Hardcover book processing has always been a binding technology that people in the industry are concerned about. In order to experience this unique technology, this reporter interviewed Nanjing Aide and Beijing Aide Company, which are quite experienced in the production of hardcover books, and interviewed them for many years. Technical staff with hard working experience. Let's have a Deluxe Edition hardcover book that will take you into the world of hardcover bookmaking combined with manual and equipment.
Hardcover books related information
1. Hardcover features
The flip of the book block has a thumb index hole. Three corners of the book block have a gold finish, a zippered leather cover, thin paper printing, and rounded corners.
2. Binding material
Folio 32 open size (125mm x 185mm); Bible paper basis weight paper is 30g / m 2; a book envelope is 1 50g / m 2 paper jam mounted leather; backing ring is offset paper basis weight 150g / m2 of According to the design requirements of the hardcover book, the ring backing paper was printed as black solid; the stamping material was selected from the German Kurz's anodized aluminum; in addition, the white glue was purchased from the market. Leather (pigskin), zippers, stickers and other materials.
3. Binding equipment Flatteners, presses. Three-side cutters, gilding die-cutting machines, sewing machines, and thumb index holes. Rolling machine special equipment.
Book block processing
1. Process flow
Flattening â†’ first brushing â†’ cutting â†’ three grinding (coarse grinding, fine grinding, fine grinding â†’ rolling round. Ridged â†’ second brushing â†’ glue sticking core â†’ belt and adhesive plug cloth â†’ third Brush glue â†’ sticky gauze. Sticky paper back paper â†’ cutting â†’ rolling mouth â†’ processing thumb index hole a label
2. Processing points
(1) The book's circle potential is calculated from the thickness of the book block, and the length of the book block arc is approximately 12 times the thickness of the book block.
(2) The book block ribbon sandwiched between the pages of the book is glued to the back of the book at a distance of about 10 mm from the top of the sky. Its length is based on the length of the diagonal of the book. Normally, the length of the book block should exceed 10-20 mm. A thin book generally uses 1 ribbon, but considering that the content of the hardcover book is divided into two parts, the processing design uses 2 ribbons for ease of reading and research needs.
(3) When sticking the head cloth, the position should be correct and not be skewed. The edge of the plug cloth should be exposed on the outside of the book block, the upper end of the cut, and be parallel to the cut surface. The width of the plug cloth is generally 10-1 5mm, and the length is the arc length of the back of the book.
3. Processing features
(1) Rounded corners
1 According to the size of the book and the thickness of the book block, to determine the radius of the rounded corners, the range of change is generally 2-8mm. If the customer has a recommendation, the binder can also refer to it.
2 The rough grinding and fine grinding of the rounded corners are done by the machine, and the grinding is done by hand.
3 Because the rounded part is easy to wear during use, the process requirements for the round corners are relatively strict.
(2) Gold rolling mouth
1Requires that the nouging mouth is shiny and can not fall off gold, especially in the round corner; ensure the cleanliness of the production and processing environment, because once the dust adheres to the incision during the processing, the hot iron will come off and will be there. The formation of white spots will result in a gold spill.
2 Under normal circumstances, no matter how large the size of a book is, the three-side incisions of the book's core are required to add 1 mm to the cuts on the three sides of the finished book block, which are used as the process loss during the process of grinding the three sides of the incision.
(3) Thumb index hole
According to customer's request. The specific content of the book, design layout of the thumb index hole. For example, there are 39 thumb holes in the hardcover book, and the design is arranged in 4 rows, with 2 rows in the forward direction and 2 rows in the reverse direction.
The processing points are as follows:
1 Record the specific page number of the page where the thumb index mark is located in a certain order as a preparation before processing.
2 The tool diameter of special equipment has a variety of specifications. When it is used for punching, the diameter of the final thumb index hole will be slightly larger than the diameter of the special tool, but it should not be too large. Take special care not to damage the center of the printing plate.
3Requires thumb index hole layout is reasonable. The size is uniform; the spacing between the index holes of the thumb is required to be equal; the incision of the index hole of the thumb is required to be smooth, and no burrs are allowed; the key is to check whether the incision of the thumb index hole on the front side of the mark is smooth.
4 Taking into account the requirements of the customer and the content of the book, under the premise of meeting the technical requirements, customize the thumb index mark according to the needs and processing parameters.
Book shell processing
1. Process flow
Gluing â†’ Adhesive Cover â†’ Edge Angle â†’ Flattening â†’ Indentation (for decoration only) â†’ Hot Stamping â†’ Upper zipper
2. Processing points
(1) The four sides of the book case should be firmly bonded and not allowed to loosen or soak. Wrinkles and other phenomena.
(2) The surface of the book case should be flat and neat with 4 round corners to ensure that the rounded corners are not angular.
(3) The edge size of the four sides of the book case should be the same. The width of the hemming is determined to be 15mm. The standard requirement is that the hemming width be within the range of 12-16mm.
(4) Each corner of the book case should be made with six pleats. Theoretically, it must have no less than five pleats, and the number of fillet pleats of the four rounded corners must be the same.
(5) Preparation of the zipper should be done before the book shell is processed.
(6) After the book shell is processed, the teeth of the zipper must not be in contact with the three-sided incisions of the book block, so as to avoid damage to the gold seal.
1. Process flow
General assembly process of hardcover book: coating adhesive â†’ sleeve â†’ pressure slot qualitative â†’ lining â†’ flattening
2. Processing points
(1) The three sides of the floating port must be the same, and the standard floating port width of the open size is 32 (3 0.5 mm).
(2) The pressure groove should be immediately after completion of the sleeve operation, because the setting effect is best when the adhesive is not yet dry.
(3) When the lining is used, the amount of the adhesive should be as small as possible and uniform. No smearing, no flowers, and no smearing.
(4) The groove line after pressing groove should be straight. No wrinkles. No cracks, clear and smooth indentations.
Common quality problems
1. Loosening of the book
Cause of failure: book block, book back processing is not tight.
Solution: Make the book block and book back tighter; choose the right adhesive.
2. Gold matte finish
Cause of failure: Improper selection of hot stamping material; three-sided incisions are not smooth enough; hot stamping temperature is too high.
Solution: Select the right stamping material; smooth the three sides of the incision; reduce the stamping temperature.
3. Rolling gold out of gold
Cause of failure: The hot stamping material is not in conformity with the object to be heated; the quality of the anodized aluminum layer is poor; the hot stamping temperature is too low and the hot stamping pressure is too small; the hot stamping material does not help the adhesive material; the dust attached to the three side incisions is too much; Inappropriate human use.
Solution: Correctly use hot stamping materials such as anodized aluminum; re-adjust the stamping temperature and stamping pressure; check before using anodized aluminum, if there is any problem, replace it in time; add hot-rolling material without adhesive layer; During the grinding process, residual dust is removed in time; readers should pay attention to protecting books.
4. Three-sided incision
Cause of failure: Since the three-sided incision has been very smooth, the temperature is easily raised during the grinding process, resulting in three-sided incisions.
Solution: Adjust the pressure applied by the grinding wheel to the three-sided incision and adjust the grinding time. work plan. The temperature of the environment and the speed of the grinding wheel, the type of grinding wheel is reasonably selected.
5. Logos Zhang Guan Li Dai
Cause of failure: The logos are misaligned; the logo is affixed to the next side; the logo is affixed to the previous side.
Solution: Find the correct page number for the thumb index logo on the page.
6. The logo is beyond the front or white side
Cause of failure: The position of the thumb index mark is inaccurate and the operator's inexperience.
7. Thumb trap hole is trapezoidal
Cause of failure: The back of the book is loose and the operator has insufficient experience.
8. Ring liner paper wrinkled
Cause of failure: The quality of the ring liner and the adhesive are poor; the pressure exerted by the applicator is too great; the hygroscopicity of the ring lining: human error in the lining operation.
Solution: Use high quality. Appropriate ring liners and adhesives; adjust the pressure of the applicator; apply an adhesive and insert a piece of padding paper between the ring liner 2 and the ring liner 3 (membrane facing toward the book block, paper facing the book Encapsulation), and properly control the temperature and humidity of the book storage environment; standardize operating disciplines and improve employee's work responsibility.
From a professional and technical point of view, Mr. Wei Aiyong believes that to identify the quality of a hardback book binding quality to do a "three look": to see whether the three sides of the mouth is consistent, read the book spine and book back is docile, see if the plug cloth binding Firm, although these do not constitute a direct impact on consumer reading, and are even ignored by consumers.
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