Method of manufacturing photo album pages

Abstract

An improved method for manufacturing photographic album pages of a type including a base having an attached clear synthetic resinous overlay on each side of the base detachably adhered by pressure sensitive adhesive areas permitting the assembly of the overlay with the base after the step of coating the latter by utilizing a base of paper, the surfaces of which have substantial absorptive capacity in conjunction with an aromatic solvent rubber base adhesive. The adhesive is applied in predetermined dot pattern, permitting the adhesive solvent vehicle to be at least partially absorbed into the paper, to vaporize with time and pass between the adhesive dots to the open top, bottom and side edges of the page after the application of the overlay, and before use.

Description

This invention relates generally to the field of photographic album pages of a type having a paper base and a synthetic resinous overlay detachably adhered thereto to pressure sensitive adhesive. Pages of this general type are well known inthe art, and the invention lies in the improved method by which the same may be conveniently fabricated as a continuous line operation, as distinguished from prior art methods which require a separate heating step prior to assembly.

BRIEF DESCRIPTION OF THE PRIOR ART

In the prior art, the most common method for fabricating pages is to provide a blank of paper of twice the area of the finished page, and a similarly sized synthetic resinous overlay. The blank of paper is coated on one side with lines of pressure-sensitive adhesive of various types, following which the coated paper is baked in an oven or kiln to harden the coated adhesive and evaporate the solvent or vehicle therefrom. The transparent synthetic resinous overlay is then adhered to the now dried adhesive, and the exposed opposite surface of the paper base is coated with a glue, following which the laminated base and overlay are folded transversely of the principal axis and pressed for several hours to make a four-laminae sandwich. This process, while effective, is not suitable for in-line operations, because of the pressing step required to set or cure the glue.

BRIEF DESCRIPTION OF THE PRESENT INVENTION

Briefly stated, the invention contemplates the provision of a paper base lamina which while calendered, is relatively uncoated on the exposed surfaces thereof so as to possess a reasonably high absorptive quality. The adhesive applied to the surfaces is of a rubber base titanium oxide type having an evaporable vehicle which may be absorbed without damage by the paper stock leaving the deposited adhesive on the surface of the paper. The transparent overlay is applied immediately after coating while the adhesive is still moist, and after such application under pressure, the paper base lamina continues to absorb the evaporable vehicle from the cement which does not penetrate the surface, but remains above the same. Since the base lamina and overlay are disconnected on three sides, evaporation to the atmosphere of the vehicle commences almost immediately, and through capillary action ultimately all of the vehicle is evaporated over the course of several days at room temperature. This period allows ample time before the page is manufactured into an album and is subsequently used after retail sale. However, the pressing step required in the prior art method is completely eliminated, and the pages may be formed in an in-line operation from web stock, thereby materially reducing the time of manufacture as well as the cost thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, to which reference will be made in the specification, similar reference characters have been employed to designate corresponding parts throughout the several views.

FIG. 1 is a view in elevation of a completed album page made in accordance with either prior art methods or the method disclosed herein.

FIG. 2 is a sectional view as seen from the plane 2--2 in FIG. 1.

FIG. 3 is a view in elevation of a paper blank forming a base member of a completed page formed in accordance with prior art methods.

FIG. 4 is a view in elevation showing the blank of FIG. 3 after coating on one surface thereof with a pressure sensitive adhesive.

FIG. 5 is a view in elevation showing a transparent overlay used in accordance with the prior art method.

FIG. 6 is a view in elevation showing a final step including the lamination of the structure shown in FIGS. 4 and 5.

FIG. 7 is a transverse sectional view as seen from plane 7--7 in FIG 6.

FIG. 8 is a view in elevation showing a coated paper blank in accordance with the disclosed method.

FIG. 9. is a fragmentary view in elevation showing a transparent overlay used in conjunction with the structure of FIG. 8.

FIG. 10 is a view in elevation showing the lamination of the structure of FIGS. 8 and 9 in accordance with the disclosed method.

DETAILED DESCRIPTION OF THE DISCLOSED METHOD

Prior to a description of the disclosed method, a brief review of the best known prior art method, for purposes of comparison, is considered apposite.

Referring to FIGS. 1 to 7 inclusine in the drawing, a conventional page, generally indicated by reference character 10 is illustrated. The page includes a paper base lamina 11, having first and second surfaces 12 and 13, and bounded by an upper edge 14, a lower edge 15, an inner end edge 16 and an outer end edge 17. A pair of tape hinge members 18 and 19 interconnect the base lamina 11 with a mounting strip 20 having holes 21 for binding. A transparent overlay element 22 may be formed either integrally, or to include first and second transparent sheets 23 and 24 having a tape strip interconnecting means 25. The sheets may be formed of cellulose acetate, but in the present state of the art, they are more commonly formed from thin guage vinyl material.

Referring to FIG. 3, in accordance with prior art methods, it is customary to start with a paper blank 29 of approximately twice the area of the desired finished page. To what becomes an outer surface 30, a pressure sensitive adhesive is applied in lines in a desired pattern, as seen in FIG. 4, following which a plurality of such blanks are subjected to a baking operation at a temperature sufficient to evaporate the vehicle of the adhesive without scorching the paper.

Following the baking step a correspondingly sized vinyl or acetate overlay 32 is laminated to the cured adhesive, and the laminated unit is then folded about a line 33 after the exposed surface of the blank 29 is coated with a permanent adhesive to form a sandwich of four laminae illustrated in FIGS. 6 and 7. The laminae are then pressed together for several hours while the adhesive is set or cured.

The obvious disadvantage of the above described method is the loss of time during the pressing step, and the necessity of forming separate blanks for the pressing operation.

With the foregoing discussion in mind, reference may be made to FIG. 8 in the drawing which illustrates a base 40 formed of relatively thicker paper stock which has been calendered to a degree wherein a pair of surfaces, one of which is designated by reference character 41 still retain considerable moisture absorptive capacity. No resin coating has been applied to the finished surface. As compared with the blank 29, the base 40 is of reduced size, and is bounded by an upper edge 42, a lower edge 43, an outer edge 44 and an inner edge 45 prior to attachment of the mounting means (not shown).

The surfaces 41 are coated with dots or spots of pressure sensitive adhesive, preferably in accordance with the teaching of my copending application, Ser. No. 106,880, filed Jan. 15, 1971 now U.S. Pat. No. 3,720,130. The adhesive may be of a known formulation including natural latex, titanium oxide, and casinate salts in an aromatic solvent, the solvent being approximately 5percent by weight of the entire composition. However, the process is also suitable for use with water-ammonia vehicle adhesives as well.

The adhesively coated areas will correspond to the area of the overlay element 48 (FIG. 9) preferably made to include first and second laminae 49 and 50 interconnected by a tape hinge 51. The overlay is applied to the base 40 immediately after the latter has been coated, under pressure, wherein the finished device takes the appearance shown in FIG. 10.

It will be observed that the overlay is applied while the adhesive is still in relatively soft and uncured condition, preferably by passing the layers to be laminated through a pressure roller set (not shown). This will result in a slight spreading of the adhesive areas, and the level of the adhesive being somewhat closer to the level of the coated surfaces than in the prior art method, although the actual saving in the amount of adhesive required is not of substantial proportions. After the laminating step has been completed, the solvent phase of the adhesive continues to be absorbed by the paper base through capillary action, the thicker adhesive remaining on the surface thereof. For practical purposes, the completed page is "dry" thus permitting subsequent manufacturing operation, including the application of the hinge means and the incorporation of the page into a finished photo album. The vehicle continues to evaporate through the free side and end edges of the page, a process which may require several days at room temperature, but which is completed long before the completed album is shipped for retail sale, so that by the time it is put to use by a purchaser, all of the solvent has been volatilized, together with any accompanying odor.

I wish it to be understood that I do not consider the invention limited to the precise details of structure shown and set forth in this specification, for obvious modifications will occur to those skilled in the art to which the invention pertains.

Claims

I claim:

1. The method of manufacturing a photo album page having a paper base lamina and a clear synthetic resinous overlay extending over the surface of said base lamina, comprising the steps of: providing a base lamina of paper stock, the surface of which has substantial moisture aborptive capacity; applying an evaporable vehicle latex-based adhesive pressure sensitive to at least one surface of said base lamina in disconnected substantially circular areas such that the applied adhesive areas are substantially surrounded by uncoated surface areas of the base lamina; while said applied adhesive is still in a relatively uncured state, applying said overlay to said adhesive-coated base lamina under pressure; allowing said base lamina and attached overlay to remain relatively undisturbed at room temperature for a period of time sufficient to allow the evaporable vehicle phase of the adhesive coating to first be at least partially absorbed by said coated surface of said base lamina, and subsequently evaporated past the free edges of said overlay, prior to use.

2. The method in accordance with claim 1, in which the adhesive includes natural latex, titanium oxide, and caseinate salts in a aromatic solvent, the solvent being approximately 5percent by weight of the entire composition.

3. The method in accordance with claim 1, in which the adhesive is of a water-ammonia vehicle type.