Summary of the hottest hardcover book processing

2022-07-24
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Hardcover book processing summary

hardcover book processing has always been a binding technology concerned by people in the industry. In order to personally experience this unique process, this magazine visited Nanjing aide and Beijing aide, which have considerable experience in hardcover book production, and interviewed technicians with years of hardcover work experience. Now let's take a deluxe hardcover book to the world of hardcover book processing technology combining manual and equipment

hardcover book related data

1. hardcover features

the turnover of the book block has thumb index holes. The three sides of the book block are cut with rolled gold mouth, leather cover with zipper, thin paper printing and round corner processing

2. the size of binding material

format is 32 (125mm x 185mm); The paper is Biblical paper with a ration of 30g/m2; The book cover is made of 150g/m2 cardboard and leather; The ring lining paper is a double offset paper with a weight of 150g/m2; According to the design requirements of the hardcover book, the ring lining paper is printed as black 5. In the work, it is prohibited to remove and change the mandrel, change the angle of view and change the speed; The hot stamping material is electrochemical aluminum from Kurtz, Germany; In addition, we bought milk white glue from the market. Leather (pigskin), zipper, self-adhesive and other materials

3. binding equipment

flattening machine and grooving machine. Three side book cutting machine, stamping die-cutting machine, sewing machine, and thumb index hole. Special equipment for rolling mouth, etc

book block processing

1. process flow

flattening → first glue brushing → cutting → three grinding (rough and fine grinding. Fine grinding → rounding and ridging → second glue brushing → sticking book block wire → tape and stick plug cloth → third glue brushing → stick gauze. Sticking book back paper back paper → cutting → rolling gold mouth → processing thumb index hole one stick identification

2. processing points

(1) the circle potential of book back is calculated based on the thickness of book block, After rounding, the length of the book block arc is about 12 times the thickness of the book block

(2) the book block ribbon clamped in the middle of the book page is glued to the back of the book about 10mm away from the upper end of the head. Its length shall be subject to the length of the book diagonal according to gb/t7689.5 ⑵ 001 test method for woven fabrics of reinforced materials Part 5: Determination of tensile breaking strength and elongation of glass fiber. After normal straightening, the lower part shall exceed the book block by mm. Generally, one ribbon is used for thin books, but considering that the hardcover book is divided into two parts, in order to facilitate reading and research, two ribbons are used for processing design

(3) when sticking the plug cloth, the position should be correct and not skewed. The edge of the plug cloth should be exposed outside the upper and lower cuts of the book block and parallel to the cut surface. The width of the plug cloth is generally 5mm, and the length is the arc length of the back of the book

3. processing features

(1) fillet

① determine the radius of the fillet according to the size of the book and the thickness of the book block, and its variation range is generally 2-8mm. If the customer has a recommended value, the binding factory can also refer to it

② rough grinding and fine grinding of fillet are completed by machine, and fine grinding is completed by hand

③ since the fillet is easy to wear during use, the process requirements for fillet are relatively strict

(2) knurled joint

① it is required that the knurled joint should be glossy and free of gold dropping, especially at the fillet; Ensure the cleanness of the production and processing environment, because once the dust is attached to the incision during the processing, the hot trace will fall off, and a white spot will be formed here, resulting in the phenomenon of gold falling from the gold rolling mouth

② generally, no matter how large the size of book 7 and fuse is, 1mm is required to be added to the three-sided cut of the bare book block compared with the three-sided cut of the finished book block, which is used as the process loss in the process of polishing the three-sided cut

(3) thumb index hole

according to customer requirements. The specific content of the book, design the arrangement of thumb index holes. For example, there are 39 thumb index holes in the hardcover book, which are designed to be arranged in 4 rows, 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 book page where the thumb index hole is marked one by one in a certain order as preparation before processing

② the tool diameter of the special equipment has various specifications. When drilling with it, the diameter of the thumb index hole will be slightly larger than that of the special tool, but not too large. Pay special attention not to damage the layout center

③ the layout of thumb index holes shall be reasonable. Uniform size; The spacing between thumb index holes shall be equal; It is required that the notch of the thumb index hole shall be smooth and clean without burrs; Focus on checking whether the notch of the thumb index hole on the front side of the mark is smooth

④ considering the requirements of customers and the contents of books, on the premise of meeting the process and technical requirements, customize the thumb index identification according to needs and processing parameters

book cover processing

1. process flow

gluing → sticking the cover → wrapping corners → flattening → indentation (only for decoration) → hot stamping → zipper up

2. processing points

(1) the four sides of the book cover shall be firmly bonded without looseness or blisters. Wrinkles, etc

(2) the surface of the book cover shell and the four rounded corners shall be flat and tidy to ensure that the rounded corners are free of edges and corners

(3) the binding size of the four sides of the book cover shall be consistent. The binding width shall be determined as 15mm. The standard requires that the binding width be within the range of 12-16mm

(4) each round corner of the book cover shell shall be pleated with 6 folds, which shall not be less than 5 theoretically, and the number of pleats of the 4 round corners shall be the same

(5) make preparations for the zipper before processing the book cover

(6) after the processing of the book cover, the teeth of the zipper are not allowed to contact the three sides of the book block, so as to avoid damaging the gold rolling mouth

nesting processing

1. process flow

nesting processing process of general hardcover books: coating middle seam adhesive → casing → pressing groove for qualitative determination → lining sweeping → flattening

2. processing points

(1) the three sides of the floating opening should be consistent, and the width of the standard floating opening with a size of 32 is (3 Soil 0.5) mm

(2) the grooving shall be carried out immediately after the casing operation, because the setting effect is the best when the adhesive has not been dried

(3) the amount of adhesive used during lining cleaning shall be as small and uniform as possible, and there shall be no overflow, flower and missed coating during coating

(4) the groove line after grooving shall be straight without wrinkles. There is no crack, and the indentation is clear and flat

common quality problems

1. loose book back

fault cause: the book block and book back are not tightly processed

solution: make the book block and back more compact; Choose the correct adhesive

2. tarnish of gold rolling mouth

fault cause: improper selection of hot stamping materials; The incision on three sides is not smooth enough; Hot stamping temperature is too high

solution: select the correct hot stamping materials; Make the three side cuts smooth; Reduce the hot stamping temperature

3. gold falling from the gold rolling mouth

fault cause: the hot stamping material does not conform to the hot object; The quality of electrochemical aluminum adhesive layer is poor; The hot stamping temperature is too low and the hot stamping pressure is too small; Hot stamping materials are not sticky; Too much dust is attached to the three side cuts; Improper human use

solution: correctly use anodized and other hot stamping materials; Readjust the hot stamping temperature and pressure; Check before using electrochemical aluminum, and replace it in time if there is any problem; When the hot stamping material has no adhesive layer, add adhesive AIDS; Remove the residual dust in time during the three grinding process; Readers should protect books

4. three side cuts and edges

fault cause: because the three side cuts are very smooth, the temperature is easy to rise during grinding, resulting in three side cuts and edges

solution: adjust the pressure exerted by the grinding wheel on the three side cuts and adjust the grinding time. Working stroke, ambient temperature, speed of grinding wheel, reasonable selection of type of grinding wheel, etc

5. signs are worn with hats and hats

fault cause: signs are misaligned; The logo is pasted to the next side; The logo is pasted on the upper side

solution: find out the correct page number marked by the thumb index in the book page

6. the sign exceeds the front mouth or shows the white edge

fault cause: the pasting position of the thumb index sign is inaccurate and the operator is inexperienced

7. the notch of the thumb index hole is trapezoidal

fault cause: the back of the book is loose and the operator is inexperienced

8. wrinkle of ring lining paper

fault cause: poor quality of ring lining paper and adhesive; Excessive pressure applied by the flattening machine; Moisture absorption of annular lining: human error during lining sweeping

solution: select high quality. Appropriate ring backing paper and adhesive; Adjust the pressure of the flattener; After applying the adhesive, add a piece of film covering pad paper (the film surface faces the book block and the paper surface faces the book cover) between the ring lining II and the ring lining III, and properly control the temperature and humidity of the book storage environment; Standardize operation discipline and improve employees' working spirit

from the perspective of professional technology, Mr. weiaiyong believes that to identify the binding quality of a hardcover book, we should "look at three aspects": whether the three sides are consistent, whether the reading ridge and the back of the book are comfortable, and whether the binding of the plug cloth is firm, although these do not constitute a direct impact on the reading of consumers, and even are ignored by consumers

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