In-line Personalization Line for Variable Information Printing
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Solution Overview
Problem
Current personalization processes in the print industry are limited, particularly in matching production speeds of binding lines, and often restrict personalization to page-by-page or less than full print space due to printing and space constraints.
Innovation Solution
A method involving a personalization line with a printer and converter that prints and converts substrates into personalized signatures, allowing for variable information to be printed on a continuous web, which is then cut and stacked into signatures that can be fed directly to a binding line at production speed, enabling full-page personalization and efficient assembly of personalized books.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If personalization is performed offline on generic pages before delivery to the binding line, then personalization can be achieved, but complicated verification processes are required to ensure proper coordination of personalized pages into publications
Solution Approach 1:
The patent applies preliminary action by printing variable information directly on pages during the printing process itself, rather than performing personalization as a separate offline step. This integration eliminates the need for subsequent verification processes to match personalized pages with their intended publications, as the personalization occurs at the source of page production
Solution Approach 2:
The patent merges the personalization function with the printing process by integrating variable information printing capabilities directly into the printing press. This combination of printing and personalization in a single operational flow eliminates the separate personalization step and its associated verification requirements
2Device complexity
If print-on-demand personalization is performed on the binding line, then complicated verification controls are eliminated, but the process is limited to page-by-page personalization which cannot match the production speeds of the binding line
Solution Approach 1:
The patent applies preliminary action by completing personalization during the high-speed printing process before pages are delivered to the binding line. This allows personalization to occur at printing speeds rather than being constrained by the slower binding line speed, effectively preparing all personalized pages in advance for efficient binding line operation
Solution Approach 2:
The patent transitions from page-by-page personalization to signature-level personalization by printing variable information on multiple pages simultaneously as they pass through the printing press. This dimensional shift from individual page processing to multi-page batch processing enables personalization speeds that match or exceed binding line capabilities
3Adaptability or versatility
If traditional personalization processes are used on the finishing line, then personalization can be applied to assembled books, but personalization is restricted to less than all available print space due to printing and space constraints
Solution Approach 1:
The patent applies universality by designing a printing system capable of printing variable information across the entire surface area of each page, including areas traditionally reserved for binding or considered non-printable. This multi-functional printing capability allows personalization of any portion of the complete print space, maximizing adaptability and coverage
Data Source
AI summary
A system is provided for printing and assembling printed products. The system includes a binding line and a plurality of pockets for delivering signatures to the binding line. A personalization line is associated with one of the plurality of pockets. The personalization line includes a printer configured to print variable information on a substrate and a converter positioned downstream of the printer and configured to convert the substrate into a variable signature including the variable information.