On-Demand Book Printing System Using Continuous Sheet Strips
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Solution Overview
Problem
The existing book manufacturing processes face challenges in efficiently producing books on demand with varying formats and limited quantities, leading to high production costs and waste due to the need for mass production and limited flexibility in book sizes and types.
Innovation Solution
A system that uses continuous sheet strips of standard width to print books with different orientations, allowing for the production of books of varying formats by printing book codes, sheet codes, and cover codes for precise control of the manufacturing process, enabling high flexibility with minimal manpower and using commercial binding machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mass production by offset printing is used, then production velocity and economy are improved, but waste increases and adaptability to limited demand deteriorates
Solution Approach 1:
The patent changes the production parameter from mass production to on-demand production using digital printing technology. This allows books to be printed individually or in small batches based on actual demand, eliminating the need to print thousands of copies in advance and thereby reducing waste while maintaining production velocity through automated digital printing processes.
2Adaptability or versatility
If on-demand printing with separate book block and cover production is used, then adaptability to limited demand is improved, but production cost increases
Solution Approach 1:
The patent merges the production of book blocks and covers into a single integrated printing process. Both components are printed on the same printing press using the same ink and paper supply systems, eliminating the need for separate production lines. This integration maintains adaptability to on-demand production while significantly reducing production costs by sharing resources and simplifying the manufacturing process.
3Adaptability or versatility
If manual insertion of book blocks into binders is used, then adaptability to different book types is improved, but productivity deteriorates
Solution Approach 1:
The patent replaces manual mechanical insertion operations with an automated binding system. The printing press is directly integrated with a binding mechanism that automatically attaches covers to book blocks without manual intervention. This automation maintains versatility in handling different book types through programmable settings while dramatically increasing production speed by eliminating manual operations.
4Ease of manufacture
If fixed sheet dimensions for maximum book formats are used, then ease of manufacture is improved, but adaptability to different book sizes deteriorates
Solution Approach 1:
The patent implements dynamic sheet size adjustment capability in the printing system. The printing press can automatically adjust sheet dimensions and layout configurations based on the specific book format requirements. This allows the system to maintain ease of manufacture through standardized processes while adapting to any book size by dynamically reconfiguring the printing parameters and sheet utilization.
Data Source
Figure 1
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Figure 3a~3c
AI summary
A system (22) for manufacturing books on demand (23), with formation of a book block (36) having basic sheets (29) and pre-formation of covers (26) comprises a binding machine (37) and manufactures books of varying format, with different orientations of the basic sheets belonging to the principal formats of books. The basic sheets of each book are printed on a longitudinal section of paper strips (281, 28r) together with a book code (121), and sheet codes (122) for the basic sheets, while the cover (26) and a cover code (123) are printed on a respective cover sheet (32). Two input and forming equipments (331, 33r) respond to the book codes and the sheet codes for separating the basic sheets from the sheet strips and a cover pre-forming equipment (39) responds to the cover code for pre-forming the covers (26) from the cover sheets. The binding machine (37) bounds the book block and the cover in dependence of agreement of data from the book code and the cover code, while finishing equipments (41) trim the book (23) according to finishing data.