BOOKLET OF FOLDED WEB CONSTRUCTION AND METHOD OF MANUFACTURE

Abstract: A booklet suitable for use as a workbook or as a supple­ ment to other printed publications is made from a single continuous web of paper, printed on both sides thereof, which has been folded in alternately opposite directions along successive perforated lines extending transversely of the web at constant longitudinal spacings. The folded web is stapled or otherwise held together along a binding edge. The thus produced booklet has every two neighbouring leaves thereof joined together at their unbound edges op­ posite the binding edge. Such joined leaves are to be sepa­ rated by the reader by tearing along the row of perforations between their unbound edges. The top and bottom edges of every two neighbouring leaves, extending between the binding and unbound edges, may further be pasted together in a readily openable manner. In the use of this booklet as a workbook, for example, questions and answers may be printed on the outer and inner pages, respectively, of every two joined leaves.

Description: My invention relates to book format in general and, in particular, to a novel construction of a book that may more aptly be classified as a booklet, being made from a continuous, folded web of paper or like material, and to a method of manufacturing such a booklet The booklet in accordance with my invention finds optimum use as workbooks, as manuals, or as supplements to other printed publications such as larger books or magazines, although other uses may of course be found within the scope of my invention. A consideration of conventional workbooks or drill books, a typical application of the booklet in accordance with my invention, will serve best to illustrate its utility. Workbooks are in common use among students and pupils which contain both questions or problems to be solved and their answers. With the conventional format of workbooks, or of books or other printed publications in general, the answers have been given either on the same pages as the questions, or on pages following the question pages. Such usual arrangements of questions and answers are subject to the objection that the student, when unable to solve the questions, is easy to turn to the answers before fully reconsidering the questions or referring to some pertinent book or the like. He will then learn from the workbook not so much as he would if he endeavoured hard enough before seeing the printed answers. The same holds true with manuals for the mastery of an art or skill such as, for example, chess. The student of the art or skill will make greater progress by fully studying the problems given in the manual before looking up their solutions. I have hereby invented a booklet of novel format which is admirably well suited for use as workbooks or manuals containing both questions or problems to be solved by the reader and their solutions. My invention further comprehends a method of manufacturing the booklet in what I believe is the simplest and most practical way. Briefly summarized in one aspect thereof, my invention provides a booklet particularly suitable for use as a workbook, as a manual, or as a supplement to other printed publications such as books or magazines, comprising: (a) an elongate web (28) printed on both sides thereof by an endless flexible letterpress printing plate and being folded in alternately opposite directions along successive predetermined folding lines extending transversely of the web at constant longitudinal spacings to define leaves (12,14,16) of the booklet joined at a pair of opposite edges by fold lines; (b) means (18) for binding the folded web along one of said edges to form a binding edge (20) and to define a plurality of pairs of every two neighbouring leaves of the booklet, the neighbouring leaves of each pair being joined together along their unbound edges (22) opposite the binding edge (20); (c) there being a row of perforations (30) disposed along the fold lines joining the unbound edges (22) of every two joined leaves of the booklet whereby any two joined leaves can be readily torn open along the row of perforations. According to another aspect of my invention, there is provided a method of manufacturing a booklet which comprises: (a) preparing a web (28) which is printed on both sides thereof by using an endless flexible letterpress printing plate and forming therein rows of perforations (30) extending transversely thereof at constant longitudinal spacings; (b) folding the web along the successive rows of perforations alternately in opposed directions to define leaves (12,14,16) of the booklet joined at a pair of opposite edges by fold lines; and (c) binding the folded web along one of said edges to form a binding edge (20) and to define a plurality of pairs of every two neighbouring leaves of the booklet, the neighbouring leaves of each pair being joined together through a row of perforations (30) disposed along the fold lines joining the unbound edges (22) opposite the binding edge (20) whereby any two joined leaves can be readily torn open along the row of perforations. Thus, for the manufacture of a workbook in the format of my invention, questions may be printed on one side, and their answers on the other side, of the continuous web. This web may then be folded and bound as above stated so that the question side of the web may come on the outer pages of every two joined leaves of the booklet, and the answer side of the web on the inner pages of such leaves. As required, every two neighbouring leaves may be united together in a readily separable manner, as by pasting, at their top and bottom edges in addition to at their unbound front edges. The reader can then see only the question pages of the booklet and must tear every two joined pages apart along the perforated line between their front edges and, as necessary, along the pasted regions adjacent their top and bottom edges as well, for referring to the answer pages. There is accordingly a far less likelihood of the reader seeing the printed answers before solving the questions or before giving full thought thereto. As an additional advantage of my novel format, the answers can be given on the page immediately following the page bearing the problems. Therefore, once any two joined leaves are torn open, the student can examine the problems and answers given close to each other. DE-C-10939 discloses a method of making a booklet involving printing on both sides of a sheet of paper and folding the paper along fold lines some of which are defined by lines of perforations. However, DE-C-10939 does not envisage creation of a booklet having pairs of every two adjacent leaves joined along their edges opposite to the bound edge by a row of perforations to thereby enable answers printed on one side of the web to remain hidden until neighbouring leaves of a joined pair are separated. In addition,, DE-C-10939 does not disclose printed matter on both sides of a web which has been produced by an endless flexible letterpress printing plate nor does it disclose folding of a web alternately along successive folding lines extending transversely of the web. According to the method of my invention summarized previously, the continuous printed web is folded in alternately opposed directions along the successive perforated lines preformed therein at constant longitudinal spacings. The folding of the web is therefore easy. In the completed booklet, moreover, those of the perforated lines which are at its front edge serve the additional purpose of expediting the tearing of every two united leaves. Furthermore, as will be understood by those versed in the bookbinding art, the complete process of booklet manufacture in accordance with my invention can be performed all by streamlined, automatic equipment comprising printing, perforating, pasting, folding, and binding sections. Reference is now made to the accompanying drawings, in which:- Figure 1 is a perspective view of a preferred form of the booklet embodying the principles of my invention; Figure 2 is a fragmentary plan view showing one side of the continuous web of printed, perforated paper from which the booklet of Figure 1 is made, the web side shown here forming the outer pages of every two united leaves of the booklet; Figure 3 is a view similar to Figure 2 but showing the other side of the web; and Figure 4 is an enlarged, fragmentary plan view of an alternative form of the web which can also be processed into the booklet of Figure 1. I believe that my invention is best embodied in the booklet 10 of Figure 1, in which I have shown exaggerated the thickness of the covers and leaves of the booklet to expedite illustration and understanding. It will be observed from this figure that the representative booklet 10 is fabricated from a continuous web of paper which has been folded to provide a single leaf front cover 12, a single leaf rear cover 14, and a group of leaves 16 in between. All these covers 12 and 14 and leaves 16 are shown bound together by a row of wire staples 18 along the predetermined rear edge or spine 20 of the booklet 10. It will also be noted that every two neighbouring ones of the leaves 16 are joined, or left uncut, at the front edge 22, opposite the rear edge 20, of the booklet 10. In this particular embodiment, moreover, every two such joined leaves 16 are further pasted together along their top 24 and bottom 26 edges extending between the rear edge 20 and front edge 22, as will be better understood as the description proceeds. Figures 2 and 3 are illustrations of the opposite sides of the continuous web 28 of paper or any other material from which the booklet 10 is made. The web 28 has formed therein rows of minute perforations 30 such as those which may be made by a sewing needle. These perforated lines 30 extend transversely of the web 28 at constant longitudinal spacings thereby marking the boundaries between what are to become the covers 12 and 14 and leaves 16 of the booklet 10. In the use of the booklet 10 as a workbook, for example, there may be printed questions or problems, perhaps together with other comments and illustrations, on the front side of the web 28 seen in Figure 2 and on those portions thereof which are to become the pages of the booklet. I have indicated by the reference numeral 32 such printings on the front side of the web 28. On the rear side of the web 28 seen in Figure 3, then, and on those portions thereof which are to become the pages of the booklet 10, there may be printed the answers or solutions for the questions or problems, together with any other pertinent matter. The reference numeral 34 designates such printings on the rear side of the web 28. As will be seen also from Figure 1, the web 28 has two rows of sprocket holes 36 extending along the opposite longitudinal edges thereof. These sprocket holes are for engagement with sprocket teeth on an endless, flexible letterpress printing plate on a printing press in making the printings 32 and 34 on the web 28. I recommend the use of such a printing plate because it makes possible the printing of the complete length of the web 28 at one stretch. Further, preferably, the printing press may be incorporated with bookbinding equipment for the streamlined fabrication of the booklet 10 in accordance with my invention. As indicated above, every two joined leaves 16 may be connected together along their top 24 and bottom 26 edges and as shown in Figure 3 such connection may be achieved by providing the web 28 with a pair of continuous adhesive regions 38, (only one being seen in Figure 3) in the shape of slender strips formed on its rear side only and extending along the opposite longitudinal edges of the web except its end portions which are to become the covers 12 and 14 of the booklet 10. The adhesive regions 38 on every two opposed pages are to stick together in the completed booklet 10. A pair of rows of small perforations 40, one seen in Figures 2 and 3 and both shown in Figure 1, are formed just inwardly of the two rows of sprocket holes 36 and also extend parallel to the longitudinal edges of the web 28. These rows of perforations 40 are intended for use in tearing off the pasted top and bottom edge portions of the leaves 16 of the booklet 10. The pair of perforated lines 40 may be omitted, however. In Figure 4 I have shown an alternative web 28 a wherein an adhesive layer is provided in the form of a series of isolated spots 38 a extending along each longitudinal edge of the web and located just outwardly of each row of sprocket holes 36. Cemented together through such isolated adhesive spots 38 a , any two joined leaves 16 of the booklet 10 will readily come apart without tearing. For the manufacture of the booklet 10 by the method of my invention, the web 28 of Figures 2 and 3 (or the web 28 a of Figure 4) is folded in alternately opposite directions along the successive perforated lines 30, by first folding the web end portion 42, which is to become either the front 12 or rear 14 cover of the booklet 10, in a direction away from the rear side of the web on which the adhesive regions 38 are formed. Then the folds of the web may be bound together along the rear edge 20 by the wire staples 18. Wire stapling is, of course, but an example of binding means that are adoptable for holding together the folded web in accordance with my invention. Additional examples include thread stitching or sewing, pasting, and loose leaf binding. As required, pressure may be exerted on the folded web in its thickness direction in order to assure firm cementing of the top and bottom edge portions of every two joined leaves 16 via the adhesive regions 38 (or 38 a ). The fabrication of the booklet 10 has now been completed. Every two leaves 16 of the thus completed booklet 10 are joined through the fold at the front edge 22. After solving the questions or problems printed on the exposed pages of such joined leaves, the student may tear them apart along the perforated line 30 at the front edge 22 of the booklet and along the perforated lines 40 along the top 24 and bottom 26 edges, thereby gaining access to the printed solutions on the hidden pages. In the case of the Figure 4 embodiment the student may tear along the perforated line 30 and then pull the two leaves apart to separate their top and bottom edges that have been pasted by the series of adhesive spots 38 a . It is understood that the foregoing detailed disclosure is by way of example only and not to impose limitations on my invention, as a variety of modifications or alterations will readily occur to one skilled in the art of book manufacture. For example, the printed and perforated web may be so folded as to form no front or rear cover but to provide only leaves every neighbouring two of which are united, and these leaves may, or may not, be fitted and sealed into a separate cover. As another possible modification of the illustrated embodiment, every two neighbouring leaves may not necessarily be pasted together along their top and bottom edges, since the objectives of my invention can be largely accomplished if the leaves are united at the front edge only.

Claims: A booklet particularly suitable for use as a workbook, as a manual, or as a supplement to other printed publications such as books or magazines, comprising: (a) an elongate web (28) printed on both sides thereof by an endless flexible letterpress printing plate and being folded in alternately opposite directions along successive predetermined folding lines extending transversely of the web at constant longitudinal spacings to define leaves (12,14,16) of the booklet joined at a pair of opposite edges by fold lines; (b) means (18) for binding the folded web along one of said edges to form a binding edge (20) and to define a plurality of pairs of every two neighbouring leaves of the booklet, the neighbouring leaves of each pair being joined together along their unbound edges (22) opposite the binding edge (20); (c) there being a row of perforations (30) disposed along the fold lines joining the unbound edges (22) of every two joined leaves of the booklet whereby any two joined leaves can be readily torn open along the row of perforations. A booklet according to Claim 1, wherein every two neighbouring leaves of each pair are further cemented together along their top and bottom edges (24,26), extending between the binding and unbound edges, in a manner permitting ready separation. A booklet according to Claim 2, wherein each leaf has additional rows of perforations (40) extending along its top and bottom edges, whereby the cemented top and bottom edges of every two neighbouring leaves are separable by tearing along the additional rows of perforations. A booklet according to Claim 2, wherein every two joined leaves are cemented together at rows of isolated spots (38a) along the top and bottom edges thereof. A booklet according to any preceding claim, further comprising a single leaf front cover (12) formed by a folded end portion of the printed web and/or a single leaf rear cover (l4) formed by another folded end portion of the printed web. A method of manufacturing a booklet which comprises: (a) preparing a web (28) which is printed on both sides thereof by using an endless flexible letterpress printing plate and forming therein rows of perforations (30) extending transversely thereof at constant longitudinal spacings; (b) folding the web along the successive rows of perforations alternately in opposed directions to define leaves (12,14,16) of the booklet joined at a pair of opposite edges by fold lines; and (c) binding the folded web along one of said edges to form a binding edge (20) and to define a plurality of pairs of every two neighbouring leaves of the booklet, the neighbouring leaves of each pair being joined together through a row of perforations (30) disposed along the fold lines joining the unbound edges (22) opposite the binding edge (20) whereby any two joined leaves can be readily torn open along the row of perforations. A method of manufacturing a booklet according to Claim 6, wherein adhesive layers (38) are formed on one side of the web (28) to extend along its opposite longitudinal edges, whereby the neighbouring leaves of each pair are further joined together along their top and bottom edges (24,26), extending between the binding and unbound edges via the adhesive layers. A method of manufacturing a booklet according to Claim 7, wherein additional rows of perforations (40) are formed to extend along the opposite longitudinal edges of the web inwardly of the adhesive layers (38), whereby the joined top and bottom edges of every two neighbouring leaves are separable by tearing along the additional rows of perforations (40). A method of manufacturing a booklet according to Claim 6,7 or 8, wherein the prepared web is folded so as to leave a single leaf front cover (12) and/or is folded so as to leave a single leaf rear cover (14). A method of manufacturing a booklet according to any of Claims 6 to 9, wherein the web is provided with rows of sprocket holes (36) extending along the opposite longitudinal edges thereof to facilitate printing thereon.

Inventors: FUKUDA, MANABU
Applicants: FUKUDA, MANABU
Application year: 1985
Main classification: B42D1
IPC codes: B42C3, B42C9, B42D15, G09B3, B42D1