Document Production with Selective Adhesive Bonding
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Solution Overview
Problem
The production of documents with varying page thicknesses is complex and costly, requiring separate types of paper and multiple printing operations, followed by a sorting process to combine pages, which increases costs and complicates the process.
Innovation Solution
A method using a rotary printing machine to continuously print a paper web, separate it into partial webs, and then selectively coat and bond pages using an adhesive to create thickened pages, allowing for the production of documents with varying thickness in a single operation, utilizing a device with a gluing machine and detection system for automated adhesive application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If multiple types of paper with different thicknesses are used to produce documents with varying page thickness, then the document quality and aesthetic appeal are improved, but the production process becomes more complex and costly
Solution Approach 1:
The document is segmented into different page types (thick cover pages and thin inner pages) that are produced separately on the same paper web, then selectively bonded together. This allows varying thickness requirements to be met without requiring multiple paper storage systems, as all pages are initially produced from a single continuous paper web.
Solution Approach 2:
Different regions of the paper web are treated differently to create local quality variations. Specifically, certain pages are selected for adhesive bonding to create thickened sections, while other pages remain unbonded and thin. This local differentiation achieves the desired document structure without complex global processing.
2Manufacturing precision
If multiple printing operations are performed on different paper types, then the document quality is improved, but the production time and cost increase
Solution Approach 1:
Multiple printing operations that would traditionally be performed on different paper types are merged into a single continuous printing process. The rotary printing machine prints on the entire paper web in one pass, and subsequent processing steps (separation, adhesive application, bonding) are integrated into the same production line, eliminating the need for separate printing operations and temporary storage.
Solution Approach 2:
The production process maintains continuous action throughout. The paper web moves continuously through the rotary printing machine, and the adhesive bonding process occurs continuously as pages pass through the bonding section. This eliminates stopping, starting, and temporary storage operations, maintaining high productivity while achieving high document quality.
3Manufacturing precision
If pages are temporarily stored and then sorted to combine different page types, then the document assembly accuracy is improved, but the production cost and time increase
Solution Approach 1:
Pages are prepared in advance during the continuous printing process with adhesive applied to designated bonding areas before the pages are fully separated. This preliminary adhesive application ensures that when pages are eventually bonded, the assembly is accurate and efficient, eliminating the need for complex sorting operations afterward.
Solution Approach 2:
Adhesive serves as an intermediary that facilitates the bonding process. By applying adhesive to specific pages during the continuous printing process, the system enables accurate page assembly without requiring complex mechanical sorting or temporary storage systems. The adhesive mediates the connection between thick and thin pages, achieving precise assembly continuously.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables the production of cost-effective documents with varying thickness and rigidity in a single manufacturing operation, enhancing the aesthetic appeal and reducing production costs by automating the process and eliminating the need for multiple paper types and sorting.
Implementation Method 1
at least one page of the first partial web is coated at least selectively with adhesive and is adhesively bonded to at least one facing page of the second partial web
Data Source
AI summary
A method and a device for producing a document and a document produced in a corresponding manner are presented, said document being produced from a paper reel (1), being printed in a continuous rotary method, being divided into partial webs (4.1 to 4.4) and being assembled to form a document which is ready for use and has a plurality of sheets or pages. The thickness of individual pages or sheets of said document can be increased by the fact that a gluing machine (26) is integrated into the production process of said document, the gluing machine gluing individual page sections, individual pages or entire sheets of said document to one another. A second paper reel or second type of paper or second paper quality having a higher paper thickness or paper quality is therefore unnecessary.