Now manufacturers of hardcover books generally have shell making machines and hardcover linkage production lines. However, when small companies produce hardcover books in small batches, it is impossible to invest heavily in automated production. When receiving small batch orders for bids and classmates, you can only rely on existing equipment for processing. Due to processing conditions, you can only strictly control the quality standards for each process. Products that do not meet the quality standards and requirements are absolutely Can not flow to the next process, strictly control on-site quality management. The following author discusses the main points of processing hardcover books.

Control of raw materials

1. Use of cardboard

The book cover cardboard specially produced for hardcover books and albums should be selected, and the storage time should be more than half a year. The shrinkage of this kind of paperboard is small, which can reduce the possibility of deformation when making book covers. When the paper cutter is cutting, first add 2mm margin on each side of the finished product size. After the hair sample is cut out, the cut bevel is processed into a smooth edge to eliminate the bevel generated by single-knife cutting and reduce the margin after the edge. The bubble and edging are skewed. The size of the cardboard is the length of the book block plus 6mm, and the width is the width of the book block minus 2mm.

2. Use of medium diameter paper

Generally choose 80 ~ 240g / m2 paper. If the paper is cut in the direction of the longitudinal grain and used as the length of the middle-diameter paper, the back of the book can be prevented from being uneven after shrinking. The length of the middle-diameter paper is equal to the length of the book cover, and the width is the arc length of the back of the book after the ridge is rounded (the square back is the width of the back of the book plus 2 times the thickness of the cardboard).

3. Use of auxiliary materials

(1) The caulking cloth is first sizing with starch. The position of the plugging cloth should be correct and not skewed; the corners of the plugging cloth should be exposed outside the cutouts of the upper and lower ends of the book block, and parallel to the cutouts; after pasting, it should be straight and should be firmly bonded with the same margin on both sides. Its length is 1mm longer than the back of the book.
(2) Gauze chooses sizing gauze. Its length is 22 to 26mm shorter than the book block. The width is 40mm thicker than the book block.
(3) Generally, 100 ~ 120g / m2 offset paper is used for the back of the book, so that the vertical lines run along the top and bottom of the back of the book to facilitate the division.
(4) The book block tape uses a 5 to 8mm wide silk ribbon, with the diagonal length of the book block as the ribbon length, and is generally pasted on the back of the book at 15mm.

4. Use of cover material

The customer requires that the size of the lacquered paper full fabric is: the length is the cardboard length plus 30mm, the width is 2 times the cardboard width plus the middle diameter paper width and then 44mm (the edge size is 15mm). After the materials are prepared, hot stamping and shell manufacturing are carried out to prevent the cardboard from being uneven due to glue brushing after the shell is manufactured, resulting in hot stamping patterns, wild gold and insufficient brightness.

Control of book block processing

The structure of various book blocks is different, and the modeling and processing methods and steps are also completely different, but the basic processing such as book back brushing, adhesive gauze, adhesive plug cloth, adhesive book back paper, etc. are basically the same. After the first few steps, it enters the flattening step.

1. Flatten

Because the book block is compressed, the stress can be eliminated, the needle is closed, and the back of the book is flat and at a right angle, the book block root is compressed and the folding product book block is pressed to prevent the step after the book is completed. In addition, every book is subject to a general inspection at this time, to check more posts and fewer posts, and to mark the responsibility of inspection on the back of the book, so as to ensure that there are no wrong posts in the book block. When flattening, the book blocks after the thread lock are collided, laid flat, and placed upright. The pressure is appropriate to make the book blocks have the same firmness, that is, to ensure the same thickness of the back of the book, and to prevent the phenomenon of shrinking, pressing, and rolling.

2. First glue application

After the book block is bundled, use thin adhesive material to paint on the back of the book at intervals to form a layer of flexible film, so that the book block is basically shaped so that there is no misalignment during the next process, and the first brushing is completed .

3. Cut the book

Three-sided cutting requires the book to be square and the cutting error is small.

4. Grilled round

The standard arc of the back of a hardcover book should take the thickness of the book block as the diameter. The center angle of the arc on the back of the book is about 130 °, but the thicker the book block, the smaller the roundness. The thinner the book block, the more rounded. Bigger. In order to unify the arc size of the book block after processing, each book should be compared with the arc of the dedicated mold after rounding, to ensure that the arc length and the drift of the subsequent process are consistent. You can use a steam iron to fold the book by hand, stack the books with the back facing up, put a towel on, and iron it back and forth several times with steam to soften the back of the book, and then use a wooden hammer to beat it. It can prevent the interleaf of coated paper from being damp, wrinkled or sticky, and improve the binding quality.

Finally, stick the ribbons and "three sticks" according to the quality requirements.

Control of book cover making

When making a book cover, first adjust the size of the mask frame, and make a wide mark on the back of the upper gauge to ensure that the back of the book is centered. When loading the paperboard, the paperboard should lean to the left and right sides to overcome the error in the cutting of the paperboard and ensure that the size of each book cover is the same after it is made. After the book cover is made according to the quality requirements, use four sides of the book to scrape the edges tightly with bamboo scrapers to prevent the edges from becoming tight and empty. Then the two book covers are stacked two by two, and the middle seam is lined with cardboard of the same thickness as the book cover, so that the middle diameter of the cover is pressed down. Each pile of book covers just finished is pressed once under controlled pressure, and then the cover is separated, the pads are taken away, and the stack is spread out in one direction, and then a heavy object is pressed on top to prevent warping. Before you open the cover of the book, the cover should be erected to dry in the shade and let it dry naturally. In the rainy season, preservatives should also be added to the shell gum to prevent mildew when it is naturally dry.

Before the upper case of the round back book, the center seam should be preheated and formed on the self-made round back tool to facilitate its coincidence with the back of the book and make the back of the book coincide with the middle of the book cover. Focus on preventing the warpage of the surface of the book cover: (1) Use animal glue with low moisture, quick drying and good shaping. (2) Adjust the internal and external tension of the book cover cardboard to balance the internal and external moisture. (3) After stacking the finished products, flatten them, and then blow dry them with circulating air. After completely drying, check or package them.

Control of the sealing process

When loading the book cover, first apply glue to the inner groove of the book cover, then press the book block and the book cover anyway to carry out a test case, so that the three sides of the sky, the foot, and the front mouth are equal, use a pressure groove After the machine presses the groove, it is passed to the liner sweeper for liner sweeping. The groove is pressed first and then the liner is swept to prevent liner liner paper with strong moisture absorption ability from spitting.

Next, open the book cover above, dip an appropriate amount of paste with a 7-inch wool brush, and apply evenly from the middle of the ring liner to the four sides. Then stack the front opening of the book staggered to the front opening and flatten it to eliminate the air remaining between the liner and the cover of the book to make them stick more firmly and evenly. In the case of coated paper ring liner, between two pages, a waste cover covered with film must be placed. The film side faces the book block to help absorb moisture and prevent moisture from entering the ring liner and wrinkling the pages. In addition, the case personnel are required to cover the ring liner with a personal ID to prevent the book block from being turned upside down. The book after the test case should be checked for consistency on three sides, and whether the back of the book and the spine are even. The lining sweeper should lift the brush when it is almost to the side to prevent wild glue and sticking of the incision.

In addition, we should pay attention to the control of the groove process and the inspection control of book completion. Groove process control: use a special groove plate to perform groove groove, which requires the groove line to be aligned with the book groove. A layer of books and a laminated groove plate are stacked to a certain height and then pressurized. The book groove is shaped for 4 hours to prevent the book groove from Firm. Finished book inspection control: books with wild glue should be polished with fine sandpaper and separated, and the final inspection of the book block problem should be done, and the inspection mark should be marked before being packaged and shipped.

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