Method for manufacturing an insert for a passport booklet data page

Description

[0001] The invention relates to a method for manufacturing a data page for a passport booklet, whether for a conventional passport or an electronic passport with radio-frequency contactless reading. It also relates to a passport data page obtained by said method, and to a booklet-shaped passport, sewn or stapled, incorporating such a data page. In the following, the invention will be described primarily in relation to a passport, although the invention can be used with other security documents using a data page. State of the art

[0002] In this application, a "data page" refers to a relatively rigid insert, usually made of polycarbonate, forming the page of a passport booklet on which the passport holder's biometric data is recorded. It is generally understood that the data recorded on such a data page should be very difficult to alter or falsify, at least without highly specialized equipment.

[0003] This data page has the same format as the other pages of the passport booklet, except that it features a hinge at the folding and assembly area of ​​the passport pages. This allows the data page to be joined to the other passport pages, usually by sewing or stapling them together at the fold. To reinforce the data page's resistance to tearing, the hinge area extends beyond the fold.

[0004] A flexible passport data sheet is already known from document EP 1 245 407 B2. This sheet combines a plastic (polycarbonate) layer suitable for laser engraving, which is relatively weak against repeated bending, with a much stronger HDPE (High Density Polyethylene) layer that extends to the hinge of the data sheet. These layers are laminated together, resulting in a considerable thickness of approximately 600 micrometers. Despite this thickness, the data sheet exhibits relatively low tear resistance compared to a passport booklet because all the layers are made of plastic, including the hinge extension. This makes the entire sheet quite easy to tear at the booklet's seams.

[0005] We also know from document WO 2015 / 018615 A1 of an insert sheet for passport booklet, having an extension beyond the hinge area, but again this insert sheet does not have a metallic layer capable of both strengthening the mechanical resistance of the insert and constituting an antenna.

[0006] We finally know, from US document 10,688,821 B2 (or FR 3 038 865 A1), of a passport insert comprising a plastic core with a metallic layer, which is used to form the coils of an antenna. This metallic layer extends across the entire data page and into the hinge area. This structure offers significant improvements over pre-existing inserts, particularly much higher mechanical strength than existing data pages, due to the metallic hinge. However, the market most often demands completely separate antennas, so only the hinge needs to be metallic, without the metallic sheet needing to cover the entire surface of the data page to form an antenna.

[0007] WO 2017 / 071937 A1 describes the preamble of claim 1.

[0008] A new technical problem then arises, consisting of attaching a simple metal strip acting as a hinge and securing it to one side of a data page that does not incorporate a metal layer over its entire surface. Objectives of the invention

[0009] A general aim of the invention is therefore to propose a new method of manufacturing a data page insert for a passport booklet or other security document in booklet form, which is free from the aforementioned disadvantages.

[0010] A particular aim of the invention is to propose a new reliable and economical method for attaching a simple metal strip forming the hinge of the data page for a passport booklet to the data page. Summary of the invention

[0011] To this end, the principle of the invention provides for a new, more reliable and economical method for manufacturing a passport booklet data page incorporating a metal hinge. This new method comprises two essential phases: first, the creation of a data page blank by laminating all its components, including the metal layer intended to form the hinge, which is thus embedded in the laminated structure; and second, the release of the metal hinge through localized removal of the outer layers of the laminated blank.

[0012] A first type of passport booklet data page insert includes a metallic antenna obtained in particular by removing material from a solid metal sheet, and enabling communication with a remote reader.

[0013] The invention is also applicable to a second type of data page insert, namely non-electronic data pages, without an antenna.

[0014] The invention therefore relates to a method for producing a data page for a passport booklet, formed by a multilayer complex comprising a thin and flexible plastic core terminated on one side by a metal strip intended to form a hinge where the data page is to be sewn or stapled into a passport booklet, and two external plastic layers arranged on the two faces of said core, this method comprising steps consisting of: superimpose the core and the two outer layers and roll them together by applying a predetermined rolling temperature and pressure; remove excess parts of said outer layers located at the right of said metal strip; characterized in that to remove said excess part, it comprises a step consisting of making a pre-cut in each outer layer so as to obtain a weakened zone on each outer layer, corresponding to the excess part, followed by a step of removing said weakened zone along said pre-cut.

[0015] Preferably, the material of the outer layers is chosen to exhibit low adhesion to the metal strip at the end of the rolling stage.

[0016] According to one embodiment, said pre-cutting of the outer layers is carried out in the thickness of the outer layers along a line parallel to the junction between the metal strip and the plastic core.

[0017] According to one embodiment, said pre-cutting is carried out mechanically by a cutting line made using a blade or a cutting protrusion directly provided on the lamination plates used during the lamination phase of the layers.

[0018] According to another embodiment, said pre-cutting is carried out by applying a heating blade or heating wire to the outer layers at a temperature higher than the melting temperature of the outer layers.

[0019] According to one embodiment, said pre-cutting is carried out by applying a vibration at an ultrasonic frequency to the outer layers along the pre-cutting line.

[0020] According to the invention, the step of removing the weakened end of the outer layers is carried out by one of the following techniques on the weakened ends: gripping and peeling, application of a suction cup, application of a blower or suction, application of a rough or notched rotary wheel, insertion of a tool into the pre-cut followed by ejection of the weakened end.

[0021] According to an advantageous variant of the process according to the invention, it includes, between the pre-cutting step and the step of removing the weakened ends, a step of folding the hinge so as to reduce the adhesion between the material of the metal hinge and the material of the external layers.

[0022] The invention also relates to a data page, which is not claimed, for a passport booklet, obtained according to the above process, and a passport booklet, which is also not claimed, comprising such a data page.

[0023] According to one embodiment of the data page, the outer layer material is non-friable, which facilitates the removal of excess material from the metal hinge area after it has been weakened. Furthermore, the outer layer material has a melting point less than half the melting point of the metal hinge, ensuring low adhesion between the excess material of the outer layers and the surface of the metal hinge.

[0024] According to one embodiment, the metal band of the hinge is made of aluminium, the core is made of PET (polyethylene), and said outer layers are made of PC (polycarbonate).

[0025] According to one embodiment, the metal hinge has two layers of aluminum arranged on either side of the core.

[0026] According to one embodiment, the core has a thickness of between 20 and 80 micrometers, preferably about 40 micrometers, the metal hinge has a thickness of between 10 and 40 micrometers, preferably about 20 micrometers, and said outer layers have a thickness of between 150 and 400 micrometers, preferably about 300 micrometers.

[0027] Other features and advantages of the invention will become apparent upon reading the detailed description and accompanying drawings, in which: there Figure 1A is a schematic cross-sectional view of a passport data page with a metal hinge glued to one side of the data page; figure 1Bis a schematic cross-sectional view of a passport data page with a metal hinge inserted and laminated to the central core of the data page; figure 2 is an enlarged perspective view of the structure of a data page according to the figure 1B after assembling the layers but before removing the metal hinge; the figure 3 is a top view of the data page of the figure 2 , at the interface between the central core and an external layer of the data page; the figure 4 is a view similar to that of the figure 2 , after a pre-cutting step of the outer layers of the data page; the figure 5 is a view similar to that of the figure 2 , at the beginning of a localized peeling phase of excess material from an outer layer of the data page; the figure 6 is a perspective view similar to that of the figure 2, after the step of releasing the hinge from the data page in accordance with the method according to the invention. Detailed description

[0028] In Figure 1AA known data page 10, intended to be sewn at its hinge 5 into a passport booklet 11 or other type of booklet, is shown. The hinge 5 is usually a strip of plastic, glued with a line of glue 13 to a sheet 1 of the data page. This design has several drawbacks, notably increasing the rigidity of the data page beyond what is desired and resulting in insufficient reliability of the glued bond between the hinge 5 and the body 1 of the data page 10. Furthermore, this reliability has been found to be even lower when the hinge 5 is made of metal to increase the tear resistance of the data page compared to the passport booklet 11.

[0029] A structure better suited to the use of a metal hinge 5 is shown schematically in figure 1BIn this case, the data page 10 consists of a central core 2 made of plastic, surrounded by two outer layers 1 and 3, also made of plastic. The central core 2 terminates on the side of the data page 10 intended to be sewn into the booklet 11, with a metal band hinge 5. This structure exhibits the desired flexibility, provided a reliable method can be found for securing the metal hinge 5 to the outer plastic layers 1 and 3. A logical approach would be to pre-assemble the various elements 1, 2, 3, and 5 in their final position as shown, with the hinge 5 protruding beyond the other elements, and then laminate the various elements together by applying appropriate lamination temperature and pressure.In reality, this method is too difficult to implement, particularly due to the difficulty of manipulating and precisely positioning elements 1, 2, 3, 5 which have a thin thickness of a few tens of micrometers.

[0030] The invention therefore consisted of finding an alternative method for assembling and manufacturing a data page according to the figure 1B which is capable of guaranteeing reliable assembly of a data page made up of plastic layers and a metal hinge. The intermediate steps of this new process are shown schematically in the figures 2 to 6 .

[0031] As depicted in figure 2We begin by manufacturing a rough draft of data page 10, in which the metal hinge 5 is bonded to the core 2 and completely enclosed between the outer layers 1 and 3. At this stage, the metal hinge 5 is thus sandwiched and protected between the outer plastic layers 1 and 3. To create this rough draft, all the components 1, 2, 3, and 5 are stacked in their final position and laminated to bond them together. During the lamination cycle, the temperature is raised to between 175 °C and 220 °C, and the structure is subjected to a pressure cycle ranging from 175 N / cm² to 380 N / cm² for a duration of 50 seconds to 30 minutes, depending on the equipment used and the number of data pages to be laminated simultaneously.

[0032] The draft data page comprises a core 2 with one or two metal strips 5 on one side. In one embodiment, the core 2 is made of a highly flexible plastic, in particular a polymer such as PET (polyethylene), having a flexural modulus of approximately 1 GPa. The metal strips 5 are preferably made of aluminum. The outer layers 1, 3 are made of a plastic that is not brittle at room temperature and are more rigid than the material of the core 2, having, for example, a flexural modulus at least twice that of the core 5. This is, for example, polycarbonate, which has a flexural modulus of approximately 2.3 GPa. The thicknesses of the different layers are typically as follows: Core core 5: 20 to 80 micrometers, preferably 40 micrometers. Metal strips 5: 10 to 40 micrometers, preferably 10 to 20 micrometers. Outer layers 1, 3: 150 to 400 micrometers, preferably around 300 micrometers.

[0033] To strengthen the bond between the core 2 and the outer layers 1, 3, it is useful for the central core 5 to have openings or slots 4 as shown in figure 3 , so that the material of the outer layers 1, 3, heated during the lamination phase, can flow into these slots 4, which ensures strong cohesion between the core 2 and the outer layers 1, 3, outside the hinge area 5.

[0034] Then, in a second step, once the rough shape is complete, the process according to the invention involves exposing the hinge 5 by removing the excess material from the outer layers 1, 3 located opposite the hinge 5. These steps are illustrated schematically in the figures 4 to 6 .

[0035] To that end, as outlined in figure 4 The process according to the invention involves making a pre-cut 6 in the outer layers 1,3 opposite the metal hinge 5. This operation makes it possible to delimit a weakened part 14 of these outer layers 1,3 intended to be removed in a subsequent operation in order to free the hinge 5.

[0036] For this purpose, the pre-cut 6 extends into the thickness of the outer layers 1, 3, parallel to the junction line between the core 2 and the metal strip 5.

[0037] According to the invention, several methods are possible for the pre-cutting operation. It can be carried out mechanically by a cutting line made using a blade or a cutting protrusion directly provided on the laminating plates used during the lamination phase of the layers to create the roughing.

[0038] Alternatively, said pre-cut 6 is carried out by applying along the pre-cut line 6 on the outer layers 1,3 a heating blade or a heating wire at a temperature higher than the melting temperature of the outer layers, which will locally melt the outer layers 1,3 at the level of the pre-cut line.

[0039] Another method would be to apply an ultrasonic frequency vibration to the outer layers along the pre-cut line 6.

[0040] Then, as outlined in figure 5 , the excess material 7 is removed from the weakened area 14 of the outer layers 1, 3, along the pre-cut line 6, in order to partially expose the metal hinge 5, while the rest of the metal hinge located upstream of the pre-cut line 6 remains caught between the outer layers 1,3.

[0041] Alternatively, instead of a two-layered metal hinge 5 on either side of the core 2, one could also have a single metal layer 5, surrounded on either side by an external layer 1,3 of plastic material.

[0042] To ensure the smoothest possible removal of the weakened areas 14 of the outer layers 1,3, it is beneficial for the outer layers 1,3 to be relatively resistant to lamination with the metal hinge 5. This means that the materials chosen for the outer layers 1,3 and the metal hinge 5 should inherently exhibit low mutual adhesion after lamination, without the need for an anti-adhesive agent. Furthermore, it is advantageous for the material of the outer layers 1,3 to be non-friable, allowing for easy removal in a single operation of the pre-cut portion 14 of these layers, particularly by peeling from the end 7 of the weakened areas, as illustrated schematically in figure 5 .

[0043] In general, these conditions are met if the material constituting the outer layers 1, 3 has a melting temperature less than half the melting temperature of the material chosen for the hinge 5.

[0044] These conditions are met in particular if aluminium is chosen for the hinge 5, having a melting point of 660 °C, and polycarbonate for the outer layers 1,3, having a melting point of 230 °C.

[0045] According to an optional step (not shown in the figures), the pre-cutting operation can be followed by a folding operation of the hinge 5 or a breaking of the pre-cut area 14 in order to obtain additional weakening before the release phase of the hinge 5 and to facilitate obtaining a peeling start 7 of the weakened area 14 of the outer layers 1,3.

[0046] According to one embodiment, the step of removing the weakened end 14 from the outer layers 1,3 is carried out by one of the following techniques applied to the weakened end 14: gripping and peeling, application of a suction cup, application of a blower or suction, application of a rough or notched rotary wheel, insertion of a tool into the pre-cut 6 followed by ejection of the weakened end 14. Advantages of the invention

[0047] Ultimately, the invention achieves its stated goals. It allows for the production, in a single operation, of a data page 10 for a passport, which is equipped with a metal hinge 5, manufactured in a very economical and reliable manner, whereas previous processes required several independent phases.

[0048] Furthermore, manufacturing a monolithic blank by laminating all the components allows for better relative positioning of the outer layers on either side of the central core.

[0049] Furthermore, the new process according to the invention can easily be automated.

Claims

1. Method for producing a data page (10) for a passport book, formed by a multilayer complex including a central core (2) made of plastic material ending on one side in at least one metal strip intended to form a hinge (5) where the data page (10) is intended to be sewn or stapled into a passport book, and outer layers (1, 3) made of plastic material disposed on each face of said central core (2), this method including steps consisting in: - superimposing the central core (2) and the outer layers (1,3) and laminating them together by applying a predetermined lamination temperature and pressure; characterized in that it further includes the step of: - freeing the metal hinge (5) by removing an excess part of each outer layer (1,3) located vertically in line with said at least one metal strip (5); - and in that to remove said excess part, it includes a step consisting in making a pre-cut (6) in each outer layer (1,3) so as to obtain a weakened zone (14) on each outer layer (1,3), corresponding to the excess part, followed by a step of removing said weakened zone (14) along said pre-cut (6).

2. Method according to claim 1, characterized in that the material of the outer layers (1,3) is chosen to have low adhesion with respect to the metal hinge (5) at the end of the lamination step.

3. Method according to claim 2, characterized in that said pre-cut (6) of the outer layers (1, 3) is made in the thickness of the outer layers along a line parallel to the junction between the metal hinge (5) and the core (2) made of plastic material.

4. Method according to claim 3, characterized in that said pre-cut (6) is made mechanically by a cutting line made using a blade or a cutting protrusion directly arranged on the lamination plates used during the phase of laminating the layers.

5. Method according to claim 3, characterized in that said pre-cut (6) is made by applying onto the outer layers a heated blade or a heated wire at a temperature higher than the melting temperature of the outer layers.

6. Method according to claim 3, characterized in that said pre-cut (6) is made by applying onto the outer layers along the pre-cut line (6) a vibration at an ultrasonic frequency.

7. Method according to any one of claims 3 to 6, characterized in that the step of removing the weakened end (14) of the outer layers (1, 3) is carried out by one of the following techniques on each weakened end (14): gripping and peeling, applying a suction cup, applying a blower or suction, applying a rough or notched rotary wheel, inserting a tool into the pre-cut (6) followed by ejecting the weakened end (14).

8. Method according to any one of claims 3 to 7, characterized in that it includes, between the pre-cut step and the step of removing the weakened end (14), a step of folding the hinge (5) so as to reduce the adhesion between the material of the metal hinge (5) and the material of the outer layers (1, 3).

9. Method according to one of the preceding claims, characterized in that it uses a material of the outer layers (1, 3) that is not brittle and has a melting temperature lower than half the melting temperature of the metal hinge (5).

10. Method according to claim 9, characterized in that the metal hinge (5) used has two layers of aluminum disposed on either side of the core (2).

11. Method according to any one of claims 8 to 10, characterized in that the metal hinge (5) is made of aluminum, the core (2) is made of PET (polyethylene), and said outer layers (1,3) are made of PC (polycarbonate).

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