The present invention is in the field of preparation of books and printed materials, and specifically in the field of binding the pages of a book.
Books, when opened, do not lay flat. The pages form a curve on either side of the opened page. Because of this curvature, book readers will have to move their head to see the printed content beyond the curvature. The curvature, therefore, creates annoyance for the reader, specially in situations when the reader is sharing the contents of the book with others. Therefore, there is a need in the art for a binding for books that allows the book to lay flat when opened.
In one aspect, disclosed herein is a method of producing a book, comprising: obtaining a plurality of pages having a first page, a second page, a penultimate page, a last page, a top edge, a bottom edge, a turning edge, and a spine edge, wherein the plurality of pages form a stack of pages glued together at the spine edge of the stack of pages; placing a rod between the first page and the second page of the plurality of pages; positioning the rod parallel to the spine edge and at a first distance away from the spine edge; and forming a fold on the first page at both sides of the rod, the fold running from the top edge to the bottom edge.
In another aspect, disclosed herein is a method of producing a stack of pages, comprising a) obtaining a plurality of sheets of paper, wherein each sheet of paper is twice as wide as a page of the plurality of pages; b) printing content on a front side of each of the plurality of sheets of paper; c) folding each of the plurality of sheets of paper in half to obtain a plurality of folded sheets of paper, such that the front side of one half of a folded sheet of paper faces the front side of the second half of the same folded sheet of paper; d) gluing the back side of a first folded sheet of paper to the back side of a second folded sheet of paper to obtain a stack of folded sheets of paper; e) gluing the back side of another folded sheet of paper to the back side of the top sheet in the stack of folded sheets of paper; and f) repeating step e) for the remainder of the plurality of the folded sheets of paper.
In yet another aspect, disclosed herein is a bound book, comprising a first page, a last page, and a plurality of pages therebetween; a front channel between the first page and the plurality of pages; and a back channel between the last page and the plurality of pages.
In another aspect, disclosed herein is a stacker, comprising a baseboard; a plurality of page-positioning means; and an adjustable bar.
In the drawings, like reference characters generally refer to the same parts throughout the different views. It will be appreciated that the drawings are not necessarily to scale, with emphasis instead being placed on illustrating the various aspects and features of embodiments of the invention, in which:
Embodiments of the invention are described below. It is, however, expressly noted that the invention is not limited to these embodiments, which are shown for purposes of illustration and not limitation.
The following definitions apply throughout the present disclosure. Each piece of paper has four edges and two sides. The “spine edge” is the edge of the paper that is glued in the binding. The “turning edge” is the edge of the paper opposite the spine edge, where a reader grabs the paper to turn the page while reading the book. The “top edge” is the top of the page, while the “bottom edge” is the bottom of the page. In some embodiments described herein, a printed paper is folded in half to form two pages of the book. In these embodiments, the paper is folded along a straight line running from the top edge to the bottom edge along the center of the unfolded paper. Once folded, the folded line becomes the spine edge. The two edges of the unfolded paper that do not connect with the straight line become the turning edges of the two resulting pages. The “front side” is the surface of the paper that is printed. The “back side” is the surface of the paper that is not printed. In the embodiments where the paper is folded, it is folded such that the front side is on the inside, i.e., the resulting two printed surfaces face each other. Once a plurality of pages are put together in a stack or block, the collective spine edges form the “spine” of the stack or block.
In the first aspect, disclosed herein is a multi-positional stacker, also referred to as a multi-positional adhesive stacker, comprising a baseboard, a plurality of page-positioning means, and an adjustable bar. The multi-positional stacker serves to hold all the pages that will be bound in a book stacked straight.
In some embodiments, such as the one depicted in
The stacker 102 also comprises an adjustable bar 108. At least one positioning rod 112 connects the adjustable bar 108 to the positioning means 110. The positioning means 110 can be a screw, a grip, a friction lock, a snap lock, a wing nut, and the like. When the positioning means 110 is loose, it allows the rod 112, and therefore the bar 108, to move in the directions shown by arrows 114 and 116. But when the positioning means 110 is tightened over the positioning rod 112, the bar 108 is held in place.
In some embodiments, such as the one depicted in
The pegs 106 and the bar 108 form three sides of a the interior volume of the stacker 102, into which papers are placed to be stacked. The adjustable bar 108 preferably has a flat surface at the side facing the interior volume of the stacker 102, which flat surface is perpendicular to the top surface of the baseboard 104.
In some embodiments, such as the one depicted in
In other embodiments, the page-positioning means comprises a combination of pegs and a bar. In these embodiments, one of the two perpendicular lines formed by the page-positioning means comprises pegs while the other of the two perpendicular lines is a bar.
Other aspects of the present invention are directed to methods of preparing the pages of a book and binding them, so that when the book is opened, it lies flat.
In certain embodiments, the content of the book, e.g., the text or pictures, is printed on a plurality of sheets of paper. In some embodiments, the content is printed using a laser printer. In other embodiments, the content is printed using an inkjet printer. In further embodiments, the content is printed using a commercial industrial printer commonly used for printing books.
In some embodiments, the width of the sheet of paper is the same as the width of a page in the book. In other embodiments, the width of the sheet of paper is twice the width of a page in the book. The sheet of paper can be of any size, material, or quality. In some embodiments, the sheet of paper is made up of such material that prevents glue from soaking through the paper from one side to the other. In certain embodiments, the sheet of paper is suitable for use in an inkjet printer. Examples of inkjet paper include, but are not limited to, matte paper, heavy matte paper, glossy paper, high gloss paper, luster paper, premium luster paper, premium matte, polar matte, hot press rag, cotton etching, textured fine art, air dried fibre matte air dried fibre, photo rag 188 gsm, Fine art bright 190 gsm and fine art natural 190 gsm. In some of these embodiments, the paper is a premium luster inkjet paper. Paper from several manufacturers, such as Epson Paper Company, Red River Paper Company, Moab Paper Company and Lexjet Paper Company, can be used.
In some embodiments, the printed sheets of paper are allowed to dry for a period of time, ranging from a few minutes to several hours, before proceeding with subsequent steps. However, in other embodiments, drying is not necessary.
In some embodiments, for example when photos are printed on the sheets of paper, the sheets of paper are coated with a protective coating. The protective coating can prevent scratching or from the color to fade. In other embodiments, the coating prevents light from reflecting from the pages of the book, and thus, the coating prevents glare, thereby allowing a more comfortable viewing of the contents.
In certain embodiments, the sheets of paper are coated using an automated liquid laminator. Examples of liquid laminators include, but are not limited to, the Accu-18XE liquid laminator (Neschen Accutech, Elkridge, Md.), the AquaSeal™ AS1600 liquid laminator (Bulldog Products, Anaheim, Calif.), Daige EZ-Glide 55 liquid laminator (Machine Runner, Inc., New York, N.Y.), the StarLam 1.6 SF (Clearstar Coatings Corp., Isle of Palms, S.C.), and other similar devices. Examples of protective coating for use with the methods described herein include, but are not limited to, Acculac 1400C, Bulldog Ultra coatings, ClearShield®, ClearJet®, and other similar coatings.
In some embodiments, when the width of the sheet of paper is twice the width of a page in the book, the printed sheet of paper is scored in the middle to allow easy folding of the sheet of paper in half. In certain embodiments, the sheet of paper is scored with a scoring machine, whereas in other embodiments, the sheet of paper is scored by hand using a sharp object. In certain embodiments, the sheet of paper is scored on the back side, i.e., on the side that is not printed. In other embodiments, the sheet of paper is scored on the front side, i.e., on the side that is printed.
Once the sheets of paper are scored, each sheet of paper is folded in half along the scored line so that the two printed sides face each other. In some embodiments, as shown in
In some embodiments, the strip of paper 204 is between about 1 inch to about 3 inches wide. In certain embodiments, the strip of paper 204 is about 2 inches wide.
In some embodiments, when the width of the sheet of paper is the same as the width of a page in the book, the sheet of paper are not scored and the spine edge is covered with a strip of reinforcing paper. In these embodiments, the length of the reinforcing paper runs from the top edge to the bottom edge of the sheet of paper. As shown in
Once each individual sheet of paper is folded and is ready for binding, the last page of the book is placed in the multi-positional adhesive stacker 102, as shown in
In some embodiments, the moisture absorbing paper 308 is a sheet of 175 gsm/259.0 M domestic etching paper. In certain embodiments, the moisture absorbing paper 308 is white, while in other embodiments, the moisture absorbing paper 308 is off white. In further embodiments, the color of the moisture absorbing paper 308 matches the color of the printed paper.
After the glued moisture absorbing paper 308 is placed on the first sheet of paper 202 in the multi-positional adhesive stacker 102, glue is applied to the next sheet of paper or folded sheet of paper 310, either manually or using an automated device, and the sheet of paper 310 is placed on top of the moisture absorbing paper 308 in the multi-positional adhesive stacker 102. Then glue is applied to another moisture absorbing paper, which is then placed on top of the second sheet of paper 310. This process is continued until the last page is glued and placed in the multi-positional adhesive stacker. Throughout this process, the adjustable bar 108 of the stacker 102 is adjusted to ensure that the papers are all stacked straight one on top of another, and that the turning, spine, and bottom edges of the stack each forms a flat surface.
Thus, at this stage, as shown in
Once all the pages are glued and placed in a stack, the block of glued pages is removed from the multi-positional adhesive stacker and placed in a binding press. The pages are pressed together for a period of time until the glue is dried and the pages are firmly stuck together. In some embodiments, the block of pages is pressed for a few hours. In certain embodiments, the block of pages is pressed for more than 6 hours. In other embodiments, the block of pages is pressed for more than 10 hours. In yet other embodiments, the block of pages is pressed for 12 hours. In still other embodiments, the block of pages is pressed for longer than 12 hours.
In some embodiments, prior to pressing the block of pages, a sheet of paper is placed between each page, thus preventing the printed material to contact each other during the pressing. The placement of the paper also prevents ink or glue to transfer between the pages. In some embodiments, the sheet of paper is of a material impermeable to ink and glue. In certain embodiments, the sheet of paper is wax paper. In other embodiments, the sheet of paper is wf-12 PaperCon Heavyweight interfold delicatessen paper, herein referred to as innerwrap.
After the pressing is complete, in some embodiments, the spine of the block of pages, is covered with another sheet of paper. In some embodiments, as shown in
The pages in the block are then trimmed in a pre-trim step on all sides, excluding the spine side. In some embodiments, the pre-trim step precedes the addition of the sheet of paper 402, described above. In other embodiments, the pre-trim step follows the addition of the sheet of paper 402. Enough of the paper is trimmed so that the edges of the top, turning, and bottom edges are smooth and even. In some embodiments, only a fraction of an inch is trimmed from the sides. In some of these embodiments, 0.25 inch is trimmed. In other embodiments, more than 0.25 inch is trimmed, while in yet other embodiments less then 0.25 inch is trimmed. In some embodiments, a mechanical trimmer is used. Examples of mechanical trimmers include, but are not limited to Triumph 3600, Triumph 3905, Triumph 3915, Triumph 4700, Triumph 4810, Triumph 4850, Triumph 4850-EP, Triumph 5221-95, Triumph 5550, Triumph 6550, Triumph 6550-EC, Triumph 6550-EP, Titan 200, Titan 265, Champion 305, Champion 370, Challenge Model 20, and Challenge 305 CRT.
In some embodiments, the book produced by the methods disclosed herein features two channels adjacent to the first and last pages, respectively.
In another aspect, disclosed herein is a method of creating channels on the first and last pages of a book. As shown in
In some embodiments, the rod 602 has a circular cross section. In other embodiments, the rod 602 has a triangular cross section. In yet other embodiments, the rod 602 has a square or rectangular cross section. Rods having other geometric cross sections, such as elliptical, rhomboid, or polygonal (pentagonal, hexagonal, heptagonal, or octagonal) can also be used with the methods described herein.
In certain embodiments, the rod 602 is a steel rod. In other embodiments, the rod 602 is made of other metals, such as aluminum, copper and the like. In some embodiments, the rod 602 is wooden. In yet other embodiments, the rod 602 is plastic.
In some embodiments, the cross sectional diameter of the rod 602 is less than one inch. In other embodiments, the cross sectional diameter of the rod 602 is less than or equal to 0.5 inch. In other embodiments, the cross sectional diameter of the rod 602 is less than or equal to 0.25 inch. In other embodiments, the cross sectional diameter of the rod 602 is less than or equal to 0.125 inch. In some embodiments, the cross sectional diameter of the rod 602 is 0.125 inch.
In some embodiments, the distance 610 is less than one inch. In other embodiments, the distance 610 is less than 0.5 inch. In other embodiments, the distance 610 is less than 0.25 inch. In other embodiments, the distance 610 is less than 0.125 inch. In other embodiments, the distance 610 is 0.25 inch.
In some embodiments, the fold 614 on either side of the rod is made by running an object with a sharp point along the side of the rod 602 from one of the top or bottom side to the other of the top or bottom side. In some embodiments, the object with a sharp point is a bone folder. In other embodiments, the object is a knife. A quality of the sharp object is that while it creates a fold in the paper it does not tear the paper when appropriate pressure is applied.
After the channels are created, the book is covered. In some embodiments, the resulting book is a hardcover book. In certain embodiments, methods of applying a hardcover to a book known in the art now, or later developed, can be used. However, some hard covers conventionally used warp over time. Therefore, in some embodiments, two one ply boards are glued together to form the hardcover, with the grains running cross each other, e.g., the grain of one board runs north/south while the grain of the other board runs east/west. The boards can be cardboard, wood, or plastic. In some embodiments, the resulting two-ply board is covered with thick paper to increase its strength. The thick paper can be a drafting paper.
The boards are then cut to the appropriate size for the book, pre-glued and placed in the appropriate location in a case-making gauge. In some embodiments, a one ply board is placed in the exact location for the spine in a case-making gauge. This provides extra rigidity for the book and allows each page spread to open and lay flat. The glue is then allowed to dry for a period of time, such as 12 hours, or whatever length of time that is appropriate.
The first and last pages are then glued to the cover, while the rest of the pages are held perpendicular to the cover. Each respective channel is pressed onto the inside of the book cover using a sharp object, such as a bone folder. In some embodiments, the channel is not glued to the book cover.
The book is then closed and the book assembly (comprising covers, block of page spreads, and interfolded innerwrap sheets) is pressed for a period of time, such as 12 hours. Once the pressing period is complete, the book assembly is removed from the press and the innerwrap sheets are removed from between the pages.
The invention may be embodied in other specific forms besides and beyond those described herein. The foregoing embodiments are therefore to be considered in all respects illustrative rather than limiting, and the scope of the invention is defined and limited only by the appended claims and their equivalents, rather than by the foregoing description.
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Number | Date | Country | |
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20070296199 A1 | Dec 2007 | US |