Booklet Insert with Coplanar Coupling Elements
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing security booklet inserts with plastic components face challenges in creating a reliable and secure joint between elastic and plastic layers, as current methods rely solely on lamination, which lacks robustness and integrity.
Innovation Solution
A multilayer laminate sheet insert with an internal elastic layer extending beyond other layers, joined using coupling elements like threads or rivets that are laminated to ensure a secure attachment, where the external surface of the coupling element remains coplanar with the external layers, enhancing the joint's reliability and security.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If layers are joined together by lamination only, then the manufacturing process is simple, but the joint reliability and security are insufficient
Solution Approach 1:
The patent combines multiple joining methods (lamination and stitching with coupling elements) into a hybrid joining system. The elastic layer is both laminated to the plastic layers and stitched through them with coupling elements, creating a composite joining approach that leverages both adhesive bonding and mechanical interlocking for enhanced reliability.
Solution Approach 2:
The patent uses a composite joining approach combining organic materials (thread/coupling elements) with inorganic materials (lamination adhesive). This composite joining system integrates different material properties to achieve both strength and flexibility in the joint between elastic and plastic layers.
2Strength
If coupling elements extend above the external surface, then the joint strength is enhanced, but the surface finish and aesthetics are compromised
Solution Approach 1:
The patent applies different properties to different parts of the coupling element. The portion of the coupling element that provides structural strength can have different characteristics than the portion that contacts the external surface. The external surface of the coupling element is treated or shaped to be coplanar with the external layers, while the internal structure maintains joint strength.
Solution Approach 2:
The coupling element is nested within the laminate structure such that its external surface is flush with the external layers. The coupling element is positioned and configured so that it is embedded or integrated into the laminate assembly, with only the necessary functional portions exposed or visible, while the rest is concealed within the layered structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a robust and secure attachment between the elastic and plastic layers, making it difficult to remove or replace the coupling elements, thus improving the integrity and detectability of the joint, facilitating secure booklet construction.
Implementation Method 1
the coupling element is laminated with the one or both external layers
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
An insert for a booklet, the insert having a form of a multilayer laminate sheet, wherein one internal elastic layer (130) extends beyond the other layers (110, 120, 125, 126, 127) to form an elastic attachment part (132) for attaching the insert to the booklet. The internal elastic layer (130) is joined with at least one other layer of the laminate by at least one coupling element (140, 141, 142, 160) extending through the joined layers, wherein the external surface of the coupling element (140, 141, 142, 160) does not extend above the external surface of the external layers (110, 120).