A data page for a security document

Abstract

The present invention refers to a data page for a security document, which comprises a top layer, a bottom layer, and at least one intermediate layer positioned between the top layer and the bottom layer so as to form a stacked structure. The intermediate layer is made of plastic material, and at least one portion of the intermediate layer protrudes from a side of the stacked structure with respect to both the top layer and the bottom layer, and the at least one protruding portion is configured to be connected to a hinge layer of a security document, thereby forming a hinge connection. The present invention also refers to the security document including such data page and to methods of forming same.

Description

[0001] A DATA PAGE FOR A SECURITY DOCUMENT

[0002] FIELD OF THE INVENTION

[0003] The present disclosure refers to the field of data pages for security documents, such as passports.

[0004] STATE OF THE ART

[0005] Data pages in security documents, such as passports, serve as the primary medium for storing and presenting critical personal and biometric information. Data pages are designed with advanced security features to prevent counterfeiting and ensure durability over the document's lifespan.

[0006] A crucial aspect of data page design is its integration with the hinge mechanism, which connects the data page to the rest of the document booklet. The hinge must provide a secure and flexible attachment that allows repeated opening and closing without compromising the integrity of the document. Various bonding techniques, such as thermoplastic welding, reinforced stitching, or specialized adhesives, are employed to enhance durability and resistance to tampering. The connection between the data page and hinge also influences the overall security architecture, as any weak points could be exploited for fraud or document manipulation.

[0007] Woven hinges are an example of a robust mechanical connection for attaching data pages to the booklet structure of security documents like passports. These hinges consist of tightly interwoven synthetic fibers, often made from materials such as polyester or aramid, which are then treated with ultrasonic mesh welding to attach the data page to the rest of the booklet structure.

[0008] However, woven hinges can experience fraying during use, depending on factors like the material, weave structure, and environmental conditions. For example, when woven fabrics are cut, the interlaced threads lose tension, allowing them to unravel overtime. Hence, without proper edge finishing, the fibers can start to separate, leading to fraying. Moreover, repeated bending, folding, and rubbing against surfaces, or exposure to moisture and temperature fluctuations can weaken the fiber structure and can accelerate thread loosening.

[0009] Thermoplastic polyurethane (TPU) hinges are another example of a flexible structure designed to facilitate repeated opening and closing of the security document, while maintaining durability. TPU is often used for these hinges due to its elasticity and resistance to wear. However, a significant drawback arises from TPU's lower glass transition temperature compared topolycarbonate. This results in reduced thermal stability, making the hinges more susceptible to deformation, softening, or mechanical failure under elevated temperatures. Additionally, the lower glass transition temperature can lead to increased wear and potential delamination over time, compromising the overall integrity and security of the passport.

[0010] It is therefore an object of the present invention to provide a data page for a security document with a hinge connection, such as a woven or a TPU hinge connection, which solves one or more of the problems outlined above.

[0011] SUMMARY

[0012] According to an aspect of the present invention, a data page for a security document is provided, wherein the data page comprises a top layer; a bottom layer; at least one intermediate layer positioned between the top layer and the bottom layer so as to form a stacked structure, wherein the at least one intermediate layer is made of plastic material, and at least one portion of the at least one intermediate layer protrudes from a side of the stacked structure with respect to both the top layer and the bottom layer, and the at least one protruding portion is configured to be connected to a hinge layer of a security document, thereby forming a hinge connection.

[0013] The advantage of this configuration is that the at least one protruding portion can be easily connected to the hinge layer of the security document, because it can be easily accessed from the top side and the bottom side.

[0014] Each intermediate layer may comprise any number of protruding portions, such as one, two, three, four, or more. These protruding portions may form an attachment portion configured to be connected to a hinge layer of a security document, thereby forming a hinge connection. Preferably, each protruding portion of the intermediate layer may be configured to be connected to a corresponding portion of the hinge layer. Alternatively, each protruding portion of the intermediate layer may be configured to be connected to a common portion of the hinge layer.

[0015] Preferably, the protruding portions may be integrally formed with the intermediate layer. Alternatively, the protruding portions may be attached to the intermediate layer.

[0016] Preferably, the at least one intermediate layer is made of thermoplastic material.

[0017] According to preferred configurations, the stacked structure has the shape of a parallelepiped with one or more protruding portions due to the one or more intermediate layers. Preferably, the top layer and the bottom layer are aligned to each other along the sides of the parallelepiped stacked structure. Preferably, the one or more intermediate layers are aligned to the top layer andthe bottom layer along all the sides of the parallelepiped stacked structure, except for the side in correspondence with the at least one protruding portion.

[0018] The intermediate layer may be a single film or a multi-layered film.

[0019] According to an embodiment of the present invention, a data page is provided, which comprises two or more intermediate layers partially protruding from a side of the stacked structure, wherein one of the intermediate layers is made of a plastic material and is configured to be connected to a hinge layer of the security document, thereby forming a hinge connection.

[0020] Preferably, the two or more intermediate layers may be completely aligned to each other and may extend over the top layer and the bottom layer with corresponding portions having the same length. Alternatively, the two or more intermediate layers may be only partially aligned to each other and may extend over the top layer and the bottom layer with corresponding portions having different lengths. For example, a first intermediate layer may extend over the top layer and the bottom layer with a first portion and the second intermediate layer may extend over the top layer and the bottom layer with a second portion, wherein the first portion has a different length (i.e. shorter or longer) than the second portion. For example, a first intermediate layer may extend over the top layer and the bottom layer with a first portion and the second intermediate layer may extend over the top layer and the bottom layer with a second portion, wherein the first portion and the second portion have the same length.

[0021] According to an embodiment of the present invention, a data page is provided, which comprises two or more intermediate layers partially protruding from a side of the stacked structure, wherein each of the intermediate layers is made of a plastic material and is configured to be connected to a hinge layer of a security document, thereby forming a hinge connection.

[0022] Preferably, the two or more intermediate layers may be completely aligned to each other and may extend over the top layer and the bottom layer with corresponding portions having the same length. Alternatively, the two or more intermediate layers may be only partially aligned to each other and may extend over the top layer and the bottom layer with corresponding portions having different lengths. For example, a first intermediate layer may extend over the top layer and the bottom layer with a first portion and the second intermediate layer may extend over the top layer and the bottom layer with a second portion, wherein the first portion has a different length (i.e. shorter or longer) than the second portion. For example, a first intermediate layer may extend over the top layer and the bottom layer with a first portion and the second intermediate layer may extend over the top layer and the bottom layer with a second portion, wherein the first portion and the second portion have the same length.According to an embodiment of the present invention, a data page is provided, which further comprises one or more security features formed on the at least one protruding portion of the at least one intermediate layer.

[0023] The advantage of this configuration is that, if the data page is counterfeited, the security features gets damaged and the resulting damage, such as a change in the optical pattern, can be detected by the operator. Moreover, addition of a security feature such as a photo of the document proprietor enables personalization of the document.

[0024] According to an embodiment of the present invention, a data page is provided, wherein the one or more security features are made of a laser-engravable material, an Optically Variable Ink (OVI) material, an Optical Variable Material (OVM), a UV fluorescent material, and / or a Photo Chromic material.

[0025] According to another aspect of the present invention, a security document, such as a passport, is provided, wherein the security document comprises a data page as the ones disclosed above, and a hinge layer, wherein the at least one protruding portion of the at least one intermediate layer is laminated to at least one portion of the hinge layer, thereby forming a hinge connection.

[0026] The advantage of this configuration is that the at least one protruding portion of the data page can be easily laminated to the hinge layer of the security document, because it can be easily accessed from the top side and the bottom side. Moreover, since the at least one protruding portion of the data page and the hinge layer of the security document overlap, they can be laminated over a large surface, thus ensuring a stable and robust connection, which can withstand the mechanical stress due to frequent opening and closing of the document.

[0027] In the present disclosure, it is to be understood that the lamination process includes lamination of the at least one protruding portion both to the woven hinge and to the TPU hinge.

[0028] Lamination of the at least one protruding portion to the woven hinge includes allowing the material of the protruding portion to penetrate the woven mesh during high-pressure lamination: under heat and pressure, in fact, molten material of the protruding portion flows into the mesh structure, forming a mechanical interlock as it cools and solidifies.

[0029] Lamination of the at least one protruding portion to the TPU hinge includes bonding the material of the protruding portion to the TPU hinge under heat and pressure. TPU typically softens at a lower temperature than the plastic material of the protruding portion, thus allowing it to create a strong adhesive bond with the polycarbonate layers. In the present disclosure, a security document refers to a passport, or the like.According to an embodiment of the present invention, a security document is provided, wherein the hinge layer is a woven layer.

[0030] The advantage of this configuration is that the woven hinge layer is laminated to the at least one protruding portion of the hinge layer and is protected against tearing or fraying when cut or pierced.

[0031] According to an embodiment of the present invention, a security document is provided, wherein the hinge layer is made of PET, polymide, or the like.

[0032] According to an embodiment of the present invention, a security document is provided, wherein the hinge layer and / or the at least one intermediate layer are made of thermoplastic polyurethane.

[0033] Preferably, both the hinge layer and the intermediate layer are made of thermoplastic polyurethane. This configuration is advantageous because, if the hinge layer and the intermediate layer are made of the same material, they have similar thermal properties, such as melting point and thermal expansion, and they can be easily and efficiently laminated together.

[0034] According to an embodiment of the present invention, a security document is provided, wherein one or more security features are formed, partially or entirely, on the laminated portion of the hinge layer.

[0035] The advantage of this configuration is that the security features can be formed, partially or entirely, on the overlapping portion of the intermediate layer of the data page and of the hinge layer of the security document. In this way, if the data page is removed from the security document and a different (e.g. counterfeited) data page is connected to the security document, the security features gets damaged and the resulting damage, such as a change in the optical pattern, can be detected by the operator. On the other hand, while the data page is connected to the security document, the risk of damaging the security features formed on the laminated portion of the hinge layer is significantly reduced, because the present solution ensures stability and flexibility of the security document during use.

[0036] According to preferred configurations, the security features may reproduce, for instance, a logo from the producer of the security document. In this configuration, the security features may be made of thermoplastic material and may include printed features. This allows personalization of the security document.

[0037] According to other preferred configurations, the security features may reproduce, for instance, an image or a photo of a user of the security document, or a predefined image or pattern. In thisconfiguration, the security features may be made of thermoplastic material and may include printed features. This allows personalization of the security document.

[0038] According to an embodiment of the present invention, a security document is provided, wherein the one or more security features are made of a laser-engravable material, an Optically Variable Ink (OVI) material, an Optical Variable Material (OVM), a UV fluorescent material, and / or a Photo Chromic material.

[0039] According to another aspect of the present invention, a method for forming a data page for a security document is provided, and the method comprises the following steps:

[0040] a) providing a top layer;

[0041] b) providing a bottom layer;

[0042] c) positioning at least one intermediate layer made of plastic material between said top layer and said bottom layer, so that at least one portion of said at least one intermediate layer protrudes from a side of both said top layer and said bottom layer; and

[0043] d) forming a stacked structure comprising said top layer, said bottom layer, and said at least one intermediate layer with said at least one protruding portion.

[0044] The advantage of this method is that it allows an easy and stable connection between the at least one protruding portion of the data page and the hinge layer of the security document, because the at least one protruding portion can be easily accessed from the top side and the bottom side.

[0045] According to another aspect of the present invention, a method for forming a security document is provided, and comprises the following steps:

[0046] e) forming a data page for a security document with the method disclosed above;

[0047] f) providing a hinge layer; and

[0048] g) laminating the at least one protruding portion of the at least one intermediate layer to at least one portion of the hinge layer, thereby forming a hinge connection.

[0049] The advantage of this method is that it allows easy and efficient lamination of the at least one protruding portion of the data page to the hinge layer of the security document, because the at least one protruding portion can be easily accessed from the top side and the bottom side. Moreover, since the at least one protruding portion of the data page and the hinge layer of thesecurity document overlap, they can be laminated over a large surface, thus ensuring a stable and robust connection, that can withstand the mechanical stress due to frequent opening and closing of the document.

[0050] According to an embodiment of the present invention, a method for forming a data page or a security document is provided, wherein the method is carried out by means of a lamination stackup process.

[0051] The advantage of this configuration is that the method can be carried out in a fast and efficient way.

[0052] In the present disclosure, the term “lamination stackup process” refers to the process for manufacturing security documents, which includes layer-by-layer composition of the elements used to manufacture the data page, before undergoing lamination and personalization. A datapage stackup, or lamination stackup, or stackup, refers to the layered structure before the lamination process in security document manufacturing.

[0053] The methods of the present invention can be carried out with different orientations of the intermediate layer, and / or of the stacked structures, and / or of the security documents in the stackups.

[0054] According to preferred embodiments, a method for forming a data page or a security document is provided, wherein the stackup obtained after the step d) comprises a plurality of stacked structures and, in each stacked structure, the at least one protruding portion of the at least one intermediate layer faces the same side of the stackup.

[0055] Preferably, that side is an edge of the stackup.

[0056] Preferably, that side is parallel to the conveying direction of the stackup.

[0057] According to other preferred embodiments, a method for forming a data page or a security document is provided, wherein the stackup obtained after the step d) comprises a plurality of stacked structures and, in the stacked structures, the protruding portions of the at least one intermediate layer face different sides of the stackup.

[0058] Preferably, the protruding portions of the intermediates layer face different edges of the stackup.

[0059] Preferably, the protruding portions of the intermediate layers face different sides of the stackup, wherein the sides are defined as parallel to the conveying direction of the stackup. According to alternative configurations, the protruding portions of the intermediate layers face different sidesof the stackup, wherein the sides are defined as perpendicular to the conveying direction of the stackup.

[0060] It is to be understood that these methods for forming a data page and / or a security document can be used to form the data pages and / or security documents disclosed above.

[0061] FIGURES

[0062] In the following description, reference is made to the following figures:

[0063] Fig. 1 schematically illustrates a side view of a data page according to an embodiment of the present invention;

[0064] Fig. 2 schematically illustrates a side view of a data page according to another embodiment of the present invention;

[0065] Fig. 3 schematically illustrates a top view of a data page according to embodiments of the present invention;

[0066] Fig. 4 schematically illustrates an exploded view of a data page according to embodiments of the present invention;

[0067] Fig. 5a schematically illustrates a stackup for producing a data page according to an embodiment of the present invention;

[0068] Fig. 5b schematically illustrates a stackup for producing a data page according to another embodiment of the present invention;

[0069] Fig. 5c schematically illustrates a stackup for producing a data page according to another embodiment of the present invention;

[0070] Fig. 5d schematically illustrates a stackup for producing a data page according to another embodiment of the present invention;

[0071] Fig. 6 schematically illustrates a manufacturing step for producing a data page according to an embodiment of the present invention.

[0072] DETAILED DESCRIPTION

[0073] The present description is provided for purposes of illustration but is not intended to be exhaustive or limited to the disclosed embodiments. The scope of protection of the present disclosure is defined in the appended set of claims. Many modifications and variations will be apparent to thoseof ordinary skill in the art without departing from the scope of the disclosure. The embodiments were chosen and described in order to best explain the principles of the disclosure and the practical application, and to enable others of ordinary skill in the art to understand the disclosure for various embodiments with various modifications as are suited to the particular use contemplated. Finally, those fields considered known to the skilled person will not be described to avoid covering in a useless way the described invention.

[0074] In the present invention, it is to be understood that the terms “top”, “bottom”, “right”, “left”, “side”, and variations thereof refer to the orientation of the figures but they do not intend to limit the invention.

[0075] Fig. 1 schematically illustrates a side view of a data page for security document according to an embodiment of the present invention.

[0076] The data page 100 comprises a stacked structure, which includes the intermediate layer 110 positioned between, or sandwiched between, a top layer 130 and a bottom layer 150. The stacked structure further comprises layers 140 and 150 attached to the top layer 130. For example, the layers 150 may be printed layers of the data page including printed features, such as images or photos of the user. The intermediate layer 110 is made of plastic material, such as PET or polyimide or the like.

[0077] Even if the data page of Fig. 1 comprises five layers, it is to be understood that the stacked structure may be formed of any number of layers, for instance it may comprise any number of layers positioned on top of the intermediate layer 110 and at the bottom of the intermediate layer 110.

[0078] Moreover, the intermediate layer 110 may be a multi-layered film and may comprise a plurality of sub-layers (not shown).

[0079] As visible in Fig. 1 , the top layer 130 and the bottom layer 150 are aligned to each other along all directions, such as along the right side and the left side shown in the figure and along the front and rear sides perpendicular to the right side and the left side. The intermediate layer 110 is aligned to the top layer 130 and the bottom layer 150 along the right side in the figure, the rear, and the front side, but is not aligned along the left side in the figure. A portion 112 of the intermediate layer 110 protrudes from the left side of the stacked structure in Fig. 1 and extend over the stacked structure. The protruding portion 112 is configured to be connected to the hinge layer 120 of the security document that includes the data page 100.Fig. 1 schematically illustrates a configuration of the data page 100 connected to the hinge layer 120 made of a woven material. The woven hinge 120 extends from the booklet of the security document and is connected to the intermediate layer 110 by means of the overlapping portions 112 and 122. Since the intermediate layer 110 is made of plastic material, it can be laminated to the corresponding hinge layer 120 by applying increased temperature and pressure on the overlapping portions 112 and 122. In this way, the data page 100 is connected to the rest of the security document by means of the hinge connection between the hinge layer 120 and the intermediate layer 110. The hinge connection provides a secure and flexible attachment that allows repeated opening and closing without compromising the integrity of the document. Moreover, since the plastic intermediate layer 110 is laminated to the hinge layer 120 made of woven material, the latter is less prone to fraying when cut or pierced.

[0080] Fig. 2 schematically illustrates a side view of a data page according to another embodiment of the present invention.

[0081] The data page 100' of the embodiment of Fig. 2 is obtained by dividing into two parts the thermoplastic urethane (TPU) structure 200. The TPU structure 200 is a multilayered laminated structure comprising layers made of TPU. After lamination of the layers, the TPU structure 200 is cut along the line A shown in Fig. 2 to obtain two symmetric datapages 100' and 100”.

[0082] The data page 100’ comprises a stacked structure, which includes the intermediate layer 110’ positioned between, or sandwiched between, a top layer 130’ and a bottom layer 150’. The stacked structure further comprises layers 140’ and 150’ attached to the top layer 130’. For example, the layers 150’ may be printed layers of the data page including printed features, such as images or photos of the user. The intermediate layer 110’ is made of TPU.

[0083] Even if the data page of Fig. 2 comprises five layers, it is to be understood that the stacked structure may be formed of any number of layers, for instance it may comprise any number of layers positioned on top of the intermediate layer 110’ and at the bottom of the intermediate layer 110’.

[0084] Moreover, the intermediate layer 110’ may be a multi-layered film and may comprise a plurality of sub-layers (not shown).

[0085] As visible in Fig. 2, in the data page 100' on the left, the top layer 130’ and the bottom layer 150' are aligned to each other along three directions, i.e. the left side shown in the figure and along the front side and the rear side perpendicular to the left side. The top layer 130’ and the bottom layer 150’ are not aligned along the right side of Fig. 2. The intermediate layer 110’ is aligned to the top layer 130’ and the bottom layer 150’ along the left side in the figure, the rear, and the frontside, but is not aligned along the right side in the figure. A portion 112’ of the intermediate layer 110’ protrudes from the right side of the stacked structure in Fig. 2 and extend over the stacked structure. The protruding portion 112' is configured to be connected to the hinge layer 120’ of the security document that includes the data page 100’.

[0086] In a similar way, in the data page 100” on the right of Fig. 2, the top layer 130” and the bottom layer 150” are aligned to each other along three directions, i.e. the right side shown in the figure and along the front side and the rear side perpendicular to the right side. The top layer 130” and the bottom layer 150” are not aligned along the left side of Fig. 2. The intermediate layer 110” is aligned to the top layer 130” and the bottom layer 150” along the right side in the figure, the rear, and the front side, but is not aligned along the left side in the figure. A portion 112” of the intermediate layer 110” protrudes from the left side of the stacked structure in Fig. 2 and extend over the stacked structure. The protruding portion 112” is configured to be connected to the hinge layer 120’ of the security document that includes the data page 100”.

[0087] Fig. 2 schematically illustrates a configuration of the data pages 100’ and 100” connected to the hinge layer 120’ made of TPU. The woven hinge 120’ extends from the security document and is connected to the intermediate layers 110’ and 110” by means of the overlapping portions 112', 112” and 122’. Since the intermediate layers 110’ and 110” and the hinge layer 120' are made of TPU, they can be laminated together by applying increased temperature and pressure on the overlapping portions 112’, 112’ and 122’. In this way, each data page 100’ and 100” is connected to the rest of the security document by means of the hinge connection between the hinge layer 120’ and the intermediate layers 110’, 110”. The hinge connection provides a secure and flexible attachment that allows repeated opening and closing without compromising the integrity of the document. Moreover, since the intermediate layers 110’, 110” and the hinge layer 120’ are made of the same material (TPU), the lamination process is particularly simple and efficient.

[0088] Fig. 3 schematically illustrates a top view of a data page according to some embodiments of the present invention. The data page of Fig. 3 may be a data page with a woven hinge connection similar to the data page 100 of Fig. 1 , or a data page with a TPU connection similar to the data page 100' of Fig. 2.

[0089] One or more security features may be provided on the hinge connection of the data page 100, 100’.

[0090] As schematically shown in Fig. 3, security features 124, 124’, 126, and 126’ are formed on the connecting portion 122, 122’ of the hinge layer 120, 120’ that is connected to the protruding portion 112, 112’ of the intermediate layer 110, 110’. Since the connecting portion 122, 122’ of the hinge layer 120, 120’ is laminated to the protruding portion 112, 112’ of the intermediate layer110, 110', the security features 124, 124’, 126, and 126’ can be formed on both the hinge later 120, 120' and the intermediate layer 110, 110’.

[0091] The security features 124, 124’, 126, and 126' may be made of any of the following materials: laser-engravable material, Optically Variable Ink (OVI), Optical Variable Material (OVM), UV fluorescent material, and / or a Photo Chromic material. Therefore, the security features 124, 124’, 126, and 126’ can be visible when opening the security document at the data page 100, 100’ and illuminating it with a predefined wavelength, such as visible light, infrared radiation, UV radiation, or the like.

[0092] The security features 124, 124’ may reproduce, for instance, a logo from the producer of the security document.

[0093] The security features 126, 126’ may reproduce, for instance, an image ora photo of a user of the security document, or a predefined image or pattern.

[0094] The security features 124, 124’, 126, and 126' are tamper evident features. In fact, if the data page 100, 100' is removed from the security document and a different (e.g. counterfeited) data page is connected to the security document, the security features 124, 124’, 126, and 126’ gets damaged and the resulting damage, such as a change in the optical pattern, can be detected by the operator.

[0095] Fig. 4 schematically illustrates an exploded view of a data page according to embodiments of the present invention. The data page of Fig. 4 may be a data page with a woven hinge connection similar to the data page 100 of Fig. 1 , or a data page with a TPU connection similar to the data page 100’ of Fig. 2.

[0096] As schematically shown in Fig. 4, the intermediate layer 110 comprises three protruding portions 114, 112, and 116. The protruding portions are separated by gap portions 111 and 113.

[0097] Even if Fig. 4 schematically shows three protruding portions, it is to be understood that any number of protruding portions may be formed, for instance one, two, three, four, or more.

[0098] The three protruding portions 114, 112, and 116 form an attachment portion configured to be connected to the corresponding portion of the hinge layer 120. In Fig. 4, the portion of the hinge layer 120 suitable for the hinge connection forms a continuous layer.

[0099] The three protruding portions 114, 112, and 116 are preferably attached to the intermediate layer 110. Alternatively, the three protruding portions 114, 112, and 116 may be integrally formed with the intermediate layer 110.A possible method for forming the data pages 100, 100’ disclosed above and the corresponding security document is described below.

[0100] The data page 100 or 100’ is formed by laminating together the top layer 130 or 130’, the bottom layer 150 or 150’, and the intermediate layer 110 or 110’, which is positioned between the top layer 130 or 130’ and the bottom layer 150 or 150’, so that a portion 112 or 112’ of the intermediate layer 110 or 110’ protrudes from a side of both the top layer 130 or 130’ and the bottom layer 150 or 150’. The hinge layer 120 or 120’ is then formed and laminated to the protruding portion o112 or 112’ of the intermediate layer 110 or 110’, thereby forming a hinge connection.

[0101] This manufacturing process is preferably carried out by a lamination stackup process, which includes the following steps: sheet preparation (wherein individual sheets are cut and prepared with embedded security features); layer alignment; heat and pressure lamination; hinge attachment; personalization with further security feature; and final assembly.

[0102] Figures 5a, 5b, 5c, and 5d schematically illustrate different orientations of the intermediate layers 110 in the stackups during the manufacturing process.

[0103] In the stackup 500 of Fig. 5a, the intermediate layers 110 have different orientations with respect to the sides of the stackup. In particular, each stackup comprises a top row of intermediate layers 110 and bottom row of intermediate layers 110. In the intermediate layers 110 of the top row, the protruding portions 112 face the top of the stackup and are formed along the edge of the stackup, whereas in the intermediate layers 110 of the bottom row, the protruding portions 112 face the bottom of the stackup and are formed along the edge of the stackup.

[0104] In the stackup 502 of Fig. 5b, the intermediate layers 110 have the same orientation with respect to the sides of the stackup. In particular, the stackup comprises a plurality of rows of intermediate layers 110 and, in each row, the protruding portions 112 face the same side of the stackup, i.e. the top side of the stackup.

[0105] In the stackups 504 and 504’ of figs. 5c and 5d, the intermediate layers 110 have different orientations with respect to the sides of the stackup. In particular, the stackups 504 and 504’ comprise a plurality of rows of intermediate layers 110 and the rows are grouped into sub-groups of two rows. In each subgroup, the top row includes intermediate layers 110 having protruding portions 112 that face the bottom of the stackup 504 or 504', whereas the bottom row includes intermediate layers 110 having protruding portions 112 that face the top of the stackup 504 or 504’.In the stackup 504 of Fig. 5c, the protruding portions 112 of the intermediate layers 110 of the same subgroup are formed as a single element that will be cut into two parts at a later stage.

[0106] On the other hand, in the stackup 504’ of Fig. 5d, the protruding portions of the intermediate layers 110 of the same subgroup are formed as distinct elements that are separated by a gap portion.

[0107] It is to be understood that the stackups of figures 5a-5d are only for illustrative purposes and should not be considered as limiting for the number of rows of intermediate layers 110 shown therein.

[0108] Fig. 6 schematically illustrates a step of the manufacturing process of the security document with the data page 100. As visible in the figure, the protruding portion of the intermediate layer 110 is laminated to the corresponding protruding portion of the hinge layer 120 by means of the pair of lamination tools 600A and 600B.

[0109] LIST OF REFERENCES

[0110] 100, 100', 100”: data pages

[0111] 110, 110’, 110”: intermediate layers

[0112] 111, 113: gap portions

[0113] 112, 112’, 112”, 114, 116: protruding portions of intermediate layers

[0114] 120, 120’: hinge layers

[0115] 122, 122’: connecting portion of hinge layers

[0116] 124, 124’, 126, 126’: security features

[0117] 130, 130’, 130”, 140’, 140’, 140”: layers of data page

[0118] 150, 150’, 150”: printed layers of data page

[0119] 200: thermoplastic urethane (TPU) structure

[0120] 500, 502, 504, 504': datapage stackup

[0121] 600A, 600B: lamination tool

Claims

CLAIMS1. A data page (100, 100’) for a security document comprising:- a top layer (130, 130’);- a bottom layer (150, 150’);- at least one intermediate layer (110, 110’) positioned between said top layer (130, 130’) and said bottom layer (150, 150’) so as to form a stacked structure,wherein said at least one intermediate layer (110, 110’) is made of plastic material, andat least one portion (112, 112’) of said at least one intermediate layer (110, 110’) protrudes from a side of said stacked structure with respect to both said top layer (130, 130’) and said bottom layer (150, 150’),and said at least one protruding portion (112, 112’) is configured to be connected to a hinge layer (120, 120’) of a security document, thereby forming a hinge connection.

2. The data page (100, 100’) of claim 1, comprising two or more intermediate layers (110, 110’) partially protruding from a side of said stacked structure, wherein one of said intermediate layers (110, 110’) is made of plastic material and is configured to be connected to a hinge layer (120, 120’) of a security document, thereby forming a hinge connection.

3. The data page (100, 100’) of claim 1, comprising two or more intermediate layers (110, 110’) partially protruding from a side of said stacked structure, wherein each of said intermediate layers (110, 110’) is made of plastic material and is configured to be connected to a hinge layer (120, 120’) of a security document, thereby forming a hinge connection.

4. The data page (100, 100’) of any of claims 1 to 3, further comprising one or more security features (124, 124’, 126, 126’) formed on said at least one protruding portion (112, 112’) of said at least one intermediate layer (110, 110’).

5. The data page (100, 100’) of claim 4, wherein said one or more security features (124, 124’) are made of a thermoplastic material, a laser-engravable material, an Optically Variable Ink (OVI) material, an Optical Variable Material (OVM), a UV fluorescent material, and / or a Photo Chromic material.

6. The data page (100, 100’) of any of previous claims, comprising three protruding portions.

7. A security document, such as a passport, comprising:- a data page (100, 100’) of any of claims 1 to 6, and- a hinge layer (120, 120’),wherein said at least one protruding portion (112, 112’) of said at least one intermediate layer (110, 110’) is laminated to at least one portion (122, 122’) of said hinge layer (120, 120’), thereby forming a hinge connection.

8. The security document of claim 7, wherein said hinge layer (120) is a woven layer.

9. The security document of claim 7 or 8, wherein said hinge layer (120, 120’) is made of PET or polymide.

10. The security document of claim 7, wherein said hinge layer (120’) and / or said at least one intermediate layer (110, 110’) are made of thermoplastic urethane.

11. The security document of any of claims 7 to 10, wherein one or more security features (124, 124', 126, 126’) are formed, partially or entirely, on said laminated portion (122, 122’) of said hinge layer (120, 120’).

12. The security document of claim 11, wherein said one or more security features (124, 124’) are made of a thermoplastic material, a laser-engravable material, an Optically Variable Ink (OVI) material, an Optical Variable Material (OVM), a UV fluorescent material, and / or a Photo Chromic material.

13. Method for forming a data page (100, 100’) for a security document, the method comprising the following steps:a) providing a top layer (130, 130’);b) providing a bottom layer (150, 150’);c) positioning at least one intermediate layer (110, 110’) made of plastic material between said top layer (130, 130’) and said bottom layer (150, 150’), so that at least one portion (112, 112’) of said at least one intermediate layer (110, 110’) protrudes from a side of both said top layer (130, 130’) and said bottom layer (150, 150’);d) forming a stacked structure comprising said top layer (130, 130'), said bottom layer (150, 150’), and said at least one intermediate layer (110, 110’) with said at least one protruding portion (112, 112’).

14. Method for forming a security document comprising the following steps:e) forming a data page (100, 100’) for a security document with the method of claim 13;f) providing a hinge layer (120, 120’);g) laminating said at least one protruding portion (112, 112’) of said at least one intermediate layer (110, 110’) to at least one portion (122, 122’) of said hinge layer (120, 120’), thereby forming a hinge connection.

15. Method of claim 13 or 14, wherein said method is carried out by means of a lamination stackup process.

16. The method of claim 15, wherein the stackup obtained after said step d) comprises a plurality of stacked structures and, in each stacked structure, the at least one protruding portion (112, 112’) of said at least one intermediate layer (110, 110’) faces the same side of the stackup.

17. The method of claim 15, wherein the stackup obtained after said step d) comprises a plurality of stacked structures and, in said stacked structures, the at least one protruding portions (112, 112’) of said at least one intermediate layer (110, 11 O’) face different sides of the stackup.

18. The method of claim 16 or 17, wherein said side is an edge of the stackup.

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