Note: Descriptions are shown in the official language in which they were submitted.
W~~0/13.~26 ~ 0 ~ ~ V.Q ~ PCT/LS90/a1288
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LAMINATED ARTICLE WITH HINGE
BACKGROUND OF THE INVENTION
Field of Invention
This inventions relates to an improved laminated
article with an improved integral flexible hinge and
methods for manufacturing laminated articles.
Description of Prior Art
There are a variety of flexible hinges known in
the prior art. For example, in U.S. Patent No.
4,636,065 a flexible hinge is disclosed that attempts
to solve the stress and durability problems
associated with the folding of a copier cover plate.
The design solution involves setting back one end of
the edges of the cover plate at an angle to avoid
shearing forces. Another example of a flexible hinge
is disclosed in U.S. Patent No. 3,615,035 for the lid
of a pharmaceutical box. The unique assembly
problems associated with a box lid are solved by a
tongue and groove design. Another example of a
flexible hinge is disclosed in U.S. Patent No.
3,167,207 for a plastic container. The need for a
firm container body yet a flexible hinge is solved by
having integral hinge anchor lugs on the container
adapted to engage a separate flexible hinge assembly.
While is clear that the design in each of the
above cases represents an attempt to solve the unique
problems associated with the folding of the leaves of
the particular article requiring a hinge, there is
also a problem common to all of the cases. This
problem is the incompatibility of a flexible hinge
with sturdy leaves. That is to say, if the article is
to be cast as a single piece from sturdy material,
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the hinge will have the sturdy characteristics of the ,
leaves and will not be flexible. On the other hand,
if the article is to be cast as a single piece from
flexible. material, the hinge will be flexible while
the leaves will not be sturdy. This problem is
significant when considering large scale manufacture
where a monolithic design could result in significant
cost savings.
The present invention involves the joining of
two or more laminated leaves of an article together.
The problem of joining laminated leaves together
inexpensively such that they might fold against each
other easily and tightly has been approached in the
past in two predominant ways.
The most common solution is that employed in
restaurant menu construction. The leaves in this
case are pages, printed side by side on a single
sheet of paper. This sheet of paper is then
laminated by conventional means with relatively thin
laminating film (usually a polypropylene/mylar film
of approximately 0.008 centimeters or less), and
subsequently folded in half to create a prude hinge
apparatus. Sometimes the paper is scored during the
printing process prior to lamination to facilitate
folding.
The advantage of this process is that it is easy
to accomplish. There are many disadvantages,
however, to this method. First and foremost, because '
the web of the hinge apparatus is the exact same
material and thickness as the leaves, the hinge
apparatus of this type exhibits a significant bending
resistance. Because of bending resistance, hinges of
this type of construction have the disadvantage that
the leaves are very limited in their degree of pivot
and ease of pivot. Furthermore, because of the
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extent of bending resistance relative to the weight
of the leaves, the web of the hinge apparatus
exhibits memory. Memory is defined as the tendency
of the web via bending resistance to cause the leaves
to retreat to a prior position after manipulation to
a new position. Memory is most commonly observed
when a menu is opened flat on a table top; the menu
resists the 180° angle and the pages retreat toward '
the closed position. There are other
disadvantages that stem from the bending resistance
of the web. For example, because the hinge means
cannot effectively open up to 360°, the order of the
pages cannot be reversed, precluding the ability to
study any side of either page with the article in its
most compact configuration. Similarly, because of
bending resistance there is difficulty in handling,
low durability, and a sense of overall inferior
quality for the user. All of these problems are, of
course, compounded with multi-page articles.
2o A rarely utilized solution to the overall
problem involves the use of book tape, an adhesive
backed, 1"-2" wide, polypropylene tape. The two
pages are printed on separate sheets of paper and
then individually laminated. The two sheets are
aligned by hand, edge to edge with a small gap, and
then taped by hand with the book tape (preferably on
both the front and back sides of the joint).
The advantage of this method is that it
overcomes some of the disadvantages mentioned above.
There are, however, disadvantages with this method as
well. First, because of the hand labor involved in
assembly, the article is not easily produced
(especially in quantity) and is therefore expensive
to make. Second, because the tape is not invisible;
there is a distinct line at its edges that partially
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clouds the image underneath it. Third, the tape's
adhesive is not as permanent as the laminated pages.
Fourth, the tape's adhesive is subject to oozing at
warm temperatures. Finally, the tape's adhesive
collects dirt at the edge of the tape.
The present invention avoids these
disadvantages. The present invention provides a
laminated article of two or more leaves with an
improved hinge and methods for manufacturing the
same. When the leaves are to display printed matter,
the present invention provides hingedly joined leaves
in a suitable format for such articles as maps,
menus, references, and guides.
This improved hinge pivots easily. Moreover,
the bending resistance of the web does not act to
change the position of the leaves it connects. The
hinge opens from 0 to 360° and yet allows rigid,
substantial leaves. The hinge is integral and
invisible in its attachment, and yet is as durable as
the leaves it connects. The invention thereby solves v
the incompatibility problem associated with
monolithic designs. Furthermore, the improved hinge
neither gathers dirt nor obscures any image that
might be printed on the leaves in any way.
Importantly, this improved hinge is simple,
inexpensive, and readily assembled in quantity.
Readers will find further objects and advantages
of the invention from a consideration of the ensuing
description and the accompanying drawings.
SUMMARY OF THE INVENTION
The present invention is an improved hingedly
joined laminated article of the type wherein two or
more leaves having a thickness are spaced apart so as
to form one or more gaps having a width, and wherein
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a bottom sheet of laminating film having a thickness
contacts one side of the two or more leaves, and
wherein a top sheet of laminating film having a
thickness contacts the other side of the two or more
leaves and contacts the bottom sheet of laminating
film at one or more gaps to form one or more webs
having a bending resistance, the combination with the
one or more webs of a means for preventing said ,
bending resistance from acting to substantially
change the position of said leaves. The preventing
means, in particular embodiments, comprises means for
providing sufficient leave weight such that said
leaves exert enough moment force via gravity to
overcome said bending resistance of said webs,
In one embodiment, the present invention is an
improved hingedly joined laminated article of the
type wherein two or more leaves having a thickness
are spaced apart so as to form one or more gaps
having a width, and wherein a bottom sheet of
laminating film having a thickness contacts one side
of the two or more leaves, and wherein a top sheet of
laminating film having a thickness contacts the other
side of the two or more leaves and contacts the
bottom sheet of laminating film atone or more gaps
to form one or more webs~having a bending resistance,
the improvement comprising means for preventing the
bending resistance from acting to substantially
change the position of the leaves and means for
aligning the leaves. In one particular embodiment
the aligning means comprises one or more integrally
connected tabs bridging the gaps between the leaves.
For the manufacture of one embodiment, the
method of the present invention comprises the steps
of a) loading two or more leaves into a feed tray
having multiple compartments and b) laminating the
WO g011142fi ~' - PCT/1JS9U/01288 -..
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two or more leaves. The feed tray is used for
introducing leaves into a laminating machine and
comprises a means for supporting a p7-urality of
leaves and a means for aligning the leaves.
For the manufacture of another embodiment, the
method of the present invention comprises the steps
of a) die cutting a single leave to yield two or more
leaves separated by one or more gaps bridged by one ,
or more tabs and b) laminating the two or more
leaves.
DESCRIPTION OF THE DR-AWINGS
Figure 1 is a side view of one embodiment of the
invention.
Figure 2 is a top view of a second embodiment of
the invention.
Figure 3 is a perspective view of the feed tray
used in the manufacturing of one embodiment of the
article of the present invention.
Figure 4 is a side view of the feed tray of
Figure 3 shown in contact with the laminating
machine.
DESCRIPTION OF THE INVENTION
The present invention concerns an improved
laminated.article of two or more leaves with an
improved hinge and methods for manufacturing
laminated articles. The article might be anything
utilizing a hinge to join one or more of its
components (menu, book, container etc.). The leaves
may be made of a number of different materials (such
as paper, cardboard, wood, plastic, Masonite,
aluminum, and steel). Where it is desired that
printed matter be displayed, the leaves may contain
WO 9~II14~5 ~ ~ ~ ~ o o ~ ~ Per~us9o~olzsa
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printed matter or the laminating material may have
printed matter.
The present invention contemplates an
improvement over the article of the type having two
or more leaves having a thickness, which are spaced
apart so as to form one or more gaps having a width,
wherein a bottom sheet of laminating film having a
thickness contacts one side of the two or mare
leaves, and wherein a top sheet of laminating film
having a thickness contacts the other side of the twc
or more leaves and contacts the bottom sheet of .
laminating film at one or more gaps to form one or
more webs having a bending resistance. The present
invention contemplates a means for preventing the
bending resistance from acting to substantial7.y
change the position of the leaves. In one
embodiment, the preventing means comprises means for
providing sufficient leave weight such that the
leaves exert enough moment force via gravity to
overcome the bending resistance of the one or more
webs.
EXAMPLE 1
Figure 1 shows one embodiment of a hingedly
joined laminated article of the present invention.
From Figure 1 it is clear that this embodiment of a
hingedly joined laminated article comprises a bottom w
sheet of laminating film (24) (usually a
polypropylene/mylar film or similar material) which
is bonded in a lamination process to the underside of
the three leaves (22a, 22b, 22c) and to a top sheet
of laminating film (20) at the gaps (27) to form webs
(28). Similarly, the top sheet of laminating film
(20) is bonded in a lamination process to the top
side of the three leaves (22a, 22b, 22c) and.to the
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bottom sheet of laminating film (24) at 'the webs
(28).
In this embodiment of the invention, the
preferred thickness of the top (20) and bottom (24)
sheets of laminating film is approximately 0.008
centimeters. The leaves (22a, 22b, 22c) are between
approximately 0.04 and 0.12 centimeters in thickness,
between approximately 21 and 23 centimeters in width, ,
and between approximately 27 and 29 centimeters in
length. The gaps (27) between the leaves (22a, 22b
and 22b, 22c) are slightly (approximately 0.08
centimeters) greater than the combined thickness of
twice the thickness of one leave and four times the
thickness of a sheet of laminating film.
To facilitate folding, it is desirable to adjust
the size (length and width) of the leaves in
accordance with their relative position. For
example, in a three leave article, it is desirable to
have outer leaves that are slightly smaller than 'the
middle leaves. In this manner all folding
configurations can be more easily achieved.
Of course, the invention may comprise more than
three leaves joined together in this manner. For
example, a series of four or more leaves connected in
a fanfold, two directional fold, or other folding
arrangement is possible. Similarly, the invention
may comprise only two leaves joined together in this
manner.
An article according to the invention may have a
wide variety of dimensions, film thicknesses, leave
compositions, leave thicknesses, and gap sizes other
than those shown in Example 1. Nonetheless, the
invention preferably employs a relationship between
these variable such that, in an open or closed
horizontal position, the weight of the leaves (22a,
.. Wp9pp~l~~~ 2 d 4 9 0 0 ~ P~'/US90/01288
p9_
22b, 22c) exerts enough moment force (via gravity) to
overcome the bending resistance of the webs (28),
which in turn is determined by the thickness of the
film (20, 24), the size of the gap (27) (i.e., the
width of the web), and the subsequent radius of the
web (28) (when in a closed position). By controlling
the relationship of the above dimensions in this way,
the invention will be such that the leaves of the
articles will lie relatively flat in either an open
or closed position.
During the actual assembly of the above
mentioned component materials it is imperative to
keep the leaves (22a, 22b, 22c) aligned, with each
other and with the axial direction of the laminating
machine, to insure proper hinge operation of the webs
(28) and a high 'tolerance product.
One method of this invention involves the use of
a specially constructed feed tray for introducing
leaves into a laminating machine. This method
comprises the steps of a) loading two or more leaves
into a feed tray having multiple compartments and b) '
laminating said two or more leaves. In some cases,
the method further comprises, prior to step b),
moving the feed tray such that the two or more leaves
contact the rollers of a laminating machine. ,
Preferably, the laminating of step b) comprises
bonding i) a bottom sheet of laminating film to one
side of two or more leaves ii) a top sheet of
laminating film to the other side of two or more
leaves and iii) the bottom sheet of laminating film
at one or more gaps to the top sheet of laminating
film to form one or more webs.
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EXAMPLE 2
Figures 3 and 4 show one embodiment of a feed
tray (100) having a means for supporting a plurality
of leaves and a means for aligning the leaves during
5 the manufacture of one embodiment of the present
invention (Example 1). The supporting means
comprises a flat bottom (101) having two sides (102
and 103) and four edges (104-107). The aligning
means comprises an end guard (108) perpendicularly
l0 attached near one edge (in this case, edge 104) of
the flat bottom (101) and separation guards (109 and
110) perpendicularly attached to flat bottom (101)
and positioned in substantially a perpendicular '
relationship to end guard (108) to define compart-
ments (111-113). The compartments (111-113) are
separated from each other by approximately the, width
of the desired gaps (27) (Figure 1).
In this embodiment, the feed tray (100) has two
side guards (114 and 115) perpendicularly attached to
the flat bottom (101) near opposite edges (105 and
107) and positioned in substantially a perpendicular
relationship to end guard (108) and in a substan-
tially parallel relationship to separation guards
(109 and 110). In other embodiments, however, it is
contemplated that the feed tray (100) may have fewer
side guards and even no side guards. For illustra-
tion purposes, leaves (22a, 22b, 22c) are shown in
position for laminating.
The design of the feed tray will vary depending
on the number of leaves to be laminated. Where it is
desired to manufacture a three leave article, the
feed tray has three compartments, the width substan-
tially equal to the width of the individual leaves
and the length less than the length of the individual
leaves (preferably two thirds of the length).
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When manufacturing in production quantities, a
loading tray (not shown) is secured to a loading
table (not shown), such that the loading tray is
approximately 2.5 to 4.0 centimeters higher than the
main surface of the table. In front of the loading
tray is a space large enough to accommodate the feed
tray and a guide which is aligned with one side of
the loading tray. ,
In use, the loading tray is stocked with
approximately 100 leaves. The feed tray (100) is
then placed in front of the loading tray, aligned
with the guide, and loaded by an operator who
manually "drags" each leave from the loading tray
into the compartments (111-113) of the feed tray
(100) with the help of a rubber fingertip. The
operator then moves the feed tray to the laminating
machine (not shown), aligns the edges (105-107) of
the flat bottom (101) of the feed tray (100) with the
machine's edge guide (not shown), and pushes the feed
tray (100) toward the lamination rollers (200) until
the leaves (22a, 22b, 22c) simultaneously engage them
(Figure 4). The process is then repeated. Addi-
tional speed can be obtained through the use of
another feed tray and operator, whereby one man loads
the feed tray and the other feeds the laminating
machine.
EXAMPhE 3
Figure 2 shows a second embodiment of the
article of the present invention. This embodiment is
an improved hingedly joined laminated article of the
type wherein two or more leaves having a thickness
are spaced apart so as to form one or more gaps
having a width, wherein a bottom sheet of laminating
film having a thickness contacts one side of two or
~o~o~o~ .
WO X0/11426 PCT/US90/01288 ...v_..
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more leaves, and wherein a top sheet of laminating
film having a thickness contacts the other side of
two or more leaves and contacts the bottom sheet of
laminating film at one or more gaps to form one or
more webs having a bending resistance; the improve- y
merit comprises means for preventing said bending
resistance from acting to substantially change the
position of the leaves and means for aligning the '
leaves during manufacture.
Preferably, the aligning means comprises one or
more integrally connected tabs bridging said gaps
between said leaves. For example, Figure 2 shows ~,
relatively thin (between approximately 0.08 and 0.,16
centimeters) tabs (30a, 30b) bridging the gap, between
three leaves (26a, 26b, 26c). Of course, the tabs
(30a, 30b) could be more numerous, of various
dimensions and positioned in many different ways
other than that shown in Figure 2. It should be
noted that the bigger the tabs, the better durability
in manufacture. On the other hand, bigger tabs
typically have higher bending resistance.
The tab arrangement in this embodiment is
accomplished by a method of manufacture comprising
the steps of a) die cutting a single leave to yield
two or more leaves separated by one or more gaps
bridged by one or more tabs and b) laminating the two
or more leaves. Preferably, the laminating comprises
bonding i) a bottom sheet of laminating film to one
side of the two or more leaves ii) a top sheet of
laminating film to the other side of the two or more
leaves and iii) the bottom sheet of laminating film
at one or more gaps to the top sheet to form one or
more webs having a given bending resistance. Prefer-
ably, the weight of said leaves exert enough moment
force via gravity to overcome the bending resistance
l~fO 9~D/774Z6 ~ ~ 4 9 0 ~ 1 P~/US90/01288
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of said webs, when the article is in a substantially
horizontal position.
With the second embodiment, the number of leaves
in the laminated article is not limited by 'the width
of the laminating machine as in the first method,
because the gaps in the die cut sheet may be posi-
tioned perpendicular to the axial direction of the
machine, allowing an almost infinite string of leaves
per article. Rate of production is enhanced while
waste is held to a minimum. This embodiment greatly
facilitates mass production of the article by regis-
tering the leaves during the lamination process,
while having little negative effect on the bending
characteristics of the webs (28). This embodiment of
the article may also comprise a series of three or
more leaves connected in a fanfold, two directional
fold, or other folding arrangement. Of course, the
article may also comprise only two leaves.
While a number of manufacturing sequences are
possible for the second embodiment, the.proper
manufacturing sequence must take into consideration
the impact of each step on later steps.
EXAMPLE 4
We have found that the preferred manufacturing
sequence for making a laminated map with an impraved
integral flexible hinge is as follows:
Step 1. Cartography is selected and configured,
along with border and logos, to conform to
an 11" by 17" layout.
Step 2. This artwork is expanded in the 17"
dimension such that at the hinges the
artwork repeats itself for a short distance
either side of the center line of the
hinge.
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.;\: , .,
Step 3. Screens areshot of the artwork.
Step 4. The artwork.~is printed (using a sheet
press) four up (i.e. four repeating
patterns) and registered on both sides of
,..
23" by 35" heavy point paper sheets (16
point C2S Stellar - Gloss Cover Stock).
Printed sheets must be allowed to dry
completely to avoid "offset marring" during
ream cutting. The long grain of the paper
should be aligned perpendicular to the
slots to be die cut.
Step 5. Sheets are ream cut into smaller sheets 11"
by 17 11/64". This is necessary to
preserve the integrity of the tabs; if one
attempts to ream cut after the die cutting,
the ream cutting damages and even rips the
tabs.
Step 6. Smaller sheets are die cut according to
Figure 2 such that a slot is cut at each
hinge leaving a small connecting tab at the
top and bottom of each hinge. Die cutting
is accomplished on an old Heidelburg Fress
using a steel rule die plugged with silicon
to help eject the strip. Hand stripping
completes the die cutting process.
Step 7. Die cut sheets are fed into a laminating
machine, such as a Ledco (Hemock, New York)
Industrial 25 laminating machine, loaded '
with 18" Rexham Laminex (Charlotte, North
Carolina) Permalam 3 mil laminating film,
set at approximately 265°F and a relatively
light pressure), either by hand or with the
aid of an automatic sheet feeder, such that
the gaps are aligned with the axial
direction of the machine. (The gaps could
WO 9D1~ 1426 ~ o ~ ~ ~ ~ 1 . ' ~ PCT/US90/01288
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be aligned perpendicular to the axial
direction of the machine, but bonding at
the webs is then inferior.)
Step 8. During lamination the side edges are
trimmed.
Step 9. After passing through the laminating
machine, the laminated die cut sheets
' proceed through an automatic cut off
- machine which trims the top and bottom
edges and drops the completed product into
a receiving container. (We use an
Accumatic II 25" guillotine cutter, D & K, ,,..
Elk Grove, Illinois.)
Step 10. (Optional) The final product normally will .
have sealed edges (i.e. the laminating film
extends beyond the leawes~. As an option,
the side edges can be cut flush with the
end of the leaves during lamination. Of
.course, the side edges can be cut even
deeper such that even the tabs are cut
away, to yield finished article without
tabs.
From the above description it is clear that the
present invention avoids~the disadvantages of other
designs. This improved hinge pivots easily and does
not act to change the position of the leaves it con-
nects. The hinge opens from 0 to 360° and yet allows
rigid, substantial leaves. Furthermore, the improved
hinge neither gathers dirt nor obscures any image
that might be printed on the leaves or on the
laminated film.
The invention solves the incompatibility
' problem associated With monolithic designs. By
formulating the hinge from the flexible, laminating
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material, the hinge is 1) flexible, 2) integral and
3) invisible in its attachment. On the other hand,
the article is made sturdy by the sturdy leave
material under the flexible, laminated material.
Beeause the invention allaws for laminating in one
piece, articles made according to the present inven-
tion are readily and inexpensively assembled in
quantity. ,
While the above description contains many
specificities, the reader should not construe these
as limitations on the scope of the invention, but
merely as exemplifications of preferred embodiments
thereof. Those skilled in the art will envision many
other possible variations that are within its scope.
For example, skilled artisans will be able to
make the leaves to be hinged of many different
materials such as cloth, wood, metal, and plastic.
The film could also be made of other plastic
materials, and, as noted above, the edges of an
article according to the invention could be sealed or
flush cut in many different configurations.
The hinge arrangement could be used in the
construction of articles other than those described
above. For instance, a container could be built
using this hinge arrangement whereby an article is
laminated, and subsequently folded such that one
leave becomes a lid and another leave becomes a tray
part.
Accordingly, the reader is requested to deter-
mine the scope of the invention by the appended
claims and their legal equivalents, and not by the
examples which have been given.
