Abstract:
An apparatus is provided for applying a covering film to a book. The apparatus has a gate mechanism having open and closed states, which in the closed state presents a front surface against which a covering film may be overlaid. The spine of a book is pressed onto the covering film overlaying the front surface. The gate is then opened to admit the book to a space rearward of the gate beyond the front surface, such that the book draws the covering film into that space. A laminating mechanism is positioned rearwardly of the gate top receive the book and laminate the film against the front and rear covers to cover the book with the film.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This utility application claims the benefit under 35 U.S.C. §119(a) of United Kingdom Application No. 1317664.9 filed on Oct. 7, 2013 entitled APPARATUS AND METHOD FOR APPLYING A COVERING FILM TO A BOOK and whose entire disclosure is incorporated by reference herein. 
       TECHNICAL FIELD 
       [0002]    This invention relates to apparatuses and methods for applying a covering film to a book. 
       BACKGROUND OF THE INVENTION 
       [0003]    Adhesive covering films for books are widely available. In most cases these are applied manually by removing a release paper covering the adhesive, carefully positioning the book against the adhesive surface of the film, applying the adhesive film to the front and back covers and spine, taking care to avoid or eliminate bubbles, and finally trimming off the excess film. 
         [0004]    This procedure is time consuming for large numbers of books, making it inefficient for libraries, booksellers or publishers wishing to cover large numbers of books at the same time. Experience shows that a skilled worker can typically cover 38-60 books per hour with this method. 
       BRIEF SUMMARY OF THE INVENTION 
       [0005]    There is provided an apparatus for applying a covering film to a book, the book having front and rear covers and a spine, the apparatus comprising:
       a gate mechanism having open and closed states, which in the closed state presents a front surface against which a covering film may be overlaid whereby the spine of a book may be pressed onto the covering film overlaying the front surface, and which in the open state admits the book to a space rearward of the gate beyond the front surface such that the book draws the covering film into said space; and   a laminating mechanism positioned rearwardly of the gate, the laminating mechanism operable to receive a book admitted beyond the gate, and to apply pressure against said film onto the front and rear covers of the book to cover the book with the film.       
 
         [0008]    By presenting a front surface which can be used to support a covering film, and against which the spine of a book can be pressed to sandwich the covering film between the spine and the front surface, the book can be quickly positioned correctly on the (typically adhesive) covering film. Then by the simple mechanism of opening the gate and admitting the book into a laminating mechanism beyond the gate, we ensure that the covering film, already in position against the spine (and adhered to it if the film is adhesive-coated), is fully laminated to the book&#39;s front and back covers. 
         [0009]    In contrast to the rate of 38-60 books per hour which a skilled worker can achieve using manual methods, machines according to the invention can process over 300 books per hour. 
         [0010]    Preferably, the laminating mechanism comprises at least a first roller and a second roller operable in combination to receive the book and to apply pressure against said film onto the front and rear covers thereof as the book passes between the rollers. 
         [0011]    A motor may be provided to drive at least one roller. There can be a linkage for driving both rollers from a common motor. Alternatively each roller may have its own respective motor. Again alternatively, only one roller may be driven, the other being caused to turn by the pressure of the book against it as the book is moved by the driven roller. 
         [0012]    In one embodiment, the gate mechanism comprises a pair of doors each hinged at a respective outer edge, wherein in the closed state the doors meet at a respective inner edge, and wherein in the open state the doors hinge rearwardly about their outer edges to admit the book into said space between said inner edges. 
         [0013]    In another, currently preferred embodiment, the gate mechanism comprises a pair of doors which when in the closed state meet at a respective inner edge, and which are arranged to slide apart resulting in a gap between the respective inner edges to admit the book therebetween. 
         [0014]    The doors, in either case, preferably provide a continuous and substantially unbroken, flat surface with any gap between the doors being of a size substantially smaller than the width of a conventional book, i.e. the gap being less than 5 mm, more preferably less than 2 mm, more preferably less than 1 mm. Such a surface acts as a flat table against which the book may be compressed onto the covering film before the doors are opened. 
         [0015]    There is preferably a guide mechanism which receives a book and presents the spine of the book onto the front surface. 
         [0016]    More preferably, the gate mechanism comprises a pair of doors which when in the closed state meet at a respective inner edge, and wherein said guide mechanism is positioned relative to the pair of doors to present the spine of the book onto the adjacent inner edges of the doors. 
         [0017]    Preferably, the guide mechanism comprises first and second plates biased against one another to retain the book when introduced between the plates, while allowing the book to be pushed through and beyond the plates when the gate mechanism is open. 
         [0018]    An apparatus as claimed in claim  10  wherein the plates are biased together to form a generally Y-shaped guide mechanism, the stem of the Y-shape being formed by abutting surfaces of the two plates, and the upper branches of the Y-shape being respectively formed by an angled portion of each plate. 
         [0019]    As an alternative to angled plates, the plates can be curved along some or all of their height so that they flare away from one another to provide a guide into which the book can be admitted. 
         [0020]    In one embodiment, when the gate mechanism comprises a pair of doors which when in the closed state meet at a respective inner edge, the inner edges moving apart when the gate is in the open state, the first and second rollers can each be mounted on a respective one of the pair of doors rearwardly thereof adjacent the inner edge of the respective door. 
         [0021]    Preferably, in this case, the first and second rollers are biased against one another when the doors are closed, meeting at a point in line with the meeting point of the inner edges of the doors, and when the gate is in an open state each roller moves under a biasing force beyond the inner edge of the door on which it is mounted. 
         [0022]    A gate motor is preferably provided for opening said gate. Where there are a pair of doors, there can be a respective pair of gate motors such that each gate motor drives a respective one of said doors to open said gate. 
         [0023]    Alternatively, where the gate comprises a pair of doors, the apparatus may further comprise a linkage for driving both doors from a common gate motor. This arrangement is currently preferred as a very precise and synchronized opening of the doors can be achieved, with the gap increasing uniformly on either side of a center line as the doors open, which assists in admitting the book and cover reliably to the laminating mechanism. 
         [0024]    There is preferably a controller for activating the or each gate motor and the or each roller motor in synchronicity. 
         [0025]    The apparatus may further include a film supply mechanism for receiving a roll of covering film such that a length thereof may be drawn across said front surface in advance of a book being received. In this embodiment, the film can then be cut to a suitable length before or after the book is pressed onto the film and before the gate is opened. 
         [0026]    Alternatively, the covering film may be supplied in lengths and individual lengths can be simply placed into position. 
         [0027]    Preferably, the apparatus further comprises 5 a stop structure adjacent said gate on the front said thereof, said stop structure allowing alignment of an edge of said film with a face of said book. 
         [0028]    There is also provided a method of applying a covering film to a book, the book having front and rear covers and a spine, the method comprising:
       providing a gate mechanism having open and closed states, which in the closed state presents a front surface against which a covering film may be overlaid whereby the spine of a book may be pressed onto the covering film overlaying the front surface, and which in the open state admits the book to a space rearward of the gate beyond the front surface such that the book draws the covering film into said space;   providing a laminating mechanism rearwardly of the gate, the laminating mechanism operable to receive a book admitted beyond the gate, and to apply pressure against said film onto the front and rear covers of the book to laminate the film against the front and rear covers;   placing a cover film to overlay said front surface;   pressing a spine of a book onto said cover film overlaying the front surface;   opening the gate to admit the book to said space such that the book draws the covering film into said space; and   laminating the film against the front and rear covers with said laminating mechanism.       
 
         [0035]    Preferably, the film is adhesive on some or all of one side thereof, the adhesive side being placed facing away from the front surface, and the adhesive being a pressure adhesive, wherein the laminating process applies pressure to adhere the film to the front and rear covers. 
         [0036]    Preferably, the laminating mechanism comprises a pair of pressure rollers which receive the book and compress the film against the front and rear covers. 
         [0037]    Preferably, the film is adhesive on some or all of one side thereof, the adhesive side being placed facing away from the front surface, and the adhesive being heat activated, further comprising the step of heating the film as part of the laminating process to adhere the film to the front and rear covers. 
         [0038]    When the adhesive is heat activated, the laminating mechanism can comprise 5 a pair of pressure rollers which receive the book and compress the film against the front and rear covers, where the rollers are heated. 
     
    
     
       BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS 
         [0039]    Many aspects of the present disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views. 
           [0040]      FIG. 1  is a perspective view of an apparatus for applying a covering film to a book; 
           [0041]      FIGS. 2-6  are schematic views of the apparatus of  FIG. 1 , shown during successive stages of applying a covering film to a book; 
           [0042]      FIG. 7  is a perspective view of a covered book; 
           [0043]      FIG. 8  is an elevation of a covered book; and 
           [0044]      FIGS. 9-11  are schematic views of a second apparatus for applying a covering film to a book, shown during successive stages of applying a covering film to a book. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0045]    Referring now to the figures, wherein like reference numerals represent like parts throughout the several views, exemplary embodiments of the present disclosure will be described in detail. Throughout this description, various components may be identified having specific values, these values are provided as exemplary embodiments and should not be limiting of various concepts of the present invention as many comparable sizes and/or values may be implemented. 
         [0046]    In  FIG. 1  there is indicated, generally at  10 , an apparatus for applying a covering film to a book. The apparatus is embodied in the general form of a cabinet  12  having a work surface or front surface  14 , with operator controls  16  on a face  18  of the cabinet, and a guide and stop assembly  20  located  20  above the front surface. 
         [0047]    The guide and stop assembly has three main elements: a left-hand guide plate  22 , a right-hand guide plate  24 , and a back stop structure  26 . The guide plates are biased towards each other to provide a generally Y-shaped guide into which a book can be introduced from above. 
         [0048]    The guide plates each have a cut-away so that a gap  28  is defined between a pair of legs  30 ,  32  which extend from the guide plates down into the cabinet  20  where the biasing mechanism is situated. As a result of this gap&#39;s existence, the work surface or front surface  14  is largely unobstructed over the majority of its area. 
         [0049]    The front surface  14  is composed of the upper faces of two sliding doors  34 , 36  whose operation will be described further below. On each door, a stop plate  38  is mounted which is aligned vertically with the face of the back stop structure  26  (only the stop plate  38  on the right-hand door  36  is indicated by reference numeral). Due to this alignment, it will be appreciated that a covering film (which is assumed to have a straight edge) can be overlaid on the front surface  14 , abutting against the pair of stop plates  38 . Then a book can be introduced, spine first, between the guide plates  22 ,  24  (forcing them apart) while abutting against the stop plate  26 . Pushing the book down onto the covering film will result in an aligned covering film which is squared relative to the book&#39;s axis. (It may be preferred that the stop plates  38  are recessed, relative to the back stop structure  26 , by a millimeter or two, in which case the covering film will extend beyond the edge of the book by a corresponding amount. While this gives a greater margin of error for an operator, it results in a requirement to trim the film along this edge, as discussed further below.) 
         [0050]    Referring now to  FIG. 2 , the mechanism can be seen in schematic cross section, taken in a plane parallel to the surface of the back stop structure seen in  FIG. 1 , i.e. transverse to the plane along which the guide plates  22 ,  24  meet. 
         [0051]    In  FIG. 2  we can see the guide plates  22 , 24  each have an angled structure, so that when biased together (as indicated by the dotted arrows) they form a generally Y-shaped guide mechanism, the stem  40  of the Y-shape being formed by abutting surfaces of the two plates, and the upper branches  42 , 44  of the Y-shape being respectively formed by an angled portion of each plate  22 , 24 . There is no reason why other shapes could not also be used to guide a book into a desired position, which is aligned with a meeting point  46  between the two sliding doors  34 , 36  which together provide the front surface  14 . 
         [0052]    The terms “front” and “forward”, as opposed to “rear” and rearward”, as used herein, denote the directions outside and inside the doors  34 , 36 , respectively. Thus the guide plates  22 , 24  are forward of the front surface  14 , while the two laminating rollers  48 , 50  seen in  FIG. 2  are rearward of the doors  34 , 36  and the front surface  14 . 
         [0053]    As seen in  FIG. 2 , a covering film  52 , has been placed in position, overlaying the front surface  14 . The covering film may be, for example, an adhesive coated polyester film of known type, which is supplied in standard sizes with a release liner protecting the contact adhesive. In use the adhesive is exposed by removing the release liner, and the film  52  is placed, adhesive side up, on the front surface, generally centered over the line  46  where the doors meet, and with one edge abutting against the stop plate  38  ( FIG. 1 ). The alignment of the cover against the back stop is precise and easily achieved, while the requirement to generally center the cover over the mid line  46  is less critical—the positioning only needs to be as accurate as is required to ensure that enough film extends on either side to cover half the spine and either the rear or front cover of the book  54 . Typically, the covers will be from a few millimeters to (preferably) a few centimeters bigger in each direction than the combined width (front cover  56 +spine  58 +back cover  60 ) and the height of the book. 
         [0054]      FIG. 3  shows the next stage of operation, with the book  54  pressed fully down onto the covering film  52 , which is thus sandwiched between the book&#39;s spine and the front surface  14  of the abutting doors  34 , 36 . Due to the biasing force on the guide plates  22 , 24 , the book is precisely aligned over the line  46  where the doors  34 , 36  abut. 
         [0055]      FIG. 4  shows the apparatus just after the operator has engaged one of the controls  16  (i.e. a “start” button) which actuates both a gate motor (not shown) and a pair of roller motors (not shown). A single gate motor is used to drive apart the doors and thereby open a gap  66  below the spine of the book  54 . By using a precise linkage, the motion of the two doors can be tied, so that the inner edges  68  are always the same distance from the center line. One could, alternatively, have a pair of gate motors. A set of bearings  60  is provided for each door  34 , 36  to support it in smoothly sliding open/ 
         [0056]    Each of the laminating rollers is driven by its own motor, in the direction indicated, such that they will pull a book engaging with them from a forward to a rearward direction. Biasing spring force on the rollers ensures that they exert pressure against a book&#39;s covers as they draw it rearwardly. 
         [0057]    In  FIG. 5 , the gate (doors  34 , 36 ) has opened beyond the thickness of the book  54 , allowing the operator to push the book rearwardly of the front surface  14 . As the spine had already adhered to the covering film  52 , it is pulled evenly rearwards towards the laminating rollers  48 , 50  which catch the edges of the spine at the moment captured in  FIG. 5 . 
         [0058]    As shown in  FIG. 6 , the rollers are forced apart by the book and they drive the book rearwardly, simultaneously compressing the adhesive surface of the covering film  52  (which continues to be drawn in by the book  54 ) and adhering the film to the book&#39;s front and rear covers  56 , 60 . In  FIG. 6  the gate is fully open and the doors are no longer moving. The maximum gap can be fixed at a size big enough to accommodate most commercially produced books, or it can be adjustable by the operator for a given batch of books. 
         [0059]    It will be noted that throughout the process shown in  FIGS. 2-6 , the vertical alignment of the book is controlled by the biasing force provided by the Y-shaped guide  22 , 24  and the roller  48 , 50 . Once the book is free of the guide and of the rollers, it drops below the rollers for further processing such as by dropping onto a conveyor belt leading to a trimming station. 
         [0060]      FIGS. 7 and 8  show a covered book  54  which has been covered with film  52  by the machine of  FIGS. 1-6 . It can be seen that the film  52  is flush with the top edge  62  of the book due to the previously discussed stop structure  26  and stop plates  38  ( FIG. 1 ). At the other edges (bottom edge  64  and fore edge  70 ) the film  52  extends beyond the book&#39;s edges. Therefore the final step is to trim the book and cover using a guillotine or dedicated trimming machine along the trimming lines  72  identified in  FIG. 8 . In this way, a millimeter or so is sacrificed along each edge to achieve a sharp edge where the film is flush with the edges of the books&#39; front and rear covers and spine. 
         [0061]      FIGS. 9-11  show an alternative embodiment, using similar views to those of  FIGS. 2 ,  4  and  6 . However, the embodiment of  FIGS. 9-11  differs in two major respects. Similar parts to the earlier embodiment are indicated with reference numerals that differ by  100  (e.g. book  154  vs. book  54 ). 
         [0062]    Firstly, the gate and front surface  114  are provided by doors  134 , 136  which are each hinged along an outer edge  138  ( FIG. 9 ). The doors hinge rearwardly when the operator actuates the controls (after the book  154  has been pressed onto the covering film  152  overlaying the front surface  114 ), a gap  166  develops due to the hinging action of the doors. 
         [0063]    Secondly, the laminating rollers  148 , 150  are mounted on to the rearward side of the doors, adjacent the inner edges  168 . The rollers  148 , 150  are carried on brackets  180  which are spring loaded and biased towards each other. Thus it can be seen that as the doors begin to open ( FIG. 10 ), the rollers remain in contact with each other. Then in  FIG. 11 , the rollers have moved sufficiently to project beyond the inner edge of each door and thereby engage with and press against the book&#39;s covers  156 , 160  to laminate the book and, due to the motors, draw it rearwardly past the doors. 
         [0064]    The invention is not limited to the embodiments disclosed herein which can be varied without departing from the scope of the claimed invention.