GB2591219A

GB2591219A - A method of making a mini lay-flat book

Info

Publication number: GB2591219A
Application number: GB1916674.3A
Authority: GB
Inventors: Balcombe Andrew
Original assignee: Pocket Memories Ltd
Current assignee: Pocket Memories Ltd
Priority date: 2019-11-15
Filing date: 2019-11-15
Publication date: 2021-07-28
Also published as: GB201916674D0

Abstract

A method of making a mini lay-flat book, the method comprising the steps of: (a) folding a plurality of sheets of paper 1 such that each sheet of paper defines two inner faces and two outer faces 3; (b) adhering one of the outer faces of a first sheet of paper to one of the outer faces of a second sheet of paper using an adhesive 2; (c) adhering the remaining outer face of the second sheet of paper to one of the outer faces of a third sheet of paper using an adhesive; (d) repeating step (c) with subsequent sheets of paper to form a block of sheets of paper, each time gluing the remaining outer face of the previous sheet of paper to one of the outer faces of the subsequent sheet of paper; and (e) cutting the block of sheets of paper into a plurality of mini lay-flat books (see fig.3). The method may include inserting a sheet of stiffening material (e.g. cardboard or hardboard) between the two outer faces before they are adhered together.

Description

A method of making a Mini Lay-flat Book The present invention relates to a method of making a mini lay-flat book.

A lay-flat book is made from a plurality of sheets of paper, each which has been printed on one side, and folded in half such that the two inner faces are printed and the two outer faces are blank. Each such folded sheet of paper is known as a "signature". One of the blank outer faces of a first signature is adhered to one of the blank outer faces of a second signature, and the remaining blank outer face of the second signature is adhered to a blank outer face of a third signature. This step is repeated until all of the signatures have been adhered together to form a block in which each page, apart from the first page and the last page, is of double-thickness. The first and last pages are then usually adhered to a separate cover.

Although there is crease in the centre of the book, there is no break or cut between adjacent pages, as adjacent pages are formed by a single sheet of paper which has been folded in half. This means that lay-flat books open completely flat across the central fold, and there is no central gutter as with a conventional book. This allows photographs to be printed so that they extend from one side of the open book, across the central fold, and onto the other side of the open book. Thus, large photographs, including panoramic views, can be printed across the full width of the open book, with only a subtle central fold as opposed to a central gutter.

This ability to display photographs across the full width of an open book means that lay-flat books are an increasingly popular choice for prestige publications. However, construction of a lay-flat book is comparatively time consuming compared to construction of a conventional book with a central gutter, and this means that lay-flat books are expensive. Moreover, difficulties in handling the sheets of paper mean that lay-flat books can only be mass produced in a large size. Thus, the present standard size for a lay-flat book is between 355mm x 380mm and 180mm x 150mm. Using present methods of making lay-flat books, it is not possible to make a lay-flat book having a size of less than 100mm x 100mm. Such lay-flat books are referred to herein as "mini lay-flat books".

Accordingly, it is an object of present invention to provide a method of making a mini lay-flat book, that is, a lay-flat book having a size of less than 100mm x 100mm.

The invention provides a method of making a mini lay-flat book, the method comprising the steps of: a) folding a plurality of sheets of paper such that each sheet of paper defines two inner faces and two outer faces; b) adhering one of the outer faces of a first sheet of paper to one of the outer faces of a second sheet of paper using an adhesive; c) adhering the remaining outer face of the second sheet of paper to one of the outer faces of a third sheet of paper using an adhesive; d) repeating step c) with subsequent sheets of paper to form a block of sheets of paper, each time gluing the remaining outer face of the previous sheet of paper to one of the outer faces of the subsequent sheet of paper, and e) cutting the block of sheets of paper into a plurality of mini lay-flat books.

The present invention overcomes the problems found when handling small sheets of paper by using large sheets of paper during the steps of applying adhesive to the signatures and assembling the signatures into a block. The completed block is then cut into a plurality of mini lay-flat books.

Cutting the block into a plurality of mini lay-flat books has the added advantage of increasing productivity, thereby reducing costs. This means that mini lay-flat books can be produced not only for prestige publications, but also for standard publications.

Preferably, each sheet of paper is printed on one side, the two outer faces of each sheet of paper being blank.

In prior methods for making lay-flat books, the adhesive is heated prior to application. This facilitates application of the adhesive. However, in the method of the present invention, the adhesive may be applied without prior heating, preferably using a roller. The applicant has found that, by using a roller, it is possible to apply the adhesive without prior heating. This reduces the time required in order to set up the binding apparatus, thereby further reducing costs.

The adhesive may be a water-based adhesive.

Preferably, the block of sheets of paper is pressed before being cut into a plurality of mini lay-flat books.

A sheet of stiffening material such as cardboard or hardboard may be inserted between each two outer faces before they are adhered together.

The invention further provides a mini lay-flat book made by a method according to the invention. As previously indicated, a "mini lay-flat book" as referred to herein is a lay-flat book having a size of less than 100mm x 100mm.

The invention is illustrated figuratively and by way of example with reference to the following drawings, of which: Figures 1.1 to 1.5 show the steps required to produce a block of signatures; a Figure 2 shows a block of signatures prior to being cut into three mini lay-flat books; and Figure 3 shows three mini lay-flat books.

Figure 1.1 shows a plurality of sheets of paper, each which has been printed on one side, and folded in half such that the two inner faces are printed and the two outer faces are blank. Each such folded sheet of paper 1 is known as a "signature".

As shown figuratively in Figure 1.2, each of the signatures 1 is fed to a gluing station using an air strip. As shown in Figure 1.3, once a signature 1 reaches the gluing station, an adhesive 2 is applied to one of the blank outer faces 3 of the signature using a roller 4. The adhesive 2 is a water-based adhesive, and it is applied cold, without prior heating of the adhesive.

Once adhesive 2 has been applied to a signature 1 it is fed to a binding plate where it is retained in position by a groove, with the adhesive 2 uppermost. As shown in Figure 1.3, subsequent signatures 1 are also fed to the binding plate, where they gather in alignment due to the groove and form a block 5. If desired, a sheet of stiffening material such as hardboard may be inserted between each adjacent signature 1.

As shown in Figure 1.4, the signatures 1 are then pressed in order to adhere adjacent outer faces 3 to one another, so forming a bound block 5.

Figure 2 shows a block 4 of signatures prior to being cut into three mini lay-flat books, and Figure 3 shows three mini lay-flat books 5, each of which is 95mm x 95mm.

The above embodiment is described to illustrate the invention, and is not intended to be limiting. The skilled person will be able to devise alternative embodiments without departing from the scope of the claims.

Claims

Claims: 1. A method of making a mini lay-flat book, the method comprising the steps of: a) folding a plurality of sheets of paper such that each sheet of paper defines two inner faces and two outer faces; b) adhering one of the outer faces of a first sheet of paper to one of the outer faces of a second sheet of paper using an adhesive; c) adhering the remaining outer face of the second sheet of paper to one of the outer faces of a third sheet of paper using an adhesive; d) repeating step c) with subsequent sheets of paper to form a block of sheets of paper, each time gluing the remaining outer face of the previous sheet of paper to one of the outer faces of the subsequent sheet of paper; and e) cutting the block of sheets of paper into a plurality of mini lay-flat books.
2. A method according to claim 1, wherein each sheet of paper is printed on one side, the two outer faces of each sheet of paper being blank.
3. A method according to any preceding claim, wherein the adhesive is applied without prior heating.
4. A method according to any preceding claim, wherein the adhesive is applied using a roller.
5. A method according to any preceding claim, wherein the adhesive is a water-based adhesive.
6. A method according to any preceding claim, wherein the block of sheets of paper is pressed before being cut into a plurality of mini lay-flat books.
7. A method according to any preceding claim, wherein a sheet of stiffening material is inserted between each two outer faces before they are adhered together.
8. A method according to claim 6, wherein the stiffening material is cardboard or hardboard.
9. A mini lay-flat book made by a method as claimed in any preceding claim.