicated  14 . It can be seen that FIG. 2 b  shows the lower face of a sheet  3  leaving the gluing station  9 , whilst, in FIG. 1, the sheet is viewed from above, and the strip of adhesive applied to this sheet is shown accordingly by hatched lines. 
     Advantageously, as shown in FIG. 3, the wheel or roller  2  is associated with a blade or scraper device  15  which reduces the thickness of the layer of adhesive  11  transferred by the periphery of this wheel or roller  12 . In the embodiment illustrated, the blade or scraper device  15  is fixed to a side wall of the container  11  and its free end extends in the vicinity of the periphery of the wheel or roller  12 . 
     Advantageously, the gluing station  9  further comprises a counter-roller  16  which idles about an axis parallel with that of the wheel or roller  12  and is disposed such that it presses each sheet  3  of card against this wheel or roller  12 . 
     Downstream of the gluing station  9 , along the conveyer  4 , is provided a further station (generally indicated  17  in FIGS. 1,  4  and  5 ) in which, as will be described in further detail, a portion of a flexible strip, such as fabric or the like, is applied to the central strip, provided with adhesive, of each sheet  3 . 
     As can be better seen, in FIGS. 4 and 5, the station  17  comprises an apparatus  18  which feeds the flexible strip  19  in a controlled manner in a direction substantially at right angles to the advance direction of the conveyer  4  comprising the chains  5 . In the embodiment illustrated, this apparatus comprises a stationary support structure  20 , at one end of which a coil  21  of strip is supported such that it can rotate about a horizontal axis. From this coil, the strip  19  passes over an idling transmission roller  22  with a horizontal axis, and then between a pair of opposite, horizontal rollers  23  and  24 , of which at least one is motor-driven (preferably the lower roller  24 ). By means of these rollers, the strip  19  is advanced towards a cutting device, generally indicated  25 , disposed below the path of the sheets  3  carried by the conveyer with chains  5 . 
     The cutting device  25  comprises a fixed blade  26  directed transversely to the advance direction of the strip  19 . This blade  26  is disposed slightly above the path of the strip  19 . 
     A cutting and holding member  27 , which is movable in a vertical plane and of which one edge is parallel with and adjacent the cutting edge of the blade  26 , cooperates with the fixed blade  26 . This movable cutting and holding member  27  can in particular be moved between a lowered position, shown in FIG. 4, in which its edge adjacent the blade  26  extends below the strip  19  to be cut, and a raised position, shown in FIG. 5, in which this edge extends above the cutting edge of this blade. 
     In the embodiment illustrated, the movable cutting and holding member  27  is parallelepipedal. In its lowered state (FIG.  4 ), the upper horizontal face of this member is disposed immediately below the end of the strip  19  to be cut. 
     The member  27  is articulated on the ends of two twin cranks  28  which are torsionally rigid with two parallel, horizontal shafts  29 , of which at least one is rotatably driven by a drive assembly generally indicated  30 . The cutting and holding member  27  can, therefore, be rotated and translated in a substantially vertical plane centred between the guides  6  and associated with the conveyer with chains  5 . 
     In operation, the rollers  23  and  24  advance the end of the flexible strip  19  between the fixed blade  26  and the cutting and holding member  27  whilst the latter is in the lowered position. The drive assembly  30  then rotates the shafts  29  and imparts to the cutting and holding member  27  a rotary—translation movement such that this member, moving practically in contact with the blade  26  and with its edge turned towards the blade, cuts the end portion of the flexible strip  19  which thus rests on the upper face of this member. Advantageously, the member  27  comprises suction pipes which terminate in correspondence with apertures in its upper face. These pipes, connected to a vacuum pressure source (not illustrated) by means of a pipe indicated  31  in FIG. 4, allow the portion of the strip  19  which has been cut to be held steadily on this member, whilst this member continues its rotary—translation movement, in particular in the upward direction. 
     The operation of the feeding apparatus  18  and of the cutting device  25  is synchronized, by known means which are not illustrated, with the advance of the conveyer with chains  5  such that, when the cutting and holding member  27  reaches its highest position (FIG.  5 ), this member applies the cut strip portion  19 ′ against the central strip, provided with adhesive, of the lower face of a sheet  3  carried by this conveyer. Subsequently, this sheet  3  continues to advance, as indicated by the arrow F 2  of FIG. 5, whilst the cutting and holding member  17 , continuing its movement, returns to its lower position, in order to cut a further portion of the flexible strip  19 . 
     FIG. 2 c  shows the lower face of the sheet  3  of card or the like at the outlet of the station  17 ; as can be seen, the strip portion  19 ′ applied thereto extends beyond the longer sides of the aperture  8 . 
     On the other hand, the upper face of the sheet  3  at the outlet of the station  17  can be seen, on a smaller scale, in FIG.  1 : the flexible strip portion  19 ′ applied to its lower face can be seen through the central aperture  8 . 
     Downstream of the station  17 , the conveyer with chains  5  transfers the sheets  3  to a pressing station indicated  31  in FIG.  1 . This station comprises pairs of counter-rotating pressing rollers or a pair of counter-rotating pressing strips which compress the flexible strip portion  19 ′ firmly against the sheet of card or the like. 
     Downstream of the station  31  is provided a further station  32  for applying adhesive, similar to the station  9  described above. In this station, a wheel or roller which is immersed in the liquid adhesive present in a container applies a layer of this adhesive to a central strip of the lower face of the strip portion  19 ′ applied to each sheet  3 . The width of this strip or layer of adhesive is preferably equal to or greater than the width of the spines of the covers to be produced, and is indicated  33  in FIG. 2 d . As these Figures show, the strip of adhesive  33  is preferably narrower than the central aperture  8  in the sheet. 
     The station  32  is followed by a station  34  (FIG. 1) structurally similar to the station  17  described above. In this station, there is applied to the central strip, provided with adhesive  33 , of the lower face of the strip portion  19 ′ applied to each sheet a strip or centre consisting of card or the like, which is narrower than the central aperture  8  in the sheet and substantially the same width as the desired width of the spine of the cover to be produced. To this end, the station  34  comprises a coil  35  from which unwinds a strip  36  of card or the like, which passes over a transmission roller  37  and then between two opposite rollers, of which only the upper one can be seen in FIG. 1, in which it is indicated  38 . The strip  36  of card or the like has a transverse width which is at least equal to, but is preferably greater than, the length of the central aperture  8  in each sheet  3 . The station  34  further comprises a cutting device similar to the one described above with reference to FIGS. 4 and 5, which cuts successive strips of this strip, of which each is applied to the strip of adhesive carried centrally by the strip portion  19 ′ applied to each sheet. 
     At the outlet of the station  34 , the lower face of the sheet is substantially as shown in FIG. 2 e , in which the strip of card or the like applied centrally to the flexible strip portion  19 ′ is indicated  36 ′. 
     Downstream of the station  34 , the sheets are advanced to a further pressing station  39 , similar to the station  32  described above. 
     The station  39  is followed by a shearing station  40 . In this station, a shearing machine of known type, for example of the rotary type, shears the inlet and outlet ends of each sheet  3  perpendicular to the central aperture  8 , along parallel cutting lines indicated L 1  and L 2  in FIGS. 1 and 2 f . As can be seen better in FIG. 2 f , the cutting lines L 1  and L 2  intersect the central aperture  8  in the vicinity of its ends. Consequently, at the outlet of the station  40  (shown in FIG. 2 f ), the semifinished product is composed of two jackets or covers  3 ′ connected by the flexible strip portion  19 ′, to the centre of which a strip  36 ′ of card or the like is applied. 
     This semifinished product can in principle already be used as a cover for books and the like. In this case, the faces of the jackets or covers  3 ′ of FIG. 2 f  constitute the second and third (faces) of the cover, intended to be stuck to endpapers of a book block. In this case, the strip  36 ′ of card or the like acts as the centre of the spine of the cover, whilst the parts  19 ′ of fabric or the like between the longer sides of the strip  36 ′ and the adjacent sides of the covers  3 ′ act as hinges or joints which, in use, permit easy articulation of the cover for opening or closing. 
     In order to produce covers with margins which are more robust and better finished, the semifinished products leaving the shearing station  40  can be fed to a trimming station  41 , of known type, in which the corners of these semifinished products are sheared obliquely, their lower faces then assuming the configuration illustrated in FIG. 2 g.    
     The resultant semi-finished products are fed to a turning/gluing machine  42  (FIG.  1 ), of known type, which folds the margins of these semifinished products along the lines indicated L 3  and L 4  in FIG. 2 g  and, when adhesive has been applied, turns them onto the lower faces of these semifinished products which then assume the configuration illustrated in FIG. 2 h . This Figure shows definitively the appearance of the interior of the finished cover which can thus be applied to a book block using the casing or stitching system. 
     The covers which can be produced by the process and machine according to the invention are simpler and more economical than the conventional covers bound in rigid paper boards, and the cover planes have articulation characteristics which are considerably better than the covers of the so-called “Dutch type”. 
     Naturally, the principle of the invention remaining the same, the forms of embodiment and details can be varied widely with respect to what has been described and illustrated above purely by way of non-limiting example, without departing from the scope of the present invention.