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Claims  |
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I claim:
1. A method of forming a plurality of books comprising the steps of:
providing a moving web of coated enamel paper;
providing a moving web of groundwood newsprint paper;
printing the moving web of coated enamel paper with inks of a plurality of
colors;
subjecting the printed moving web of coated enamel paper to a heatset
operation;
printing the moving web of groundwood newsprint paper with at least one
color ink; and
thereafter associating the moving web of coated enamel paper and groundwood
newsprint paper in a pasting, cutting and folding operation to form a
plurality of books each comprising a front and rear cover page formed of
coated paper, pages of newsprint paper between the cover pages, and inside
pages of coated paper positioned between pages of newsprint paper with all
of the pages adhesively bound together along one longitudinal edge of the
book.
2. A method according to claim 1 wherein the heatset operation comprises
passing the moving web of coated paper through an oven and subjecting the
web to heated air during its passage through the oven.
3. A method according to claim 2 wherein the moving web leaving the oven is
subjected to a chilling operation.
4. A method according to claim 3 wherein the chilling operation comprises
passing the moving coated web over a plurality of chill rollers.
5. A method according to claim 1 wherein the moving web of coated paper is
further subjected to a perforating operation, prior to the associating
step, to provide perforations around coupon areas on the coated web.
6. A method according to claim 5 wherein the step of printing the moving
web of coated paper comprises printing coupon indicia within the coupon
areas.
7. A method according to claim 1 wherein the folding operation is performed
by a folder and the moving webs are delivered to the folder with the
coated web superposed to the newsprint web.
8. A method according to claim 7 wherein at least two moving webs of
newsprint paper are provided and the moving webs are delivered to the
folder in vertically stacked relation with the coated web on top.
9. A book comprising a plurality of pages of interspersed multi-color
coated pages and newsprint pages adhesively bound along one of their
common edges wherein each book has a front and rear cover page formed of
multi-color coated paper, each book includes pages of coated paper
interspersed between the cover pages with pages of newsprint paper, and at
least one of the pages of coated paper interspersed between the cover
pages with pages of newsprint paper includes perforations around coupons
printed on the coated paper page so as to facilitate separation of the
coupon from the coated page.
10. A book comprising a plurality of pages of interspersed multi-color
coated enamel pages and groundwood newsprint pages formed by providing a
moving web of coated enamel paper, providing a moving web of groundwood
newsprint paper, printing the moving web of coated enamel paper with inks
of a plurality of colors, printing the moving web of newsprint paper with
at least one color ink, subjecting the printed moving web of coated enamel
paper to a heatset operation, and thereafter associating the moving webs
of coated enamel paper and groundwood newsprint paper in a pasting,
folding, and cutting operation to form a plurality of books with each book
comprising a front and rear cover page formed of coated paper, pages of
newsprint paper between the cover pages, and inside pages of coated paper
positioned between pages of newsprint paper.
11. A book according to claim 10 wherein the moving web of coated paper is
further subjected to a perforating operation prior to the associating step
to provide perforations around coupon areas on the coated web.
12. A method of forming a plurality of books comprising the steps of:
providing a moving web of coated enamel paper;
providing a plurality of moving webs of groundwood newsprint paper;
printing the moving web of coated enamel paper with inks of a plurality of
colors;
subjecting the printed moving web of coated enamel paper to a heatset
operation;
printing each of the moving webs of newsprint paper with at least one color
ink;
positioning the moving webs in vertically stacked relation with the coated
web on top; and
associating the vertically stacked moving webs of coated paper and
newsprint paper in a pasting, cutting, and folding operation to form a
plurality of books each comprising a front and rear cover page formed of
coated paper, pages of newsprint paper between the cover pages, and inside
pages of coated paper positioned between pages of newsprint paper with all
of the pages adhesively bound together along one longitudinal edge of the
book.
13. A method for forming a plurality of books comprising the steps of:
providing a moving web of coated enamel paper;
providing a plurality of moving webs of groundwood newsprint paper;
subjecting the moving web of coated enamel paper to a perforating operation
to provide perforations around coupon areas on the coated web;
printing the moving web of coated enamel paper with inks of a plurality of
colors including printing coupon indicia within the coupon areas;
subjecting the printed moving web of coated enamel paper to a heatset
operation;
printing each of the moving webs of groundwood newsprint paper with at
least one color ink; and
associating the moving webs of coated enamel paper and groundwood newsprint
paper in a pasting, folding, and cutting operation to form a plurality of
books each comprising a front and rear cover page formed of coated paper,
pages of newsprint paper between the cover pages, and inside pages of
coated paper positioned between pages of newsprint paper with all of the
pages adhesively bound together along one longitudinal edge of the book
and each including detachable coupons on at least some of the coated paper
pages.
14. A method according to claim 13 wherein the perforated coupon areas are
provided on one or more of the inside pages of coated paper positioned
between pages of newsprint paper.
15. A printing apparatus comprising:
means defining a source of a web of coated enamel paper;
means defining a source of a web of groundwood newsprint paper;
means defining a folding location;
a plurality of printing units;
a heatset unit;
a chiller unit;
means defining a newsprint web path extending from the source of the
newsprint paper through one or more of the printing units and thence
directly to the folding location;
means for moving a newsprint paper web along the newsprint web path while
printing the newsprint web in at least one color;
means defining a coated paper path extending from the source of coated
paper to a plurality of printing units, thence to the heatset unit, thence
to the chiller unit, and thence to the folding location;
means for moving a coated paper web along the coated paper web path while
printing the coated paper web in a plurality of colors on the coated paper
web and thereafter passing the printed coated paper web through the
heatset unit and chiller unit to quickly dry the ink; and
associating means, including a folder, positioned at the folding location
and receiving the newsprint web and the coated paper web in superimposed
relation, operative to associate the moving webs of newsprint paper and
coated paper in a pasting, cutting, and folding operation to form a
plurality of books each comprising a front and rear cover page formed of
coated paper, pages of newsprint paper between the cover pages, and inside
pages of coated paper positioned between pages of newsprint paper.
16. An apparatus according to claim 15 wherein the apparatus further
includes a perforator and the coated paper web path extends through the
perforator.
17. An apparatus according to claim 16 wherein the perforator is positioned
in the coated paper path between the source of coated paper and the one or
more printing units through which the web of coated paper passes.
18. An apparatus according to claim 15 wherein at least two sources of
newsprint web paper are provided, each newsprint web moves from its
respective source along a separate path to the folder, and the webs arrive
at the folder in vertically stacked relation with the coated web on top.
19. An apparatus according to claim 16 wherein the perforating means
provides perforations around coupon areas on the coated web and wherein,
in each book, the coupon perforations are provided on one or more of the
inside pages of coated paper positioned between pages of newsprint paper. |
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Claims |
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Description |
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FIELD OF THE INVENTION
This invention relates to printing methods and apparatus and more
particularly to the formation of books comprising pages of coated paper
interspersed with pages of newsprint paper.
BACKGROUND OF THE INVENTION
There is a need in the printing industry to provide a cost-effective means
of providing individual books, each comprising a plurality of pages of
coated paper interspersed with a plurality of pages of newsprint paper.
Such a book may comprise for example a TV book provided in association
with a newspaper. It is desirable in such a book to have several pages of
coated paper included in the book to accommodate and attract advertisers
desiring glossy, multicolor advertising entries. In the past these books
have been provided by separately printing, folding, and cutting one or
more coated webs, placing the coated products in inventory, separately
printing, folding, and cutting one or more newsprint webs, placing the
newsprint products in inventory, and thereafter, at a convenient time and
place, bringing the coated and newsprint products together in a stapling
operation to provide the final book. This separate printing of the coated
and newsprint webs, followed by the final stapling of the coated and
newsprint products together to form the book, is extremely expensive and
time-consuming.
SUMMARY OF THE INVENTION
This invention is directed to the provision of an improved method and
apparatus for forming books comprising pages of coated paper interspersed
with pages of newsprint paper.
This invention is further directed to the provision of an improved method
and apparatus for forming books containing pages of coated paper
interspersed with pages of newsprint paper and further providing
perforations on the interior coated pages of the book to facilitate the
removal of coupons from the book.
According to the invention method, a moving web of coated paper is
provided, a moving web of newsprint paper is provided, the moving web of
coated paper is printed with multi-colored inks, the moving web of
newsprint paper is printed with at least one color ink, and the moving
webs of coated paper and newsprint paper are associated in a pasting,
folding, and cutting operation to form a plurality of book, each
comprising a plurality of pages of coated paper interspersed with a
plurality of pages of newsprint paper and adhesively bound together along
one longitudinal edge of the book. This method provides a simple and
efficient means of providing a book including interspersed pages of coated
and newsprint paper.
According to a further feature of the invention, at least two moving webs
of newsprint paper are provided and the moving webs are delivered to the
folder in vertically stacked relation with the coated web on top. This
method provides a simple and efficient means of providing a booklet such
as a television guide provided in association with a newspaper.
According to a further feature of the invention, each book has a front and
rear cover page formed of coated paper and each book includes pages of
coated paper interspersed between the cover pages with pages of newsprint
paper. This arrangement provides attractive front and rear cover pages and
further provides a plurality of coated pages within the book to facilitate
advertising.
According to a further feature of the invention process, the moving web of
coated paper is subjected to a heatset operation following the printing
step and prior to the associating step. This methodology allows the moving
web of coated paper to be immediately associated with the moving web of
newsprint paper to facilitate the rapid and efficient production of the
books.
According to a further feature of the invention process, the moving web of
coated paper is further subjected to a perforating operation prior to the
associating step to provide perforations around coupon areas on the coated
web. This methodology further enhances the advertising appeal of the book.
The invention apparatus includes a source of a coated paper web, a source
of a newsprint paper web, a plurality of printing units, a folder, a
heatset unit, means defining a newsprint web path extending from the
newsprint web source and through one or more printing units to the folder,
and means defining a coated paper web path extending from the coated web
source through one or more printing units, through the heatset unit, and
thence to the folder for association with the moving web of newsprint
paper.
According to a further feature of the invention apparatus, the moving web
of coated paper is delivered to the folder in superimposed relation to the
moving web of newsprint paper so as to facilitate provision of front and
rear cover pages of the book of coated paper.
According to a further feature of the invention apparatus, the apparatus
further includes a perforating unit and the moving web of coated paper is
passed through the perforating unit to define perforations around coupon
areas on the coated web. In the disclosed embodiment of the invention, the
perforating unit precedes the printing unit for the coated web so that the
perforating unit provides perforations around coupon areas on the coated
web whereafter the printing unit prints coupon indicia within the coupon
areas defined by the perforations.
The invention further defines a book comprising a plurality of pages of
interspersed multicolor coated pages and newsprint pages adhesively bound
along one of their common edges. In the disclosed embodiment, the book
comprises front and rear cover pages formed of coated paper and each book
further includes a plurality of pages of coated paper interspersed between
the cover pages with pages of newsprint paper.
According to a further feature of the invention book, at least one of the
coated pages within the book is provided with perforated coupons to
facilitate the ready detachment of the coupons from the book.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a somewhat schematic side elevational view of the invention
printing apparatus;
FIGS. 1A and 1B are fragmentary views of a coated web of paper moving
through the invention printing apparatus;
FIG. 2 is a somewhat schematic plan view of the invention printing
apparatus;
FIGS. 3 and 4 are fragmentary views of a folding unit employed in the
invention printing apparatus;
FIGS. 5 and 6 are views of a book produced in accordance with the method
and apparatus of the invention;
FIG. 7 is a perspective fragmentary view of a dryer unit employed in the
invention printing apparatus; and
FIGS. 8 and 9 are fragmentary views of alternate web configurations.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention printing apparatus, broadly considered, includes web roll
support stands 10, 12, 14, and 16; a perforating unit 18; printing units
20, 22, and 23; a dryer or heatset unit 24; a folder 26; and a trimmer 28.
A web roll 30 of coated paper is supported on web roll support stand 10;
web rolls 32, 34, and 36 of newsprint paper are supported respectively on
web roll support stands 12, 14, and 16; and a plurality of guide rollers
40 are provided to define the paths of the various webs as they move
through the invention printing apparatus.
Web roll 30 may comprise, for example, a 34 inch wide web of 40 lb. No. 5
coated enamel groundwood paper and newsprint rolls 32, 34, and 36 may
comprise 34 inch wide web rolls of 30 lb. groundwood newsprint.
Perforating unit 18 includes a housing 18a, a perforating roller 18b, and a
backing roller 18c.
Printing unit 20 may comprise a "four-high" including a housing 20a and
four vertically stacked printing couples 20b, 20c, 20d, and 20e. Printing
unit 20 is preferably of the offset type.
Printing unit 22 may also be of the "four-high" offset type and includes a
housing 22a and vertically stacked printing couples 22b, 22c, 22d, and
22e.
Heatset unit 24 includes a housing 24a, a plurality of sets of opposed
nozzles 24b, 24c, 24d, and 24e, a source of hot air 24f, and a chill unit
24g including a plurality of chill rolls 24h. Heat source 24f may include
an open gas flame providing heated air and a blower arranged to deliver
the heated air to the nozzles 24b. Each chill roll 24h is hollow and is
arranged to have refrigerant passed end to end through the chill roll in a
closed loop manner with the refrigerant leaving one end of each chill roll
and passing to a refrigeration unit 24i where it is cooled for resupply to
the other end of the chill roll.
Folder 26 includes a housing and frame structure 50; a former 52; a
roller-top-of-former 54; a pressure roller 56; adhesive nozzles 58;
point-of-former rollers 60; nipper rollers 62; a cross-perforating roller
64 coacting with a backing roller 66; a cutting cylinder 68; a half-fold
jaw cylinder 70; a rotary brush 72; a delivery board 74; a quarter folder
76; a delivery fly 78; and delivery belts 80.
Trimmer 28 is shown only schematically and includes an in-feed conveyor 90,
a right angle transition conveyor 92, and trimming knives 94, 96, and 98.
The path of the coated web through the invention printing apparatus,
broadly considered, extends from the coated web roll to the perforating
unit 18 to the printing unit 20, to the heatset unit 24, to the folder 26,
and thence to the trimmer 28. Specifically, coated web 30 extends from the
coated web roll over guide rollers 40 and enters the perforating unit 18
where it passes upwardly through cylinders 18b and 18c to receive
perforations on selected portions of the web; the web thereafter passes
upwardly out of the perforating unit and around several guide rollers 40
to enter the lower end of printing unit 20 where it passes upwardly
through the four printing couples 20b, 20c, 20d, and 20e to receive four
different color impressions from the respective four couples; the web
thereafter passes upwardly out of the printing unit and over guide rollers
40 and then downwardly into the heatset unit 24 where it is initially
exposed to the nozzles 24b supplied with hot drying air from the heater
unit 24f to heat the web and the ink lying on the coated surfaces of the
web whereafter the roll passes downwardly over the chill rollers 24h where
it is chilled to set the ink on the coated surface of the webs; the web
thereafter leaves the lower end of the heatset unit and passes around
guide rollers 40 and thence upwardly for entry into the folder 26
whereafter, after passage through the folder, the web is delivered to the
trimmer 28 for suitable trimming operations.
The path of the newsprint web 32 through the invention apparatus, broadly
considered, extends from the newsprint roll 32, through printing unit 22,
through the folder 26, and thence to the trimmer 28. Specifically,
newsprint web 32 extends from the roll around guide rollers 40 into the
mid section of printing unit 22 where it passes upwardly through printing
couples 22d and 22e to receive a black ink and a colored ink, whereafter
the web leaves the upper end of the printing unit 22 and passes around
guide roller 40 along a path extending downwardly and then beneath the
folder 26 and then upwardly into the entry of the folder 26 for passage
through the folder and thence to the trimmer 28.
The path of web 34 extends from roll stand 14, around suitable rollers 40
and into the lower end of the printing unit where it passes upwardly
through printing couples 22b and 22c to receive a black ink and a colored
ink, respectively, whereafter it passes out of the printing unit 22 and
downwardly for passage beneath the folder 26 and thereafter moves upwardly
for entry into the folder and passage through the folder to the trimmer
28.
Newsprint web 36 extends from roll stand 16 upwardly through the printing
couple 23a of printing unit 23 where it receives a black ink whereafter
the web passes upwardly out of the printing unit and then downwardly for
passage beneath the folder 26 whereafter it moves upwardly for entry into
the folder and passage through the folder to the trimmer.
The webs 30, 32, 34, and 36 arrive at the entry to the folder in vertically
stacked relation with the coated web 30 on top. As the superposed webs
approach the top of former roller 54, each of the newsprint webs 32, 34,
and 36 passes beneath two laterally spaced spray nozzles 58 which, as best
seen in FIG. 3 and FIG. 1B, act to apply an adhesive or paste along
longitudinal lines 58a on the respective webs. Page lines 58a are each
spaced equidistant from the centerline of the web and a respective side
edge of the web.
The superposed webs immediately thereafter pass between the former roller
54 and the pressure roller 56 where the webs are glued together along the
glue lines 58a, whereafter the webs pass downwardly over the former 52. As
the webs reach the nose 52a of the former, a first fold is made in the
product along the longitudinal centerline of the webs. The rollers 60
guide the webs over the former nose and help to form the fold whereafter
the folded webs travel between the nipping rollers 62 which put a sharp
crease in the first fold. As the webs move downwardly from the triangular
edges of the former to the rollers 60, a further spray nozzle 58
positioned beneath the former 52 between the two sides of the webs serves
to apply a further adhesive line 58b to one of the inner web surfaces
formed as the web is folded around the edges of the former. After the
folded web leaves roller 62 it passes through cross-perforating roller 64
and receives a further adhesive line 58c from a further spray nozzle 58,
whereafter it passes downwardly between cutting cylinder 68 and half jaw
cylinder 70 where a tucker blade on the cutting cylinder coacts in known
manner with movable and stationary jaws on the half fold cylinder to tuck
or fold the web, whereafter with further relative rotation of cylinders 68
and 70, the cylinders coact in known manner to cut the web and form a book
100 which is thereafter, in coaction with fingers carried on the rear edge
of the delivery board 74, passed upwardly between the rear edge of the
delivery board and the roller 72 for passage on the board 74 to the
quarter folder 76 which rotates in known manner and acts to put a final
fold in the book, whereafter the book passes downwardly through an opening
in the board 74 for delivery to fly 78 which deposits the book onto belt
80 which delivers the book to the delivery end of the folder. Folder 26
may for example comprise a Rockwell-Goss SSC Folder available from the
Graphic Systems Division of Rockwell International of Chicago, Ill.
As the book leaves the delivery end of the folder, it is deposited on
conveyor 90 of trimmer 28 and moved past cutter 94 which trims the face of
the book, whereafter the book is deposited onto right angle conveyor 92
where it passes between trimmers 96 and 98 which respectively trim the
head and foot of the book, whereafter the completed book is deposited in a
suitable collection receptacle. Trimmer 28 may for example comprise a
Model AGT 100 Series Trimmer available from AGE Corporation of York, Pa.
The completed book 100, as best seen in FIGS. 5 and 6, includes eight
sheets, or sixteen pages, formed from the coated web interspersed between
a plurality of sheets and pages formed from the various newsprint webs.
Specifically, the book includes a front cover FC formed of coated paper; a
back cover BC formed of coated paper; two centerfold sheets CF formed of
coated paper; and inside sheets I formed of coated paper. The inside
sheets I are positioned midway between the front cover and the respective
centerfold sheet and the rear cover and the respective centerfold sheet
with newsprint NP in between so that the book comprises a plurality of
sheets of coated paper interspersed with a plurality of sheets of
newsprint paper and adhesively bound together along one longitudinal edge
100a of the book.
In addition to providing a book comprising a plurality of sheet of
multicolor coated paper and a plurality of sheets of newsprint paper
adhesively bound along a common longitudinal edge, the invention further
enables the ready and selective provision of detachable coupons C on any
or all of the pages of the sheets of coated paper. For example, with
reference to FIGS. 1A and 5, the perforating unit 18 may be arranged such
that a series of pizza coupons PC are provided on one of the pages of one
of the centerfold sheets and a series of chicken coupons CC are provided
on an opposing page of the other centerfold sheet. As seen in FIG. 1A,
perforating roll 18b is configured to perforate the coated web passing
thereby in a manner to provide four vertically stacked pizza coupon
perforation outlined in a area of the web that will ultimately become one
of the centerfold pages and to provide a series of perforations outlining
a plurality of chicken coupons CC on the area of the web that will
ultimately become the opposing centerfold page of the final book.
Obviously, the perforating cylinder 18b may be arranged to provide
perforated coupon areas at any of the areas of the coated web passing
therebetween (including the areas BC, FC, CF, CF, III, and I) but it would
ordinarily not be desirable to provide perforation areas on the area that
will become the front cover to avoid defacing the front cover upon
detachment of the coupons. It will of course be understood that the
printing couples 20b, 20c, 20d, and 20e are arranged so as to print single
color or multicolor coupon indicia within the areas outlined by the
perforating roller 18b so as to provide the desired color and information
within each coupon area outlined by the perforating roller.
Although the invention has been illustrated and described utilizing a
coated web 30 having a width (for example 34 inches) equal to the width of
the newsprint webs, the invention also has applicability to combinations
wherein the coated web has a width less than the width of the newsprint.
For example, as seen in FIG. 8, the invention method may be carrying out
utilizing a coated web 30 having a width of 17 inches or half the width of
the newsprint webs 32, 34, and 36 or, as seen in FIG. 9, having a width of
251/2 inches or three-quarters the width of the newsprint webs 32, 34, and
36.
In the case of the half width web, as seen in FIG. 8, the coated web is
positioned with one longitudinal edge in alignment with one longitudinal
edge of the newsprint webs so that the other longitudinal edge of the
coated web coincides with the centerline of the newsprint webs and in the
case of the three-quarter width coated web, as seen in FIG. 9, the one
longitudinal edge of the coated web is aligned with one longitudinal edge
of the newsprint webs and the other longitudinal edge of the coated web is
positioned midway between the centerline of the newsprint webs and the
other longitudinal edge of the newsprint webs. It will be understood that
the arrangement seen in FIG. 8 will produce a book having four sheets, or
eight pages, formed of the coated paper, including the front and back
covers and the centerfold, and that the arrangement of FIG. 8 will produce
a book having six sheets of 12 pages of coated paper including the front
and back cover, the centerfold, and two additional coated sheets
positioned half way between the centerfold and either the front or rear
cover.
The invention will be seen to provide a method and apparatus for producing
a booklet of interspersed coated pages and newsprint pages in a
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