Patent Publication Number: US-2023148074-A1

Title: Book binding assembly

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention is generally related to the field of book binding and in particular to providing hardcover assemblies for books suitable for easy mounting of cover wraps. 
     2. Description of Related Art 
     Binding books utilizing desktop binding machines has become popular. Such books are frequently made using soft bound books incorporated into hardcovers which results in a very realistic simulated hardcover book. A final step in finishing hardcover bound books involves covering the book with a cover wrap which is frequently custom printed. It is important that the cover wrap be properly and accurately installed since minor misalignments can significantly detract from the appearance of the final product. U.S. Pat. No. 7,452,172 entitled METHOD OF MAKING AND APPLYING A HARDCOVER OVERWRAP AND GUIDE APPARATUS (hereinafter the ‘172 patent) discloses one approach for applying hardcover over-wraps (sometimes referred to herein as “cover wrap”) to a hardcover. The contents of the ‘172 patent are fully incorporated herein by reference. 
     As can be seen in the ‘172 patent (see  FIGS.  18  -  27   ) a guide  60  is used to assist in accurately securing a cover wrap 80 to a hardcover book. Although this approach has been found to be successful, a user does not always have access to binding apparatus such as guide  60 . As will become apparent to those skilled in the art upon a reading of the following Detailed Description of the Invention together with the drawings, the present invention enables an accurate application of a cover wrap so as to produce an attractive book without the need for special tools such as guide  60 . 
     SUMMARY OF THE INVENTION 
     A book binding assembly made up of a stack of identical hardcovers, with each of the hardcovers having an outer wrap layer of pressure sensitive adhesive on one side and an inner wrap layer of pressure sensitive adhesive on the other side is disclosed. Each of the outer wrap adhesives is covered by an identical liner sheet, with each liner sheet also covering the inner wrap adhesive disposed above the liner. Thus, the outer and inner wrap adhesives are protected by the liner sheets. 
     In addition, the liner sheets possess attributes which enable the sheets to be used to provides accurate placement of an cover wrap onto the underlying hardcover. Such attributes can include, for example, the position of the liner sheet over the underlying hardcover. As a further example, attributes can include the dimensions of the liner sheet. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a top view one embodiment of a bookbinding assembly in a stack showing a liner sheet on top. 
         FIG.  2    is side view of the  FIG.  1    assembly. 
         FIG.  3    is a top view of the  FIG.  1    assembly showing liner sheet folded so as to expose a portion of the underlying adhesive on the hardcover. 
         FIG.  4    is a side view of the  FIG.  3    assembly. 
         FIG.  5    is a top view of the  FIG.  1    assembly showing a cover wrap over the liner sheet, with the under lying liner sheet still folded. 
         FIG.  6    is a side view of the  FIG.  5    assembly. 
         FIG.  7    is a top view of the  FIG.  1    assembly showing the cover wrap partially attached to the hardcover, with the liner sheet serving as an alignment guide. 
         FIG.  8    is a side view of the  FIG.  7    assembly. 
         FIG.  9    is a top view of the  FIG.  1    assembly showing final removal of the liner sheet while maintaining proper alignment of the cover wrap with the hardcover. 
         FIG.  10    is a side view of the  FIG.  9    assembly. 
         FIG.  11    is a top view of the  FIG.  1    assembly showing the cover wrap secured to the upper surfaces of the hardcover 
         FIG.  12    is a side view of the  FIG.  10    assembly. 
         FIG.  13    is a top view of the  FIG.  1    assembly with the covered hardcover being lifted from the stack. 
         FIG.  14    is a side view of the  FIG.  13    assembly. 
         FIG.  15    shows the  FIG.  13    assembly flipped over revealing the unattached edges of the outer wrap. 
         FIG.  16    is a side view of the  FIG.  15    assembly. 
         FIG.  17    is a partial view of an edge of a hardcover with a portion of a liner sheet extending past the edge. 
         FIG.  18    is a top view of the  FIG.  15    hardcover showing the covering process completed. 
         FIG.  19    is a side view of the  FIG.  18    hardcover. 
         FIG.  20    is a top view of another embodiment of a bookbinding assembly in a stack showing a liner sheet over a hardcover. 
         FIG.  21    is another top view of the  FIG.  20    assembly with a fold formed in the liner sheet to assist in aligning an outer wrap over the hardcover. 
         FIG.  22    is further top view of the  FIG.  20    assembly with another fold in the liner sheet to expose a portion of the hardcover adhesive. 
         FIG.  23    is a still further top view of the  FIG.  20    assembly showing a cover wrap disposed in the fold to assist in aligning the cover wrap over the hardcover. 
         FIG.  24    is a top view of a further embodiment of a bookbinding assembly in a stack showing a liner sheet over a hardcover. 
         FIG.  25    is a top view of the  FIG.  24    assembly showing the liner sheet pulled partially back to expose a segment of adhesive on the hardcover. 
         FIG.  26    is a top view of the  FIG.  24    assembly showing a cover wrap secured to the exposed adhesive segment of  FIG.  25    thereby fixing the cover wrap alignment on the hardcover. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to the drawings,  FIGS.  1  and  2    depict a stack  30  of eight cover assemblies, with each cover assembly including a hardcover  32  and associated liner sheet  34 . Each hardcover includes front and rear cover pieces  32   a  and  32   b  and an intermediate spine piece  32   c . A hinging element (not depicted), secures the three pieces  32   a ,  32   b , and  32   c  to form a hardcover. The outer surface of the hardcover are covered with a thin layer of pressure activated adhesive (not designated) referred to as the outer wrap adhesive. This adhesive functions to secure a cover wrap  38  (see  FIG.  9   , e.g.) to the outer side of the hardcover. Typically, the cover wrap  38  includes a title and other graphics which are preprinted. The inner surface of the hardcover  32  includes a band  46  ( FIG.  15   ) of heat activated inner wrap adhesive which extends around the periphery of the hardcover. This adhesive is sometimes referred to as the inner wrap adhesive and functions to secure the wrapped edges of the cover wrap to the inner surfaces of the hardcover. It is anticipated that stack  30  would be mass produced and sold to an end user who would complete the book making process including the addition of a cover wrap as will be described. 
     As will be seen, once an end user has applied the cover wrap to the outer surface of the hardcover  32 , the edges of the cover wrap are folded around the edges of the cover sheet and held in place by the four bands  46  of inner wrap adhesive. Preferably, the edges of the hardcover are also covered with pressure sensitive adhesive which functions to further secure the cover wrap folded around those edges ( FIG.  17   ). 
     A special liner sheet  34  is disposed over the cover adhesive of each the hardcovers in the stack in order to, among other things, protect the cover adhesive from any unintended adhering. As is common with all liner sheets, a coating on the sheets prevents the sheets from strongly adhering to the pressure sensitive adhesive. However, there is some adhesion so that a selected position of the liner sheet on the underlying hardcover is maintained. A further liner sheet, substantially identical to the other liner sheets in stack  30 , is disposed below the upper hardcover, contacting the inner wrap adhesive  40  of the upper hardcover. Thus, the inner wrap adhesive is further protected from any unintended adhering. In addition, the further liner sheet is disposed over the cover adhesive of the second hardcover  32  disposed immediately below the further liner thus protecting that adhesive also. This arrangement continues for the remainder of the stack  30 , with the last liner being disposed intermediate the last hardcover and then the bottom  36  of a shipping container. Since the various layers of pressure sensitive adhesive are somewhat tacky notwithstanding the presence of the liner sheets, the entire stack  30  will form a single integral unit which makes it convenient for shipping and handling by the end user. 
     In addition to the functions described above of the liner sheets  34 , such sheets provide an important additional function. The liner sheets are configured to assist the end user to achieve accurate placement of a cover wrap on a hardcover without the aid of alignment tools such as guide  60  disclosed in the ‘172 patent. In one embodiment as shown in  FIGS.  1  -  12   , the liner sheets are dimensioned to track those dimensions of a wrap sheet designed to fit the hardcover on which the liner sheet is disposed. The wrap sheet is sized to extend over the outer cover of the hardcover and then around the edges of the hardcover and then over the pressure sensitive inner wrap adhesive  40  ( FIGS.  15  and  17   ) bands disposed on the inner surface of the hardcover  32 . 
     Some details regarding the manner in which a cover wrap, and hence a liner sheet  34  in this embodiment, wraps around one edge of a front cover  32  of a hardcover are depicted in  FIG.  17   . In this case the total length L of the hardcover is measured normal to the spine and the total width W is measured in a direction parallel to the spine An appropriate cover wrap should have a length L plus twice the distance X needed to wrap the cover around the opposite edges of the hard cover. Distance X is equal to the sum of the thickness T of the hardcover (ignoring the thickness of the thin layers of adhesive) and distance E, the width of the inner wrap adhesive band  40  extending over the interior surface of the hardcover, such as front cover  32   a . Thus, the length L1 of liner sheet  34  ( FIG.  1   ) should be L + 2X or L + 2T + 2E taking into account two edges. Similarly, the width W1 of the liner sheet ( FIG.  1   ) should be W + 2T + 2E. Note that during the manufacturing process, the liner sheets  32  are positioned on the hardcovers so that the liner sheets extend past the edges of the hardcovers by distance X on all four sides. The slight tackiness of the pressure adhesive will hold these two elements in place. In this embodiment, the liner sheet  34  is positioned on the hardcover at the final desired location of cover wrap, as will be described. 
     The process for accurately attaching a cover wrap to a hardcover will now be described. Referring to  FIGS.  3  and  4   , at this point the top most hardcover remains on the stack thereby providing a stable working platform. The end user separates a portion of the liner sheet  34   a  from the underlying outer wrap adhesive on the front cover  32   a  of the hardcover. The lifted section  34   a  of the liner sheet is folded down as shown in  FIG.  4    against the remainder of the liner sheet thereby exposing a portion of adhesive covered hardcover  32   a . 
     Next, as shown in  FIGS.  5  and  6   , a properly sized cover wrap  38  is positioned over the liner sheet, including folded section  34   a . Care should be taken not to allow the cover wrap to contact the exposed adhesive during this alignment. Note also that the alignment preferably takes place at an end of the cover wrap opposite the exposed adhesive, such as the edges designated by arrows  42   a  and  42   b . Once the respective edges of the cover wrap and the liner sheet are carefully aligned with one another, the desired relative position of the cover wrap and liner sheet (and thus the hardcover) is achieved. 
     With the wrap and liner sheet held in place by one hand, the second hand is free to press down in the area of the cover wrap indicated by arrow  44  of  FIG.  8   . At this point, the correct relative position of the cover wrap and the hardcover is secured by the exposed adhesive disposed on the front cover  32   a  of the hardcover. The user then removes the remaining portion of the liner sheet  34  by pulling on the sheet in the area indicated by arrow  48  of  FIG.  9   . Next, the user presses the liner sheet against the newly exposed adhesive on the hardcover, taking special care in the spine area as indicated by arrow  50  of  FIG.  12   . Note that this point, the hardcover is still positioned on the stack thereby maintaining a stable work surface. Care is taken to ensure that all regions of the cover wrap are smoothly pressed against the hardcover. A small hand tool can be use to assist in this smoothing process. 
     At this point the hardcover/cover wrap arrangement is lifted away from stack  30 , as shown in  FIGS.  13  and  14   , with the underlying liner sheet  34  minimizing the force required. The arrangement is then flipped over and placed on a flat surface as shown in  FIGS.  15  and  16   . The four edges of the cover wrap are then manually folded around the respective edges of the hardcover and secured in place by the various sections of the inner wrap adhesive  40 . This final process is well known in the art. One approach is to press one edge of the hardcover, along with the section of the adjacent cover wrap, against a flat surface and then rotate the hardcover so as to partially fold the cover wrap around the hardcover edge. Note that the four chamfers  38 C ( FIG.  5   ) located in the corners of the cover wrap facilitate this folding and provide the desired finished look. The user then manually finishes the wrap around process until the edge of the cover wrap is covering the associated inner wrap adhesive  40  segment. These steps are repeated for the remaining three hardcover edges thereby completing the accurate securing of the cover wrap  38  to the hardcover  32  as shown in  FIGS.  18  and  19    which show the final hardcover  56 . As before, no special tools, other than possibly a small hand held smoothing tool, are required to complete the process. 
     It can be seen that the above-described combination of hardcovers and liner sheets results in a binding product that allows for the production of an attractive hardcover book without the use of special tools, with the possible exception of the actual binding itself. Even in that case, well known techniques allow the binding to be carried out with only basic tools. The disclosed liner sheets provide not only the function of protecting the various pressure sensitive adhesives on the hardcovers from unintended adhesion, but also the function of guiding an end user in accurate placement of a cover wrap over the hardcover. To this end, the liner is configured to include certain attributes to assist in achieving this end. In the above-described embodiment, these attributes include certain dimensions of the hardcover such as the length L and width W. Those dimensions may also include values T and E as also described above. In addition, it can be seen that the position of the liner sheet over the hardcover during manufacture is an attribute of the liner sheet which also contributes to the proper alignment of the cover wrap and the hardcover. 
     A further embodiment hardcover  32  and associated liner sheet  58  is shown in stack form in  FIGS.  20  and  21   . Liner sheet  58  has a generally rectangular form, with a notch  60   located in one corner. The liner sheet includes a fold line  58 A which is spaced a distance WF from an opposite edge of the sheet. The liner sheet can be actually folded along line  58 A during manufacture or perforations can be provided to assist in folding along the line by the end user. Distance WF is the same value as previously described distance W1, namely W + 2T + 2E where W is again the width of the hardcover and T and E are, respectively, the thickness of the hardcover and the width of the inner wrap adhesive band  40  as shown in  FIG.  17   . The length LN of liner sheet  58  is not critical provided the liner sheet extends past the edge of the underlying hardcover so as to cover the cover adhesive and so as to provide an region so that a user can grip the end of the sheet. Note that line  60 C represents an ideal location to fold an end of the liner sheet to form a flap  66 . The location of line  60 C is not critical, but is ideally slightly offset from notch edge  60   b  so as to facilitate various folding steps. Note that fold line  58 A is preferably aligned with edge  60   a  of notch  60 . Liner  58  is positioned over the hardcover, and held in place there by the slightly tacky adhesion between the liner sheet and the pressure sensitive adhesive, during manufacture so that the distance between edge  62   a  of the liner sheet and the edge of the hardcover is value X or E + T ( FIG.  17   ). The distance between edge  62   b  of the liner sheet and the edge of the hardcover is also set during manufacture to value X. 
     In order to apply a cover wrap  38 , the end user leaves the top liner sheet  58  and underlying hardcover on the top of the stack so that, once again, the stack will provide a stable work surface. In the event that the liner sheet was not folded during manufacture, the end user carefully folds the liner, preferably using perforations located along line  58 A, to produce a flap member  64  as shown in  FIG.  21   . Next, the end of liner sheet is folded near line  60 C to reveal a section of adhesive located on the outer surface of the hardcover The resultant flap  66  is tucked under flap  64  as shown in  FIG.  22   . Note that the slight displacement between notch edge  64   b  and line  60   c  ( FIG.  20   ) keeps flaps  64  and  66  from interfering from one another during this operation. 
     The cover wrap  38  is then positioned on the liner sheet as depicted in  FIG.  23    taking care to not allow the sheet to contact the small portion of the exposed hardcover adhesive. The liner sheet is positioned over the folded flap  66  at this point. A long edge of the cover wrap  38  is then positioned under flap  64  until the edge is disposed along the entire length of fold line  58 A as represented by arrow  68   b . Since the edge of the liner sheet is somewhat wedged in place between flap  64  and the under lying liner sheet, the liner sheet tends to stay in place while permitting lateral movement of the sheet. An edge of the liner sheet is then moved laterally until it is aligned with an edge of the hardcover as indicated by arrow  68   a  of  FIG.  23   . With both locations  68   a  and  68   b  aligned, a correct positioning of the cover wrap  38  over the liner sheet, and hence over the hardcover, is achieved. The user then maintains this position by pressing down on flap  64  with one hand. The user then, using the other hand, forces that portion of the cover wrap extending over the exposed adhesive down against the adhesive thereby securing the cover wrap and the hardcover together with the correct alignment. The user then removes the last of the liner sheet so that the reminding hardcover adhesive  32  is exposed. The user then proceeds to complete the process of securing the cover wrap as previously described in connection with the first embodiment. 
       FIGS.  24  -  26    show a further embodiment of a hardcover/liner sheet arrangement. In this case, the arrangement is manufactured such that liner sheet  70  is positioned on the hardcover  32  such that edge  70   b  of the liner sheet is aligned with edge  72   d  of the hardcover. Similarly, edge  70   a  of the liner sheet is aligned with  72   b  of the hardcover. In order for the liner sheet to provide the desired guide function with this position, the liner sheet edge  70   c  should extend a distance past the hardcover edge  72   a  of T + E, where values T and E were previously explained in connection with  FIG.  17   . Also, the liner sheet edge  70   d  should extend past the edge  72   c  a distance of T + E. Thus, the width WA of liner sheet  70  is substantially equal to W + T + E and the length LA is substantially equal to L + T + E. (As previously noted, values W and L represent the width and length, respectively, of the hardcover.) 
     As shown in  FIG.  25   , the user then exposes a region of the outer wrap adhesive on the hardcover by lifting a section  70 A of the liner away from the hardcover. The lifted section forms a flap  70 A that is folded flat against the remainder of the liner. Next, the cover wrap  38  is positioned over the liner sheet  70  with orthogonal edges of the liner  70   b  and  70   a  being aligned with the corresponding orthogonal edges of the cover wrap (not designated). These alignment points are designated by arrows  74   a  and  74   b . Note also that the cover wrap edge extends past the corresponding edge  70   a  of the liner sheet for this embodiment. When achieving this alignment, care must be taken not to contact the exposed adhesive. Once the alignment has been made, the cover wrap is held in place to maintain the alignment while liner sheet is completely removed thereby exposing the remainder of the adhesive. The cover wrap is then presses against the adhesive over the full surface of the hardcover as previously described. The edges are then finished as also previously described thereby completing the process. 
     As described above, various embodiments of bookbinding assemblies have been disclosed which enable an end user to accurately apply an outer wrap to a hardcover without the need for specialized tools such as alignment guides. Although these embodiments have been described in some detail, it is to be understood that various changes can be made by those skilled in the art after reading the above Detailed Description of the Invention together with the drawings without departing from the spirit and scope of the invention as defined by the appended claims.