Abstract: Media binder systems with datum stops for registering physical media sheets are described. A media binder system that includes a cover, a binding system, and a datum stop. The cover includes an outwardly facing side and an inwardly facing side. The binding system is attached to the inwardly facing side of the cover and is operable to bind a spine end of a collection of physical media sheets to the cover. The datum stop protrudes away from the inwardly facing side of the cover and includes a datum stop surface against which a head end or a tail end of the collection is registerable prior to binding the collection to the cover. Methods of making media binder systems also are described.

Abstract: A method for aligning print media on a feedpath includes the steps of: aligning a sheet of print media using a deskew mechanism; measuring the skew of the sheet after it has been aligned; and comparing the measured skew with a specified skew, and if the measured value is greater than the specified value, reversing the sheet through the deskew mechanism followed by repeating the aligning, measuring and comparing steps. An apparatus for implementing alignment of print media on a feedpath comprises a deskew mechanism and sensors positioned downstream on the feedpath from the deskew mechanism to provide data sufficient to calculate the skew of the sheet.

Abstract: A sheet material trimming apparatus and method are described which are suitable for use in a booklet making system. An exemplary apparatus includes at least one cutter for trimming a first and a second edge of a sheet material in a first and a second direction, and a drive system for moving the sheet material in two perpendicular directions for trimming the first and second edges with the at least one cutter. The drive system moves the sheet material in two perpendicular directions by rotating and translating a roller. The sheet material trimming apparatus allows for automatic changes in the amount of material cut off each side of the sheet material by moving the sheet material in two directions without requiring repositioning of the cutter(s).

Abstract: Method and apparatus for assembling sheets of printing media for booklets. In one aspect the sheets are folded, sheet-by-sheet, and in another aspect the sheets are collected, sheet-by-sheet, and registered on a fold in each sheet. In still another aspect printed sheets are loaded, sheet-by-sheet, into the apparatus. Each sheet is trimmed to a pre-determined width depending on the position of the sheet in the booklet being assembled. The sheets are thereafter folded, sheet-by-sheet, and collected into a stack. The method and apparatus have particular application in finishing duplex printed sheets of paper into saddle-stitched booklets.

Abstract: A sheet folding and trimming apparatus for a booklet maker or bookbinder includes a folding apparatus and a sheetwise trimming apparatus configured to trim the folded sheet from the folding apparatus on three unfolded sides of the sheet in a sheetwise manner. The location of the sheet folder prior to the sheet trimmer allows the use of a relatively imprecise and inexpensive folding apparatus, such as a buckle folder, and adjusts for the imprecision of the fold by trimming the folded sheet.

Abstract: A booklet maker, including a pivotable collecting device including two supporting sides formed as a saddle shape, and a rotatable transferring device including a displaceable clamping component, where the transferring device delivers a folded sheet material to the collecting device along a non-linear path, and where the collecting device pivots to receive the folded sheet material from the transferring device such that different portions of the folded sheet material are supported by different sides of the two supporting sides of the collecting device.

Abstract: A sheet folding and accumulation system and method inverts folded sheets onto a saddle where the sheets are accumulated and bound into a booklet. The inverting of the sheets onto the saddle for accumulation and binding eliminates the need for the saddle or other sheet collection member to translate or pivot for location of the sheets onto the saddle. A sheet folding and accumulation system includes a folding mechanism configured to form a fold in a sheet, a saddle for collecting folded sheets into a booklet for binding, and an inverting mechanism for inverting the folded sheet and placing the folded sheet onto the saddle with the peak of the fold in the sheet pointing upward.

Abstract: Method and apparatus for assembling sheets of printing media for booklets. In one aspect the sheets are folded, sheet-by-sheet, and in another aspect the sheets are collected, sheet-by-sheet, and registered on a fold in each sheet. In still another aspect printed sheets are loaded, sheet-by-sheet, into the apparatus. Each sheet is trimmed to a pre-determined width depending on the position of the sheet in the booklet being assembled. The sheets are thereafter folded, sheet-by-sheet, and collected into a stack. The method and apparatus have particular application in finishing duplex printed sheets of paper into saddle-stitched booklets.

Abstract: Systems and methods for binding a text body are described. A multi-function sheet binder is configured to heat a preformed solid hot melt adhesive to a melting temperature, form the melted adhesive by pressing the melted adhesive into a spine of a text body and folding down edges of the melted adhesive into contact with the text body, and actively cool the formed adhesive. A spot heater is configured to heat one or more localized areas of a solid hot melt adhesive to a temperature sufficient to tack the hot melt adhesive to a text body spine. An adhesive former is configured to press a localized region of a preformed heated solid hot melt adhesive into a spine of a text body and to fold down edge regions of the preformed solid hot melt adhesive into contact with the text body.

Abstract: A pivotable collecting device for handling a folded sheet material, including a supporting edge for supporting a fold of the folded sheet material, two supporting sides opposing one another, and means for pivoting the supporting edge and supporting sides about a first axis to receive the folded sheet material such that each supporting side receives a different portion of the folded sheet material, where the supporting sides converge at the supporting edge, and where the first axis is parallel to a longitudinal axis of the supporting edge.

Abstract: A system for handling folded sheet material, including a rotatable clamping device including a linearly displaceable clamping component, and a collecting device shaped substantially as a saddle, where the rotatable clamping device is configured to simultaneously encompass opposing sides of the collecting device.

Abstract: The system and method for binding documents as described creates documents having features such as tabs, finger indexes, tear-out cards, and windows. These features are desirable for both their appearance and functionality and are easily added to a document during sheet-by-sheet processing. A sheet-wise binding system includes a sheet transport path for transporting a plurality of printed sheets in a sheet-wise manner and a punch configured to punch a feature into at least one of the sheets traveling through the sheet transport path. A stacking system is provided for stacking the punched and unpunched sheets and a binding system for binding the stacked sheets is used to form a finished document. A controller is programed to control the sheet transport path and the punch to create the features in selected sheets and at selected locations in the sheets according to a punch schedule.

Abstract: An apparatus for folding sheet material, including a fold blade having a rounded folding surface, a fold roller, and drive means for moving at least one of the fold blade and the fold roller into operable communication such that the fold roller passes around or along the rounded folding surface.

Abstract: A sheet folding apparatus is described including a fold blade, a clamp movable to engage the fold blade, and a fold blade receptacle having two flexible spring members. The flexible spring members are biased toward one another by preloading material of the spring members. The fold blade and fold blade receptacle are movable toward one another to fold a sheet of material.

Abstract: A system for folding sheet material is provided, including a fold blade, two fold components biased toward one another, and first drive means for moving at least one of the fold blade and the two fold components to position the fold blade between the two fold components and thereby displace the two components away from one another, where the two fold components are mounted on different support elements.

Abstract: Systems and methods for registering a cover with respect to a text body to create bound documents with floating and attached spines are described. In one embodiment, a text body having a front end, two opposed side ends, and a spine end that is located opposite to the front end is formed from two or more sheets, and a single-piece cover is registered with respect to at least one end of the text body.

Abstract: An apparatus for folding sheet material, including a fold blade, two fold rollers, a pinch foot for clamping against the fold blade, and drive means for moving at least one of the fold blade and the fold rollers into operable communication with one another, where each of the fold rollers rotates about an axis parallel to a longitudinal axis of the fold blade.

Abstract: A sheet folding apparatus is described including a fold blade, a clamp movable to engage the fold blade, and a fold blade receptacle having two flexible spring members. The flexible spring members are biased toward one another by preloading material of the spring members. The fold blade and fold blade receptacle are movable toward one another to fold a sheet of material.

Abstract: A method for aligning print media on a feedpath includes the steps of: aligning a sheet of print media using a deskew mechanism; measuring the skew of the sheet after it has been aligned; and comparing the measured skew with a specified skew, and if the measured value is greater than the specified value, reversing the sheet through the deskew mechanism followed by repeating the aligning, measuring and comparing steps. An apparatus for implementing alignment of print media on a feedpath comprises a deskew mechanism and sensors positioned downstream on the feedpath from the deskew mechanism to provide data sufficient to calculate the skew of the sheet.

Abstract: Systems and methods for attaching a cover to a text body to create bound documents with floating and attached spines are described. In some embodiments, a solid pressure sensitive adhesive film is applied between a cover and the side hinge areas of a text body, and a cover is bound to the side hinge areas of the text body with pressure. A solid pressure sensitive adhesive tape may be dispensed from an adhesive dispenser that includes a plug-in cartridge housing, a supply spool, and a take-up spool. In other embodiments, an adhesive sheet that includes a hot melt adhesive film and a backing is applied to the text body, with the hot melt adhesive film in contact with the side hinge areas and the spine of the text body. The hot melt adhesive is exposed in areas corresponding to the side hinge areas of the text body for attaching the cover to the text body.