Thermoplastic Elastomer Hinge Structure for Durable E-Passport Covers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing multilayer structures for passport book covers are complex and fail to adequately meet requirements for mechanical characteristics, tear resistance, bond adhesion, abrasion resistance, and integration of electronic security elements while maintaining desired properties such as color, grain, and tactile properties.
Innovation Solution
A layer structure comprising at least one outer layer of thermoplastic elastomer, preferably thermoplastic polyurethane, and at least one layer of materials like thermoplastic polymer, metal, textile, or paper, allowing for easy integration of electronic security elements and providing high bond adhesion, tear resistance, and abrasion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple material layers are used to achieve desired color, grain, and tactile properties, then the book cover meets aesthetic and functional requirements, but the manufacturing complexity and costs increase
Solution Approach 1:
The patent merges multiple material layers (textile, paper, plastics films) into a single integrated layer structure that can be produced in one manufacturing process. This eliminates the need for separate production of inlays and subsequent lamination steps, reducing manufacturing complexity while maintaining the desired color, grain, and tactile properties through the combined functionality of the integrated layers
Solution Approach 2:
The layer structure is designed to perform multiple functions simultaneously: providing aesthetic properties (color, grain, tactile feel), mechanical reinforcement, tear resistance, and accommodation of electronic security elements. This multi-functionality is achieved within a single integrated structure rather than requiring separate components and assembly steps
2Adaptability or versatility
If additional layers are added to integrate chip modules and antennas, then electronic security elements are incorporated, but the manufacturing complexity increases further
Solution Approach 1:
The patent integrates electronic security elements (chip modules, antennas) directly into the layer structure during the same manufacturing process that produces the aesthetic and structural layers. This merging eliminates the need for separate inlay production and subsequent lamination steps, reducing manufacturing complexity while maintaining adaptability for incorporating electronic elements
3Reliability
If parallel manufacturing steps are used to produce book covers with electronic elements, then the desired functionality is achieved, but the production time and costs increase
Solution Approach 1:
The patent combines multiple parallel manufacturing steps into a single integrated production process. The layer structure is produced in one continuous process that simultaneously creates the aesthetic layers, structural reinforcement layers, and integrates electronic security elements, eliminating the need for separate production of inlays and subsequent lamination operations
Solution Approach 2:
The layer structure is designed with pre-integrated electronic element accommodations (openings, recesses) formed during the primary manufacturing process. This preliminary integration of electronic element positioning and accommodation eliminates the need for subsequent separate operations to create openings and attach electronic components
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 layer structure achieves improved mechanical stability, tear resistance, and abrasion resistance, while enabling the integration of electronic components, and maintains desired properties like color, grain, and tactile properties over several years.
Implementation Method 1
at least one outer layer a) containing at least one thermoplastic elastomer, preferably a thermoplastic polyurethane
Implementation Method 2
The prefabricated inlay and the remaining layers of the passport book cover are later joined by lamination under the action of pressure and heat
Data Source
AI summary
The present invention relates to a layer structure, preferably a hinge, particularly preferably a book cover, very particularly preferably a book cover for identification and security documents, comprising at least one outer layer a) containing at least one thermoplastic elastomer, preferably a thermoplastic polyurethane, and at least one layer b) containing at least one material selected from the group consisting of a polymer, a metal, a textile, a paper and a synthetic paper, or a combination of at least two of these, and also relates to a laminate comprising the above layer structure and to the method for producing same. The invention further relates to the use of the layer structure and/or laminate for the production of a hinge, preferably a multilayer book cover, especially for security and identification documents.