Patent Publication Number: US-6705982-B1

Title: Pre-fold sword insertion device

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to folders of printing presses and more particularly to a device for folding and transporting signatures. 
     2. Background Information 
     Web printing presses print a continuous web of material, such as paper. In a folder of the printing press, the continuous web is folded by a former and cut into signatures. The signatures then may be collated in a collating device. 
     One way to open folded signatures to permit collation or transport is with a lap, i.e. an overlapping area on the folded signature. A device opens the signature using the lap and then trims the lap away. Trimming the lap generates significant waste and adds a step to the printing process, making the process less efficient and slower. 
     Another way to open folded signature is with a gripper. To open the signature, a gripping device seizes and then opens the signature. However, the gripping device can cause damage to the signature. 
     Thus, the need to open the signature, for example to deposit the signature on a saddle, results in significant fault generation in the bindery. The generation of significant faults requires the addition of multiple diagnostic parts to conventional saddle collation machines, which results in increased costs and reductions in reliability and productivity. 
     U.S. Pat. No. 3,762,697 purports to disclose a delivery apparatus for use with a folding apparatus of web-fed rotary printing machines. The paper webs are cut to copy length by cutting cylinders and then transferred to the folding blade cylinders and folded in the folding rollers. Thereafter, using the fans, the folded products are delivered to conveyor belts. 
     The device of the &#39;697 patent does not appear to provide for opening the signatures and the apparatus uses a complicated folding apparatus to fold the signatures. The fan arrangement and folding apparatus subject the device to time consuming and difficult repair and do not permit collation. 
     European Patent No. EP 0 479 067 B1 purports to disclose a collator for collecting and depositing signatures, apparently having a circulating first receiving device, which is constructed as an oblong conveyor with a plurality of receiving portions open towards the outside onto which the separate signatures are inserted and from which the signatures are combined to form book blocks. The book blocks are delivered to a first receiving device, which then delivers the signatures to a second receiving device, where the book blocks are removed with the aid of rear stops of adjustable height. The second receiving device then delivers the book blocks to the transport device. 
     With European Patent No. EP 0 479 067 B1 the signatures appear to have to enter the book blocks in the order that the signatures will be assembled, as no device is present for opening the signatures and inserting other signatures. Moreover, the device possesses a complicated arrangement of moving parts, which may make repair and servicing time consuming and expensive. 
     BRIEF SUMMARY OF THE INVENTION 
     An object of the present invention is to provide for a device for eliminating or simplifying the opening or collating of a signature in a post-folding process. 
     The present invention provides a folder comprising: 
     a first cutting device to partially cut a web of material; 
     a former to fold the web of material, so as to form a folded web; 
     a stationary signature opening device located between sides of the passing folded web; and 
     a second cutting device located downstream from the former to sever the folded web into an at least one signature. 
     With the stationary opening device, e.g. a stationary sword, of the present invention, the need to open a signature with a separate device in a post-folding process is eliminated. The stationary sword can provide the opening for the signature. Thus, the present invention eliminates the need for a signature lap to open a folded signature, which results in a more economical and efficient printing process. Moreover, the present invention eliminates the need for grippers and thus, reduces damage to the signatures. The speed of the entire collation process may also be increased. 
     The cutting devices preferably are pairs of cutting cylinders. 
     Preferably, the former of the pre-fold insertion device laterally aligns the plurality of partial cuts in the web. The lateral alignment advantageously permits the second pair of cut cylinders to sever a signature from the web by cutting the web in exactly the locations that the first pair of cut cylinders did not cut. 
     The second pair of cut cylinders of the pre-fold insertion device may further provide a recess to allow the stationary sword to pass through. The recess provides the advantage of allowing the stationary sword to project through the second pair of cut cylinders, which allows the second pair of cut cylinders to sever the signature without contacting or damaging the stationary sword. 
     The stationary sword preferably increases in thickness downstream from the second pair of cut cylinders and in so doing spreads apart the edges of a signature, so as to open the signature. Advantageously, the increase in thickness allows the signature to be placed on the moving swords without the need for a gripper or other device to open the signature. 
     Preferably, the stationary sword has an aperture that allows a plurality of moving wedge swords to pass through the stationary sword. The aperture advantageously permits the moving wedge swords to pass through the stationary sword and in so doing pull the signatures off the stationary sword. 
     The present invention may further include a sword conveyor to transport a plurality of moving swords or moving wedge swords. The sword conveyor provides the advantage of allowing the signatures on the swords to proceed to additional pre-fold sword insertion devices, where the swords receive additional signatures, or continue to other steps in the collation process. 
     Preferably, the sword conveyor moves in a direction perpendicular to the direction of the stream of signatures. 
     The sword conveyor of the present invention may also move at about a 45 degree angle to the direction of the stream of signatures. Advantageously, the motion of the sword conveyor reduces the relative velocity between the signature and the sword conveyor, thus, the present invention may function at higher speeds without damaging the signature. 
     A collating devices with two folders according to the present invention is also provided. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     A preferred embodiment of the present invention is described below by reference to the following drawings, in which: 
     FIG. 1 shows a front view of the folder, which includes a plurality of partial cuts; 
     FIG. 2 shows a side view of the folder, which includes the partial cuts; 
     FIG. 3 shows a first embodiment of the pre-fold sword insertion invention, which includes a first folder and a second folder; 
     FIG. 4 shows a second embodiment of the pre-fold sword insertion invention, which includes an open stationary sword; 
     FIG. 5 shows a top view of three open stationary swords and six signatures; and 
     FIG. 6 shows a third embodiment of the pre-fold sword insertion invention, which includes the sword conveyor. 
    
    
     DETAILED DESCRIPTION 
     FIG. 1 shows a front view of a folder  1 . A first pair of cut cylinders  20  cuts a web  6  traveling in a downstream direction  2  with a plurality of knives  30  disposed along the outer surface of at least one of the first pair of cut cylinders  20 . Each of the knives  30  making one of a plurality of partial cuts  32  in the web  6 . The web  6 , which has a side A and a side B, then passes over a former  8 , which folds the web  6  so that sides A and B meet and partial cuts  32  laterally align. Located in the “shadow” of the former  8 , i.e., the area where the former  8  displaces the web  6  and the sides A and B meet, is a stationary sword  12 , which extends to the former as indicated by the dotted lines in FIG.  1 . The web  6  exits the former  8  with the stationary sword  12  located in the web  6  between sides A and Band aligned with the partial cuts  32 . The web  6  continues past a second pair of cut cylinders  10 , which severs the web  6  into an at least one signature  22 . 
     Downstream from the second pair of cut cylinders  10 , the stationary sword  12  increases in thickness and spreads open the edges of the signature  22  opposite the fold. By increasing in thickness, the stationary sword  12  opens the signature  22 , so that the signature  22  fits over one of a plurality of moving swords  14 . The moving swords  14  are timed so that a leading side  36  of the signature  22  does not contact the top of a first moving sword  34 . While the signature  22  descends, a second signature  40  settles on a second moving sword  38  and a third signature  44  comes to rest about a third moving sword  46 . A sword conveyor  16  transports the moving swords  14 ,  34 ,  38 ,  46  in a second direction  18 , which is perpendicular to the direction of descent of the signature  22 . 
     FIG. 2 shows a side view of the folder  1 , and also shows the partial cuts  32  in web  6 . The side view shows the first pair of cut cylinders  20  in relation to the web  6 , the former  8 , and the stationary sword  12 . After folding of web  6  to form a folded edge  21 , the former  8  positions the partial cuts  32  of the web  6  in alignment with the stationary sword  12  so that the partial cuts  32  are laterally aligned. The lateral alignment allows the second pair of cut cylinders  10  to sever the signature  22  from the web  6  by cutting the web  6  in exactly the locations that the first pair of cut cylinders  20  did not. To effect the cut, the second pair of cut cylinders  10  uses a plurality of second knives  50  disposed along the outer surfaces of at least one of the second pair of cut cylinders  10 . Since the former  8  aligns the stationary sword  12  with the partial cuts  32 , the stationary sword  12  does not interfere with the second pair of cut cylinders  10 . A recess  24  allows the stationary sword  12  to project through the second pair of cut cylinders  10  and provides a clearance for the stationary sword  12 . The recess  24  also allows the stationary sword  12  to project from the underside of the former  8  through the second pair of cut cylinders  10 . 
     FIG. 3 shows an embodiment of the present invention for collation, which includes a first folder  60  and a second folder  62 , similar to the folders shown in FIGS. 1 and 2. The first folder  60  deposits the signature  22  on a first collating sword  114 , while the second folder  62  deposits another folded signature  64  on a second collating sword  66 . The other folded signature  64  thus rests over a second folded signature  68 , which the first folder  60  deposited earlier in the collation process. The sword conveyor  16  then transports the collating swords in direction  113 , so that first collating sword  114  moves to the second folder  62  and the second collating sword  66  to another folder or to some other destination. 
     FIG. 4 shows a second embodiment of the pre-fold sword insertion invention, which includes an forked stationary sword  120 . The forked stationary sword  120  has an aperture between two forked sections in the lower portion, which allows a plurality of wedge swords  100  to pass through in direction  111 . A folded edge  22  of signature  21  thus interacts with wedge swords  100  to move the signatures. The shape of the forked stationary sword  120  moves the sides of signature  22  to the outside of the open stationary sword  120 . The wedge swords  100 , which are driven by the sword conveyor  16 , pass through the aperture between the forks of the stationary sword  120  and in so doing contact the inside of the signature  22  to pull the signature  22  off the stationary sword  120 . The wedge swords  100  then transport the signature  22  downstream to another stationary sword or some other destination. 
     FIG. 5 shows a top view of a collation device with three forked stationary swords  702 ,  704 ,  706 , similar to those shown in FIG. 4, and six signatures  710 ,  712 ,  714 ,  716 ,  718 ,  720 . A first wedge sword  750 , similar to sword  100  in FIG. 4, passes through the aperture of the first forked stationary sword  702 , thus, contacting the inside of the first partially collated signature  710  and pulling the first partially collated signature  710  off the first forked stationary sword  702 . While the first wedge sword  750  passes through the aperture, a second wedge sword  752  passes through the aperture of the second forked stationary sword  704  and pulls the second partially collated signature  712  off the second forked stationary sword  704 . At the same time, a third wedge sword  754  passes through the third forked stationary sword  706  to pick up the third partially collated signature  714 . 
     Also shown are a fourth wedge sword  756 , a fifth wedge sword  758 , and a sixth wedge sword  760  each progressing in a direction  730  consistent with the collation process. The fifth wedge sword  758  carries the fourth signature  716 , while the sixth wedge sword  760  carries the sixth partially collated signature  718  and the seventh partially collated signature  720 . The fourth and sixth signatures  716 ,  718  have been pulled off the first forked stationary sword  702  and the seventh partially collated signature  720  has been pulled off the second forked stationary sword  704 . 
     FIG. 6 shows a third embodiment of the pre-fold sword insertion invention, which includes the sword conveyor  16 . The folder  1 , similar to the one shown in FIG. 4, deposits the signature  22  on one of the moving swords  14  of the sword conveyor  16 , which passes through a forked stationary sword. The sword conveyor  16  travels in a non-perpendicular direction  56  at about 45 degrees to a descending direction  58  of the signature  22 . An angle  54  defines the deviation of the non-perpendicular direction  56  from the descending direction  58  of the signature  22 . As such, the angle  54  provides a component of velocity  55  to the signature  22 , which facilitates the transfer of the signature  22  to the sword conveyor  16 . 
     “Sword” as defined herein is a three-dimensional object with one side thinner than either of the other two sides, and can be of any shape, material or size. 
     The orientation of the former board can be different from that shown in the embodiments described above. For example, the folded web could exit horizontally instead of vertically. Thus the device for example in FIG. 6 could be rotated 90 degrees clockwise so that the sword conveyor would travel towards the upper left corner of the page (instead of the lower left as shown). Gravity thus could aid in keeping the signatures on the moving swords.