Document binder with cover pocket for custom title sheet

A document binder is formed with front and back covers hinged together in articulated fashion with a spine located therebetween. An overlay is provided across the outer surface of at least the front cover and the spine and is secured by fusion to inner and outer, plastic cover sheets that encapsulate a flat, stiff, front cover core, spine, and back cover core therebetween. A front cover title sheet pocket is defined between the overlay and the outer, plastic cover sheet. The title sheet pocket is of a narrow enough width to readily accommodate title sheets printed on paper of standard width, such as eight and a half inches. The fabrication technique employed allows a title sheet pocket to be created for the front cover of the document binder which snugly confines the title sheet and prevents it from shifting laterally as occurs in conventional devices. The creation of title sheet pockets with this configuration is possible according to the method of the invention by first fusing together the overlay to the outer plastic cover sheet along a band of attachment near the demarcation between the front cover and the spine, and then fusing the overlay, outer cover sheet, and inner cover sheet together so as to encapsulate the nonfusible, flat, stiff core elements between the two cover sheets. An inside pocket sheet may also be fused to the inner cover sheet during the same step of fusion so as to form pockets on the insides of the front and back covers.

SPECIFICATION 
Background of the Invention 
1. Field of the Invention 
The present invention relates to document binders, such as ring binders, 
folders, and the like which provide the user with a means for displaying a 
customized title sheet. 
2. Description of the Prior Art 
At present documents are often organized in binders in which papers are 
fastened to a spine in various way. A number of different fastening 
systems are employed to secure documents to the spine of a binder between 
front and back covers. For example, comb binders, compression clamp 
binders, prong fastening binders and other types of document binders are 
utilized in business, in commerce, and in the field of education. Also, 
ring binders, and in particular three-ring binders, are utilized 
extensively for such applications. 
Conventional document binders are constructed with a front cover, a back 
cover, and often a spine in between. In a conventional construction the 
front and back covers of a binder are typically formed of flat, expansive 
panels, while the spine between the panels is usually of a much narrower 
width. Originally ring binders of this type were formed with stiff 
paperboard cores encapsulated within sheets of heavy paper stock. At 
present, however, the front and back covers and the spines of conventional 
ring binders usually employ cores for the covers and the spine 
therebetween fabricated of chipboard. These cores are typically 
encapsulated between inner and outer sheets of plastic that are fused 
together about their peripheral edges and at the demarcations between the 
cover cores and the spine core. The spine of such a binder is thereby 
joined to the covers in articulated fashion by hinges formed of 
longitudinal fusion lines on either side of the spine where the materials 
of the inner and outer plastic cover sheets are joined together. 
While general purpose binders of this type are sometimes suitable, it is 
often advantageous for the front cover of a binder to be customized with a 
document title or a title indicative of the entity to which the binder 
belongs. The nature of the plastic covering on conventional binders is 
such that imprinting a customized title directly on the cover sheet is 
normally impractical. The cover is too thick to pass through any type of 
printing device normally found in an office environment. Moreover, the 
rings or other fasteners at the spine of the binder would prevent printing 
in this manner in any event. The expense of printing a customized title on 
the cover during manufacture for only a limited number of binders cannot 
be justified economically. 
One attempted solution to allow customization of titles for binders has 
been to provide a binder with a transparent overlay, typically formed of 
clear plastic. The overlay is normally of a size equal or nearly equal to 
the size of the cover sheets encapsulating the stiff core elements so that 
the overlay can be used to envelope the plastic cover sheets when the 
cover sheets are fused to each other to encapsulate the core elements 
therewithin. As a consequence, the front cover and spine, and even the 
back cover of a document binder are provided with pockets on their outer 
surfaces which can receive printed sheets or strips of paper therewithin. 
Thus, a title sheet of paper can be printed with appropriate material 
using a conventional office laser printer, or any other common printing 
device. A title sheet thus printed can then be inserted into the pocket 
defined between the transparent overlay and the outer plastic sheet 
forming the outer surface of the front cover. 
One difficulty with conventional document binders employing title sheet 
pockets of this type is that the pocket for the title sheet is invariably 
much wider than the title sheet itself. As a consequence, the title sheet 
is quite likely to slide laterally within the pocket and even assume a 
cocked position within the pocket. This is visually displeasing to the 
observer and also creates a tendency for the title sheet to slide out of 
the pocket, since the mouth of the pocket is considerably wider than the 
title sheet. 
The reason that title sheet pockets on conventional document binders are 
invariable too wide for the title sheets they are designed to accommodate 
is due to certain limitations in the process for manufacturing binders and 
due to certain physical constraints concerning the binders. Specifically, 
in this country the vast majority of papers organized in ring binders and 
other types of binders are eight and one-half inches in width. In many 
other countries A4 size paper, having a width of twenty one centimeters 
(eight and one quarter inches) is the standard. Standard, accepted widths 
such as these are employed both for papers to be bound in binders, and for 
paper that is passed through printers, such as computer controlled laser 
printers. 
As a result of the standardization of paper width, the covers of binders 
must be significantly wider than the standardized paper width utilized. A 
certain portion of the width of a binder is occupied by the paper 
fastening mechanism. In the case of a ring binder the rings typically 
extend at least about one inch from the inner edges of the covers where 
the covers meet the spine. Holes are punched in the papers to be bound 
approximately three-eighths of an inch in from the inside of the paper 
edge. While this offsets somewhat the space occupied by the binder rings, 
an additional width of the binder covers beyond the width of the papers to 
be bound therein of at least about five-eighths of an inch is required due 
to the space occupied by the rings. 
Also, space must be left within the binder at the outside edges of the 
pages bound therein to accommodate oversized separate sheets and 
laterally-projecting index tabs which are very often utilized within 
binders. This requires a further width of the covers of at least about 
three-quarters of an inch. Therefore, in this country at the very minimum 
the binder covers must be about one and three-eighths inches wider than 
the standard eight and a half inch width of the papers to be bound 
therein. That is, binders for organizing papers of a standard width in 
this country must have a cover width of at least about nine inches. More 
typically, however, to ensure complete enclosure of the papers to be bound 
between the covers, binders are manufactured commercially having covers in 
a width of between ten and twelve inches. The cover width is measured as 
the distance from the outside cover edge to the inside edge of the cover 
where the cover is delineated from the spine. 
In order to manufacture a binder having an overlay forming a title sheet 
pocket with the front cover, it would be convenient to seal the overlay to 
the fusible front cover sheet of material not only at the delineation 
between the covers and the spine, but also lengthwise along a band of 
sealing spaced from the delineation between the front cover and the spine 
a sufficient distance so as to create a pocket that is no greater than 
about nine inches in width, and preferably about eight and three-quarter 
inches in width, between the band of sealing and the opposite free edge of 
the front cover. However, this has not heretofore been possible on a 
commercially feasible basis since the band of attachment between the 
overlay and the outer front cover sheet lies in registration atop the 
stiff, front cover core. The material of choice employed to fabricate the 
core panels in document binders enjoying the most widespread commercial 
use is a substance known as chipboard. While chipboard provides a suitable 
stiff quality to the document binder cover and is quite economical, it 
cannot be fusibly joined to the plastic cover material and the plastic 
overly employed in the fabrication of conventional document binders. 
While a core material that is fusible to the plastic cover and overlay 
material could be substituted for the chipboard covers now employed, the 
increased costs of such a fusible substitute material would make document 
binders fabricated in this way prohibitively expensive and therefore 
commercially unattractive. 
SUMMARY OF THE INVENTION 
The present invention provides a document binder fabricated in such a way 
as to allow a plastic overlay to be secured to an outer cover material 
sheet along a band of attachment laterally displaced from the inner edge 
of the flat front cover core, and in fact directly atop the flat front 
cover core without requiring a fusible seal between the front cover core 
and the outer covering sheet at that location. As a consequence, the 
invention allows a document binder to be produced with a front cover title 
sheet pocket that snugly accommodates a title sheet printed on paper of 
standard width at an economically competitive cost. 
A further object of the invention is to provide a document binder which can 
be assembled rapidly and economically from inexpensive materials, and 
which provides an improved front cover title sheet pocket. The pocket for 
the front cover title sheet is configured to snugly and securely 
accommodate a title sheet printed on paper of standard size and which 
requires only the print capability of equipment found in most modern 
offices and commercial establishments. 
In one broad aspect the present invention may be considered to be a 
document binder comprising front and back covers both having a length and 
width and inner and outer faces. The front and back covers both have 
perimeters of expansive, rectangular configuration. The binder also 
includes a spine having inner and outer faces interposed between and 
hinged lengthwise in articulated fashion to both the front and back 
covers. The spine has a perimeter shaped as an elongated, rectangular 
strip that is narrower than the front and back covers. A rectangular 
overlay is secured to at least a portion of the perimeter of the front 
cover and to the outer face of the front cover and extends across the 
entire width of the outer face of the front cover to define a title sheet 
pocket with an unsealed mouth. The title sheet pocket has a width of no 
greater than about nine inches. A title sheet is located within the title 
sheet pocket and is laterally confined snugly therewithin and is visible 
through the overlay. 
In another broad aspect the invention may be considered to be a method of 
manufacturing a document binder. The method involves forming a fusible 
rectangular overlay, an outer, fusible, rectangular sheet of material, and 
an inner, fusible, rectangular sheet of material, all with mutually 
parallel top edges, bottom edges, and laterally-spaced front and back 
cover side edges. The lengths of the outer and inner fusible sheets of 
material are the same as are their widths. The width of the overlay is the 
same as that of the inner and outer fusible sheets of material and the 
length of the overlay is no greater than that of the inner and outer 
fusible sheets of material. 
In the assembly steps the rectangular overlay is positioned atop the outer, 
fusible, rectangular sheet of material so that at least the side edges and 
the bottom edge of the overlay are respectively congruent to the side 
edges and the bottom edge of the outer sheet of material. That is, the 
side edges and the bottom edge of the overlay are superimposed upon and 
lie directly above the corresponding side edges and bottom edge of the 
outer sheet of material. The overlay is fused to the outer, rectangular 
sheet along a band of attachment that is parallel to the side edges and is 
laterally spaced from the front cover side edges of both the overlay and 
the outer sheet. 
The outer fusible sheet with the overlay is positioned atop the inner 
fusible sheet in congruent relationship relative thereto and with the 
overlay in at least partially congruent relationship thereto. Flat, 
nonfusible front and back cover cores and a spine cover core are 
positioned between the inner and outer fusible sheets such that the front 
cover core is disposed between the front cover side edges. The spine core 
is located laterally adjacent to the front cover core in spaced separation 
therefrom. The back cover core is located laterally adjacent to the spine 
core in spaced separation therefrom. All of the cores are positioned to 
reside within a area bounded by the top and bottom edges and the front and 
back cover side edges of the inner and outer fusible sheets. 
The fusible overlay and the outer and inner fusible sheets are then fused 
together at their edges which are mutually congruent and on both sides of 
the spine core. This procedure encapsulates the cores between the outer 
and inner sheets and forms a document binder having front and back covers 
with a spine locate therebetween and with a title sheet pocket formed on 
the outside of the front cover. The title sheet pocket has an unsealed 
mouth between the linear band of attachment and the front cover side edges 
of the overlay and the outer sheet and is no greater than about nine 
inches in width. 
In still another broad aspect the invention may be considered to be a 
method of manufacturing a document binder comprising forming inner and 
outer fusible rectangular cover sheets with top edges, bottom edges, front 
cover side edges, and back cover side edges so that the lengths of the 
side edges of each of the cover sheets are equal to each other and so that 
the widths of the top and bottom edges of each of the cover sheets are 
equal to each other. A rectangular, fusible overlay is formed with a top 
edge, a bottom edge, a front cover side edge, and a back cover side edge. 
The top and bottom edges of the overlay have the same width as the top and 
bottom edges of the cover sheets. The side edges of the overlay have a 
length no greater than the length of the side edges of the cover sheets. 
The overlay is positioned atop the outer cover sheet so that at least the 
bottom edges and the side edges thereof are aligned in mutually congruent 
relationship. The overlay is fused to the outer cover sheet lengthwise 
along a band of attachment located between and parallel to the side edges 
thereof. 
Flat, nonfusible, rectangular front and back cover cores are formed. A 
relatively narrow, nonfusible, rectangular spine cover core is also 
formed. The nonfusible cover cores are formed in sizes such that the 
lengths of each of the nonfusible cores are equal to each other and are 
less than the lengths of the cover sheets. The aggregate sum of the widths 
of the nonfusible cover cores is less than the width of the fusible cover 
sheets. The nonfusible cores are positioned side-by-side in spaced 
separation from each other atop the inner cover sheet with the nonfusible 
spine core located between the front and back cover cores so that all of 
the nonfusible cores reside within the perimeter of the inner cover sheet. 
The outer cover sheet with the overlay fused thereto is positioned atop the 
nonfusible cores and the inner cover sheet so that all of the edges of the 
inner and outer cover sheets are mutually congruent to each other and so 
that least the bottom and side edges of the overlay are congruent to the 
bottom and side edges of the cover sheet. The overlay and the inner and 
outer cover sheets are then fused together about all congruent edges 
thereof and also lengthwise on both sides of the nonfusible spine core. As 
a result, the nonfusible cores are encapsulated between the inner and 
outer cover sheets in isolation from each other. 
The invention may be described with greater clarity and particularity by 
reference to the accompanying drawings.

DESCRIPTION OF THE EMBODIMENTS AND IMPLEMENTATION OF THE METHOD 
FIG. 1 illustrates a document binder 10 which is a three-ring binder for 
accommodating papers punched with three holes spaced apart from each other 
a distance of four and one-quarter inches and in from the left marginal 
edges of the sheets of paper a distance of approximately three-eighths of 
an inch. The ring binding mechanism is indicated at 12 in FIG. 2. 
The document binder 10 is comprised of a front cover 14 and a back cover 
16. The front and back covers 14 and 16 are equal in length or height, 
which is measured parallel to the alignment of the ring binding mechanism 
12. Typically, the front and back covers 14 and 16 are each eleven and 
three-quarter inches high. The front and back covers 14 and 16 are also 
equal in width, both being between about nine and three-quarters inches 
and fifteen inches wide as measured along the upper and lower edges 
thereof perpendicular to the alignment of the ring binding mechanism 12. 
The front and back covers 14 and 16 both have perimeters of a rectangular 
configuration, the corners of which are rounded slightly for safety 
reasons. The front cover 14 has an outer, front face 18 and an inner face 
20. Likewise, the back cover 16 has an outer, back face 22 and an inner 
face 24. 
A spine 26 is interposed between and hinged lengthwise in articulated 
fashion to both the front cover 14 and the back cover 16. The spine has a 
perimeter shaped as a narrow, elongated, rectangular strip, also eleven 
and three-quarter inches in length or height. The width of the spine 26 
varies, depending upon the capacity of the document binder 10, but is 
narrower than the width of the front and back covers 14 and 16. Document 
binders 10 are sold commercially in which the spines 26 thereof are 
typically one-half, one, one and a half, two, two and a half, three, four, 
and five inches in width. The embodiment of the document binder 10 
illustrated in FIGS. 1 and 2 has a spine 26 one and one-quarter inches in 
width. 
The document binder 10 also is provided with a transparent, rectangular 
overlay 28 that is secured to the front cover 14 about its entire 
perimeter and also to the marginal portion of the outer face 18 of the 
front cover 14. The overlay 28 extends across the entire width of the 
outer face 18 of the front cover 14 to define a title sheet pocket, 
indicated at 30 in FIGS. 1 and 3A. The pocket 30 has an unsealed mouth 32. 
The overlay 28 also extends across the entire widths of the spine 26 and 
the back cover 16. The overlay 28 is secured to the lateral demarcations 
of the spine 26 at the hinges 34 and 36 where the spine 26 is hinged in 
articulated fashion to the front and back covers 14 and 16, and also at 
least along the top and bottom edges of the spine 26 as well. The overlay 
28 is also secured to the entire perimeter of the back cover 16, 
specifically along the bottom edge 37 and the outside back cover side edge 
39, and the top edge 35 thereof. 
The title sheet pocket 30 on the front cover 14 has a width preferably no 
greater than about nine inches and no less than about eight and 
five-eighths inches. As illustrated in FIG. 1 the title sheet pocket 30 
laterally confines the title sheet 42 snugly therewithin. The title sheet 
42 is visible through the transparent overlay 28. 
The method of fabricating the document binder 10 is best depicted in FIG. 
3. The front cover 14 is comprised of an outer, fusible, rectangular front 
cover sheet 46, formed of a suitable fusible plastic, such as opaque 
polypropylene. The outer cover sheet 46 has a top edge 48 and a bottom 
edge 50 which are mutually parallel to each other and a front side edge 52 
and a back side edge 54 which are laterally spaced apart and also are 
mutually parallel to each other. An inner cover sheet 56 is employed and 
likewise has a top edge 58 and a bottom edge 60 parallel to the top edge 
58. The inner cover sheet 56 also has a front cover side edge 62 and a 
back cover side edge 64. The front and back cover side edges 62 and 64 are 
laterally spaced apart and are mutually parallel relative to each other. 
The inner cover sheet 56 is also formed of opaque polypropylene. 
The lengths of the outer and inner cover sheets 46 and 56, as respectively 
measured between the top and bottom edges 48 and 50 of the outer cover 
sheet 46 and the top and bottom edges 58 and 60 of the inner cover sheet 
56 are the same, typically about eleven and three-quarter inches. 
Likewise, the widths of the outer cover sheet 46 and the inner cover sheet 
56 are the same. The width of the outer cover sheet 46 is measured between 
the cover side edges 52 and 54 while the width of the inner cover sheet 56 
is measured between the cover side edges 62 and 64. When the spine 26 is 
one and one-quarter inches in width, the widths of the front cover sheet 
46 and the back cover sheet 56 are each about twenty-two and one-quarter 
inches. 
The transparent overlay 28 employed in the fabrication of the document 
binder 10 is also of rectangular configuration. The transparent overlay 28 
is formed of clear, transparent vinyl or polypropylene plastic and has a 
top edge 68, a bottom edge 70, a front cover side edge 72, and back cover 
side edge 74. In the embodiment of the document binder according to the 
invention depicted in FIGS. 1-3A, the transparent overlay 28 has 
dimensions identical to those of the outer cover sheet 46 and also the 
inner cover sheet 56. As a consequence, the length of the transparent 
overlay 28, as measured between the top and bottom edges 68 and 70 
thereof, is the same as the lengths of the top and bottom cover sheets 46 
and 56. Also, the width of the transparent overlay 28 as measured between 
the cover side edges 72 and 74 is equal to the width of the top and bottom 
cover sheets 46 and 56. 
For reasons that will hereinafter become apparent, the portion of the 
transparent overlay 28 that is ultimately secured to the front cover 14 of 
the document binder 10 may be considered to be comprised of a marginal, 
rectangular border 76 located within the top and bottom edges 68 and 70 
and between the side edges 72 and 74. This marginal border, for example, 
may have a width of one-quarter of an inch as measured in from the top 
edge 68 and also from the bottom edge 70 and a width of three-quarters of 
an inch as measured in from the front cover side edge 72 and from the 
spine demarcation 34. The area 78 of the transparent overlay 28 
encompassed within the marginal, rectangular border 76 thereby has a 
length of eleven and one-quarter inches and a width of eight and 
three-quarter inches. 
Prior to the assembly steps, and actually in the fabrication of the 
transparent overlay 28, a laterally-extending slit 80 is die cut into the 
transparent overlay 28 across the width of the area 78 thereof one-half of 
an inch in from the top edge 68. The slit 80 extends across the entire 
width of the area 78 that is surrounded by the rectangular border 76 prior 
to fusing the overlay 28 to the outer fusible cover sheet 46. 
The overlay 28 is then positioned atop the outer cover sheet 46 so that the 
edges 68, 70, 72, and 74 thereof all reside in mutually congruent and 
coterminous relationship with the corresponding edges 48, 50, 52, and 54 
of the outer fusible cover sheet 46. The transparent overlay 28 is 
thereupon sealed to the outer plastic sheet 46 throughout the marginal, 
rectangular border 76, which includes that portion 77 of the overlay 28 
immediately adjacent to the spine demarcation 34 that serves as a band of 
attachment parallel to the side edges 72 and 74 of the overlay 28. Fusion 
is typically performed by heat sealing, although fusion by means of sonic 
welding or even a solvent adhesive may be employed as well. 
Once the marginal, rectangular border 76 of the overlay 28 has been sealed 
to the area of the outer fusible cover sheet 46 located immediately 
therebeneath, the area 78 of the overlay 28 is delineated and defined as 
an unsealed area of the overlay 28, surrounded by the sealed, marginal, 
rectangular border 76. The unsealed area 78 thereby defines the title 
sheet pocket 30 while the slit 80 formed in the transparent overlay 28 
across the title sheet pocket 30 defines the unsealed mouth 32 thereof. 
The fusible, outer cover sheet 46, with the overlay 28 fused thereto at the 
marginal, rectangular border 76, is then positioned atop the inner, 
fusible sheet 56 in congruent relationship relative thereto. In the 
embodiment of FIGS. 1-3A, the overlay 28 also is completely congruent 
relative to the outer cover sheet 46 and the inner cover sheet 56 as well. 
A flat, expansive, nonfusible, rectangular front cover core 82, a flat, 
narrow, nonfusible, spine cover core 84, and a flat, expansive, 
nonfusible, rectangular back cover core 86 are then positioned between the 
inner fusible sheet 56 and the outer fusible sheet 46. The sizes of the 
nonfusible cores 82, 84, and 86 are such that the lengths of each of the 
nonfusible cores 82, 84, and 86 are equal to each other and are less than 
the lengths of the fusible cover sheets 46 and 56. The aggregate sum of 
the widths of the nonfusible cover cores 82, 84, and 86 is less than the 
widths of the fusible cover sheets 46 and 56. 
The cover cores 82, 84, and 86 are all preferably formed of chipboard and 
are positioned side-by-side in spaced separation from each other atop the 
inner cover sheet 56, as illustrated in FIG. 3. The nonfusible spine core 
84 is located between the front cover core 82 and the back cover core 86 
such that all of the nonfusible cores 82, 84, and 86 reside within the 
perimeter of the inner cover sheet 56. All of the flat, nonfusible cores 
82, 84, and 86 reside within an area bounded by the top edges 48,58, the 
bottom edges 50,60, the front cover side edges 52,62, and the back cover 
side edges 54,64 of the outer fusible sheet 46 and the inner fusible sheet 
56, respectively. The front cover core 82 is disposed between the front 
cover edges 52, 62, and 72 of the overlay 28 and the cover sheets 46 and 
56 and the spine demarcation 34 in all of those sheets. 
In the embodiment of the invention depicted in FIGS. 1-3A, a rectangular, 
fusible, inside pocket sheet 88 is also employed. The pocket sheet 88 has 
an area smaller than that of the inner, fusible, rectangular sheet 56 and 
is provided with a top edge 90, a bottom edge 92, a front cover side edge 
94, and a back cover side edge 96. The bottom edge 92 of the inside pocket 
sheet 88 is congruent to and coterminous with the bottom edge 60 of the 
inside cover sheet 56. The front cover side edge 94 of the inside pocket 
sheet 88 is congruent to the front cover side edge 62 of the inside cover 
sheet 56, and the back cover side edge 96 of the inside pocket sheet 88 is 
congruent to the back cover side edge 64 of the inside cover sheet 56. 
Three of the edges of the inside pocket sheet 88 are thereby congruent 
with three corresponding edges of the inner fusible sheet 56. 
With all of the layers in position as depicted in FIG. 3A, all of the 
mutually congruent edges of the overlay 28, the outer cover sheet 46, the 
inner cover sheet 56 and the inside pocket sheet 88 are then fused 
together. That is, as best illustrated in FIG. 3A, the front cover side 
edges 72, 52, 62, and 94 are all fused together. Likewise, the back cover 
side edges 74, 54, 64, and 96 are all fused together. The congruent bottom 
edges 70, 50, 60 and 92 are all fused together as well. Similarly, the top 
edges 68, 48, and 58 are fused together. Since the top edge 90 of the 
inside pocket sheet 88 is not congruent to the other top edges 68, 48, and 
58, it is left unsealed. 
Concurrently with fusion of the mutually congruent edges of the overlay 28, 
the front cover sheet 46, the back cover sheet 56, and the inside pocket 
sheet 88, the overlay 28, the inside cover sheet 46, outside cover sheet 
56 and the inside pocket sheet 88 are concurrently fused together along 
the spine demarcations 34 and 36 shown in each of those sheets on both 
sides of the spine core 84. As a result, the nonfusible chipboard cores 
82, 84, and 86 are encapsulated between the fusible outer sheet 46 and the 
fusible inner sheet 56, as depicted in FIG. 3A, so as to form the document 
binder 10 depicted in FIGS. 1 and 2. 
With reference to FIG. 1, it can be seen that the pocket 30 defined at the 
front cover 14 of the document binder 10 is narrower than front cover 
sheet pockets formed in conventional document binders. Specifically, the 
width of the pocket 30 is no greater than about nine inches, and in the 
embodiment depicted and described is actually eight and three-quarter 
inches as measured across the slit 80 that extends the width of the 
unsealed area 78 of the overlay 28. The slit 80 defines the unsealed 
pocket mouth 32. 
As is evident, a printed title sheet of paper 42 can be inserted into the 
unsealed mouth 32 of the pocket 30 through the gap created by the slit 80 
between the unsealed area 78 of the overlay 28 and the outwardly facing 
surface of the outer cover sheet 46 located adjacent thereto. Since the 
width of the pocket 30 is only eight and three-quarter inches, a 
conventional eight and a half by eleven inch sheet of paper 42 is confined 
laterally snugly within the pocket 30. 
An alternative embodiment of the invention is depicted in FIGS. 4, 5, 5A, 
and 5B. FIG. 4 illustrates a document binder 100 which is similar in many 
respects and which contains many of the same components and elements as 
the document binder 10. Those components and elements of the document 
binder 100 which are also found in the document binder 10 bear the same 
reference numbers. 
The principal difference in the document binder 100 from the document 
binder 10 resides in the structure of the transparent overlay 128. Unlike 
the overlay 28, there is no rectangular, marginal border area 76 defined 
on the overlay 128. Like the overlay 28, the overlay 128 is transparent 
and has a rectangular configuration including a top edge 68 and a bottom 
edge 70 parallel to the top edge 68. The overlay 128 also includes a front 
cover side edge 72' and a back cover side edge 74'. The top edge 68 and 
the bottom edge 70 of the overlay 128 have the same width as the top edges 
48,58, and bottom edges 50,60 of the outer fusible cover sheet 46 and 
inner fusible cover sheet 56, respectively. However, the front and back 
cover side edges 72' and 74' of the overlay 128 are both equal to each 
other but one-eighth of an inch shorter than the corresponding side edges 
52,62, and 54,64 of the outer cover sheet 46 and inner cover sheet 56, 
respectively. 
In the fabrication of the document binder 100, the overlay 128 is 
positioned so that the bottom edge 70 of the overlay 128 is coterminous 
with and congruent to the bottom edge 50 of the outer sheet 46. The side 
edges 72' and 74' are also congruent to the corresponding side edges 52 
and 54 of the outer cover sheet 46, but are slightly shorter than those 
corresponding edges. The top edge 68 of the overlay 128 therefore is not 
congruent to the top edge 48 of the outer cover sheet 46, but rather is 
longitudinally offset therefrom one-eighth of an inch in the direction of 
the bottom edges 50 and 70. 
The overlay 128 is thereupon fused to the outer cover sheet 46 lengthwise 
along a band of attachment 77' that is parallel to the side edges 72' and 
74' of the overlay 128. The band of attachment 77' is preferably about one 
and one-quarter inches in width for a one inch binder and lies adjacent to 
the spine demarcation 34 and extends therefrom laterally toward the front 
cover side edge 72'. The width of the band of attachment 77' will vary, 
depending upon the ring capacity of the binder. Once the first step of 
fusion is complete, the overlay 128 is fused to the outer cover sheet 46 
lengthwise along the entire band of attachment 77', which of a uniform 
width throughout and is parallel to the side edges 72' and 74' of the 
overlay 128. A waffle-shaped pattern of sealing is employed along the band 
of attachment 77', as illustrated in FIGS. 4 and 5B. The band of 
attachment 77' is laterally spaced from the front cover side edges 72' and 
52 of the overlay 128 and the outer cover sheet 46, respectively, a 
distance such that a portion of the overlay 128 nine inches in width is 
left unsealed between the attachment band 77' and the front cover side 
edges 72' and 52. 
The flat, nonfusible, front cover core 82, the spine cover core 84, and the 
back cover core 86 are then positioned between the outer and inner fusible 
sheets 46 and 56. The nonfusible cores 82, 84, and 86 are positioned side 
by side in spaced separation from each other atop the inner cover sheet 56 
with the nonfusible spine core 84 located between the front cover core 82 
and the back cover core 86. All of the nonfusible cover cores 82, 84, and 
86 reside within the perimeter of the inner cover sheet 56. 
The outer cover sheet 46 with the overlay 128 fused thereto is then 
positioned atop the nonfusible cores 82, 84, and 86 so that all of the 
edges of the inner cover sheet 56 and the outer cover sheet 46 are 
mutually congruent to each other and so that the bottom edge 70 and the 
side edges 72' and 74' of the overlay 128 are also congruent to the 
corresponding bottom and side edges of the cover sheets 46 and 56 located 
immediately therebeneath. 
As in the embodiment of FIGS. 1-3, the document binder 100 employs an 
inside pocket sheet 88. Consequently, the congruent front cover side edges 
72', 52, 62 and 94 are all fused to each other. Likewise, the congruent 
bottom edges 70, 50, 60, and 92 are all fused to each other. Similarly, 
the congruent back cover side edges 74', 54, 64, and 96 are all fused to 
each other. As in the document binder 10, the top edge 90 of the inside 
pocket sheet 88 is left unsealed so as to form pockets at the inner faces 
20 and 24 of the front cover 14 and back cover 16, respectively. It should 
be noted that since the top edge 68 of the overlay 128 does not reside 
directly above the corresponding top edges 48 and 58 of the outer and 
inner cover sheet 46 and 56, it is also left unsealed, although the top 
edges 48 and 58 of the outer and inner cover sheets 46 and 56 are sealed 
to each other throughout. 
In the document binder 100, the transparent overlay 128 has four edges, 
namely the edges 68, 70, 72' and 74'. Three of these edges, the edges 72', 
70 and 74', are congruent with and fused to the corresponding edges of the 
inner sheet 56 and the outer sheet 46. The fourth edge of the overlay 128, 
that is the edge 68, is left unsealed and forms the mouth of the title 
sheet pocket 30'. 
As the congruent outer edges of the structure are sealed together, the 
overlay 128, the outer sheet 46, the inner sheet 56, and the inside pocket 
sheet 88 are also fused together lengthwise on both sides of the 
nonfusible spine core 84 along the lines 34 and 36 delineating the spine 
26 of the binder 100. 
In the finished structure of the document binder 100, the top edge 68 of 
the overlay 128 is not sealed to either of the fusible cover sheets 46 or 
56. The top edge 68 of the overlay 128 thereby forms the unsealed mouth of 
the title sheet pocket 30'. The title sheet 42 may thereby be inserted 
into the pocket 30' by sliding it in between the top edge 68 of the 
overlay 128 and the outwardly facing surface of the outer cover sheet 46 
at the outer face 18 of the binder front cover 14, as illustrated in FIG. 
5B. Since the top edge 68 of the overlay 128 is sealed only where it 
intersects the side cover edges 72' and 74' and the spine demarcations 34 
and 36, pockets are also formed at the spine 26 and back cover 22 of the 
document binder 100. As a consequence, a spine title strip 40 may be 
inserted into the spine pocket 41 between the top edge 68 of the overlay 
128 and the outer surface of the outer sheet 46 between the spine 
demarcations 34 and 46, also as illustrated in FIG. 5B. 
In the document binder 100 a back pocket 130 is also defined between the 
overlay 128 and the outer cover sheet 46. This back pocket 130 appears in 
FIG. 5A. Documents may be inserted into the back pocket 130 between the 
unsealed upper edge 68 of the overlay 128 and the outer surface of the 
outer sheet 46 between the spine demarcation 36 and the back panel side 
edge 54. 
Various modifications of the embodiment of FIGS. 4-5B are also possible. 
For example, in one modified form the transparent overly 128 can be 
constructed to have the same length, as well as the same width, as the 
outer cover sheet 46 and inner cover sheet 56. In such an arrangement the 
transparent overlay is precut with an elongated, longitudinally-extending 
slit immediately adjacent to the area at which the band of attachment 77' 
is to be formed. Specifically, this slit can be cut along the line 79 
indicated in FIG. 5. The slit along the line 79 is parallel to the overlay 
side edges, but does not intersect, either the top edge 68 or the bottom 
edge 70. In this modified form of the invention the transparent overlay 
128 is sealed about all of its peripheral edges to the outer and inner 
cover sheets 46 and 56, and is thus fused to the outer and inner cover 
sheets 46 and 56 throughout its entire perimeter. However, a title sheet 
pocket is still formed between the overlay 128 and the outer cover sheet 
46 and is accessible through the slit formed along the line 79 immediately 
adjacent the band of attachment 77'. This title sheet pocket is a side 
opening pocket with a mouth formed by the slit along the line 79 that 
accommodates the entire length of the title sheet 42. 
To insert or remove a title sheet the portion of the overlay 128 
immediately adjacent to the band of sealing 77' is lifted at the slit 
along the line 79, and the title sheet is inserted laterally passing 
across the band of attachment 77', through the slit formed along the line 
79, and in between the overlay 128 and the outer cover sheet 46. 
Alternatively, the longitudinal slit may be formed parallel and quite near 
to the front cover side edge of the transparent overlay 128. In still 
another modification the front cover side edge of the overlay 128 may be 
left open and unsealed from the outer cover sheet 46. Other modifications 
are also possible. 
FIGS. 6 and 7 illustrate another embodiment of a document binder 200 
constructed according to the invention. The document binder 200 employs 
many of the same components of the document binder 10 depicted in FIGS. 
1-3A. Components and elements of the document binder 200 that are found in 
the document binder 10 bear the same reference numerals. 
The document binder 200 differs from the document binder 10 primarily in 
the construction of the overlay 228, and in the utilization of a fusible 
title window sheet 240. Like the overlay 28, the overlay 228 is formed of 
a fusible plastic, such as polypropylene, and has an outer perimeter with 
dimensions identical to those of the outer cover sheet 46 and the inner 
cover sheet 56. Unlike the overlay 28, however, the overlay 228 is opaque, 
rather than transparent. Also, the fabrication of the document binder 200 
involves initially cutting a rectangular viewing opening 242 in the 
overlay 228. As a result, a marginal, rectangular border 276 is defined 
about the viewing opening 242. The outer perimeter of the rectangular, 
marginal border 276 is formed by the front cover side edge 72, the top 
edge 68 and the bottom 70 of the overlay 228, and by the spine demarcation 
34 that extends between the top edge 68 and bottom edge 70 parallel to the 
side edges 72 and 74. 
The transparent, rectangular, fusible, title window sheet 240 is formed of 
clear, transparent, polypropylene plastic and has dimensions greater than 
those of the rectangular viewing opening 242. That is, the side edges 244 
and 246 of the transparent title window sheet 240 are longer than the 
edges of the viewing opening 242 that are parallel to the front and back 
cover side edges 72 and 74. Similarly, the top edge 248 and the bottom 
edge 250 of the title window sheet 240 are wider than the upper and lower 
edges of the viewing opening 242 that are parallel to the top and bottom 
edges 68 and 70 of the overlay 228. 
In the construction of the document binder 200, the title window sheet 240 
is positioned between the opaque overlay 228 and the outer fusible sheet 
46 such that a portion of the periphery of the title window sheet 240 
around three sides thereof is entrapped between that portion of the 
overlay 228 adjacent the viewing opening 242. That is, the side edges 244 
and 246 and the bottom edge 250 of the title window sheet 240, and the 
areas of the title window sheet 240 immediately adjacent thereto, are 
entrapped between the overlay 228 and the outer plastic sheet 46. However, 
the title window sheet 240 is positioned beneath the overlay 228 such that 
the top edge 248 of the title window sheet 240 is located about an eighth 
of an inch below the top edge of the viewing opening 242. 
With the title window sheet 240 positioned between the overlay 228 and the 
outer cover sheet 46 in this manner, the marginal, rectangular border 276 
of the overlay 228 is sealed throughout to the underlying portion of the 
outer cover sheet 46 located immediately therebeneath. Since the title 
window sheet 240 is also formed of a fusible material, it likewise is 
sealed to both the overlay 228 and the outer cover sheet 46 along its 
marginal areas immediately adjacent its edges 244, 246, and 250. 
The overlay 228 is sealed to the outer cover sheet 46 and the inner cover 
sheet 56 throughout its entire perimeter. In addition, the overlay 228 is 
sealed to the outer cover sheet 46 throughout the rectangular marginal 
border area 276, including the region between the spine demarcation 34 and 
the nearest edge of the viewing opening 242, which forms an attachment 
band adjacent the spine demarcation 34 along which the overlay 228 and 
outer cover sheet 46 are fused together. 
Thereafter, the nonfusible front cover core 82, spine core 84, and back 
cover core 86 are positioned between the outer sheet 46 and the inner 
sheet 56 in manner described in conjunction with FIGS. 1-3A. Likewise, the 
inside pocket sheet 88 is formed and positioned as described in 
conjunction with those drawing figures. 
The entire perimeter of the overlay 228 is congruent to the perimeters of 
the outer cover sheet 46 and the inner cover sheet 56. The congruent edges 
of the overlay 228, the outer cover sheet 46, the inner cover sheet 56 and 
the inside pocket sheet 88 are thereupon sealed together in the same 
manner previously described. Also, the same structures are likewise fused 
together along the spine demarcations 34 and 36, likewise in the manner 
previously described. As in the other embodiments described the flat, 
nonfusible cover cores 82, 84, and 86 are trapped between the outer sheet 
46 and the inner sheet 56, and are isolated from each other by the lines 
of fusion extending along the spine demarcations 34 and 36. 
In the document binder 200, the unsecured, central portion of the upper 
edge 248 of the title window sheet 240 forms the unsealed mouth of the 
title sheet pocket 230. A title sheet may be inserted into the pocket 230 
through the gap formed between the unsealed portion of the top edge 248 of 
the title window sheet 240 and the upper edge of the viewing opening 242. 
As in the document binder 10, the document binder 200 is formed of an 
overlay 228 and inner and outer sheet 56 and 46 of plastic material that 
have perimeters defining sides, all of which are mutually coterminous 
throughout. All of the outer edges of these structures are fused together 
to encapsulate the core elements of the binder between the inner and outer 
sheets of plastic 56 and 46. The overlay 228 has a perimeter defining four 
edges 68, 70, 72, and 74 all of which are coterminous with and fused to 
the edges of the perimeters of the inner plastic sheet 56 and the outer 
plastic sheet 46. The overlay 228 is sealed to the outer plastic sheet 46 
throughout a marginal, rectangular border 276 located within the perimeter 
of the transparent overlay 228. 
Modifications of the embodiment of the invention depicted in FIGS. 6 and 7 
are also possible. The reason for forming the outer cover sheet 46 from an 
opaque material rather than a transparent material is because the 
chipboard core components 82, 84, and 86 are not particularly attractive 
in appearance, and are therefore concealed for aesthetic reasons. However, 
if a nonfusible core is employed which is aesthetically pleasing, the 
embodiment of the invention depicted in FIGS. 6 and 7 can be modified to 
permit elimination of the title window sheet 240. For example, the 
unattractive chipboard core can be painted to improve its appearance. The 
title window sheet 240 may then be eliminated if the outer cover sheet 46 
is formed of a transparent material and is initially die cut with a slit 
that extends transversely across it parallel to its upper edge 48 and 
spaced longitudinally therefrom the same distance as the upper edge 248 of 
the title window sheet 240 that is eliminated. This slit can be cut 
coextensive with the width of the viewing opening 242. Therefore, when the 
overlay 228 is sealed to the outer cover sheet 46 throughout the marginal 
rectangular border 276, a title sheet pocket is defined between the 
central region of the outer cover sheet 46 surrounded by the marginal 
rectangular border 276 and the front cover core 82. A title sheet can 
thereupon be inserted into and removed from the title sheet pocket through 
the transverse slit formed in the transparent outer cover sheet 46 that 
resides directly atop the front cover core 82 and within the lateral 
confines of the viewing opening 242 in the overlay 228. 
Furthermore, the slit in such a transparent outer cover sheet need not 
necessarily be formed to coincide with the position of the upper edge 248 
of the title window sheet 240. Rather, a slit formed in such a transparent 
outer cover sheet 46 will provide access to a pocket formed between a 
transparent outer cover sheet and the front cover core 82 if it is defined 
within the enclosure of the viewing opening 242 at any location 
therewithin. For example, such a slit could provide access to the pocket 
if formed immediately adjacent and parallel to either of the 
longitudinally-extending sides of the viewing opening 242, or just above 
and parallel to the lower edge of the viewing opening 242. Other 
modifications are also possible. 
FIGS. 8 and 9 illustrate another embodiment of a document binder 300 
according to the invention. The document binder 300 is similar in many 
respects to the document binder 100 depicted in FIGS. 4-5A, and components 
and elements depicted and described in conjunction with the document 
binder 100 which are also included in the document binder 300 bear the 
same reference numbers. 
The document binder 300 differs from the document binder 100 primarily in 
its inner core structure. As in the other embodiments of the invention, 
the core of the document binder 300 is comprised of flat, nonfusible, 
chipboard core components. The nonfusible spine cover core 84 and back 
cover core 86 are identical to those utilized in the other embodiments. 
The nonfusible front cover core 82', however, is narrower than the core 82 
employed in the other embodiments. Specifically, the nonfusible core 82' 
preferably has a width of only about eight and three-quarters inches. 
In addition to the nonfusible core elements, the document binder 300 
utilizes a flat, stiff, fusible core panel 82" that underlies the 
nonfusible core 82'. The fusible core panel 82" is disposed between the 
nonfusible core 82' and the inner fusible plastic sheet 56 prior to any 
fusion step. The fusible core panel 82" is greater in width than the 
nonfusible core 82' and extends all the way from just within the front 
cover side edges 52 and 62 of the outer cover sheet 46 and inner cover 
sheet 56 to the spine demarcation 34. The fusible core panel 82" is 
preferably formed of a sheet of polypropylene. vinyl, or fusible material 
compatible with the materials of which the inner and outer cover sheets 46 
and 56 are formed. 
The nonfusible core panel 82' has a top edge 310, a bottom edge 312, a 
front cover outside edge 314, and a front cover inside edge 316. The 
wider, polypropylene, fusible core panel 82" has a top edge 318, a bottom 
edge 320, a front cover outside edge 322, and a front cover inside edge 
324. In positioning the core components, the fusible core panel 82" is 
positioned beneath the nonfusible core panel 82' with the front cover side 
edges 314 and 322 congruent and coterminous to each other. The top and 
bottom edges 310 and 312 of the nonfusible core panel 82' are congruent to 
but shorter than the top and bottom edges 318 and 320 of the fusible core 
panel 82". As a consequence, there is a gap between the inside edge 316 of 
the nonfusible core panel 82' and the inside edge 324 of the fusible core 
panel 82". 
As a result, when all of the layers of the document binder 300 are 
assembled together, the outer fusible plastic cover sheet 46 resides in 
direct contact with the fusible core panel 82" at a band of attachment 
indicated at 326. This band of attachment lies just beyond the inside edge 
316 of the nonfusible core 82'. Consequently, the overlay 128, the outer 
fusible sheet 46, the fusible core panel 82" and the inner fusible sheet 
56 and the inside pocket sheet 88 are all fused together along the band of 
attachment 326. 
Since the inner fusible core 82" is wider than the nonfusible core panel 
82', it extends into registration with the band of attachment 326 
throughout its length. During the fusing process, the band of attachment 
326 is fused to the fusible core 82" while concurrently fusing the overlay 
128, the outer fusible sheet 46, the inner fusible sheet 56, and the 
fusible inside pocket sheet 88 together, all about the mutually congruent 
edges thereof, and also along the spine demarcations 34 and 36. 
The fabrication of the document binder 300 is advantageous in that the 
fusion together of all elements can be performed with but a single fusion 
step. However, the document binder 300 does require an additional 
component, namely the fusible core panel 82". 
While the document binder 300 can be constructed with a gap left between 
the nonfusible core panel 82' and the nonfusible spine core 84, for 
aesthetic reasons it may be advisable to utilize a nonfusible margin 
insert 328 between the band of attachment 326 and the spine demarcation 
34. The margin insert 328 may be formed as a narrow, flat, rectangular 
strip of chipboard interposed between the outer, fusible, rectangular 
cover sheet 46 and the fusible core panel 82". The margin insert 328 is 
laterally separated from both the nonfusible core panel 82' and from the 
spine panel 84 to permit fusion on either side thereof at the band of 
attachment 326 and at the spine demarcation 34. The margin insert 328 is 
positioned on an opposite side of the band of attachment 326 from the 
nonfusible core panel 82'. During the single step of fusion, the overlay 
128, the outer fusible sheet 46, the fusible core 82", the inner fusible 
sheet 56, and the inside pocket sheet 88 are fused at the band of 
attachment 326 between the nonfusible core 82' and the margin insert 328. 
As in the document binder 100, the document binder 300 is formed with more 
than a single pocket. Specifically, the document binder 300 includes a 
front cover pocket 30", a spine pocket 41, and a back cover pocket 130, 
illustrated in FIG. 9A. In addition, a narrow margin pocket 330 may be 
formed between the overlay 128 and the outer cover sheet 46. This margin 
pocket is marginally bounded by the spine demarcation 34 and the band of 
attachment 326. Since access is provided to all of the pockets in the 
document binder 300 by the unsealed portions of the top edge 68 of the 
overlay 128, a title sheet 42 may be inserted into the front cover pocket. 
An optional information strip may be inserted into the pocket 330. A spine 
title strip 40 may be inserted into the spine pocket 41. Useful tables and 
charts, or other flat materials may be inserted into the back pocket 130. 
Undoubtedly, numerous variations and modifications of the invention will 
become readily apparent to those familiar with office supply products. For 
example, in addition to the stiff core members provided, it is possible to 
additionally provide padding between the core components and the outer 
fusible plastic sheet. Also, for aesthetic reasons it is sometimes 
advisable to create patterns of fusion, such as the waffle iron grid 
pattern of FIGS. 4 and 5B, or other patterns in fusing the overlay to the 
outer cover sheet at the attachment strips and in the marginal, 
rectangular border areas. Accordingly, the scope of the invention should 
not be construed as limited to the specific embodiments of the invention 
depicted and described and the techniques for practice of the method 
thereof.