Cover Sheet Folding Device for Adhesive-Bound Printed Products
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Solution Overview
Problem
Existing devices for producing perfect-bound books with folded-in cover flaps face limitations in high production rate and accuracy during small and very small runs, due to the need for format changes and the tendency of flap corners to protrude, as well as intermittent transport and alignment issues.
Innovation Solution
A device featuring a continuous roll of envelopes, a cross-cutting and longitudinal cutting system, a pocket or knife folding device for accurate flap production without creasing, and a magazine for buffering, allowing for continuous operation and high positioning accuracy of folded edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fold formers are extended in the transport direction to achieve even flap closure, then fold quality is improved, but several envelopes must be processed simultaneously which limits productivity during format changes
Solution Approach 1:
The folding process is segmented into discrete stations (first folding station and second folding station) that process envelopes sequentially rather than simultaneously. This allows single-envelope processing while maintaining high fold quality, resolving the contradiction between precision and productivity during format changes.
Solution Approach 2:
Flap joints are produced in advance by grooves before the actual folding operation. This preliminary creasing enables precise and gentle folding without requiring extended fold formers, thereby maintaining both high fold quality and productivity during format changes.
2Stability of the object's composition
If synchronous folding over the entire length of the cover is implemented, then flap closure evenness is improved, but corner protrusion occurs and several envelopes must be processed simultaneously
Solution Approach 1:
The folding operation is divided into two separate stations: the first station produces flap joints by grooves, and the second station performs the actual folding. This segmentation allows precise control of the folding process without corner protrusion while maintaining even flap closure.
Solution Approach 2:
The flap joints are prepared in advance by grooves at the first folding station before the actual folding at the second station. This preliminary action ensures precise folding without corner protrusion and eliminates the need for simultaneous processing of multiple envelopes.
3Measurement precision
If intermittent transport with corner deflection is used for flap folding, then positioning accuracy is improved, but transport speed is limited and realignment is required
Solution Approach 1:
The device enables continuous transport of envelopes through the folding process without intermittent stopping or corner deflection. The first and second folding stations operate continuously, maintaining high transport speed while achieving precise positioning through the groove-based joint production method.
4Manufacturing precision
If joint production by groove is performed before flap folding, then positioning accuracy is improved, but additional processing time is required
Solution Approach 1:
The joint production by grooves and the flap folding operations are merged into a continuous two-station process. The first station produces grooves while the envelope continues moving, and the second station performs folding without stopping the transport, thereby achieving high positioning accuracy without significant time loss.
Data Source
Figure 1
AI summary
The present invention relates to a device for producing adhesive-bound books, brochures, magazines or similar printed products, wherein the feed of the covers (2) has two conveying sections (15, 16) with different orientations of the covers (2) or cover sheets (3) to the respective transport direction, of which the conveying section facing away from the adhesive binder includes a device (10) for folding the cover sheets (3) transversely to the transport direction.