Passport Data Page Lamination With Pre-Cut Metal Hinge Release
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Solution Overview
Problem
Existing methods for manufacturing passport data pages with metal hinges are inefficient, costly, and lack reliability, particularly in securing the metal hinge to the plastic layers, leading to increased rigidity and insufficient tear resistance.
Innovation Solution
A method involving laminating all components, including a metal hinge, followed by localized removal of excess outer layers to secure the hinge, using pre-cutting and controlled lamination to ensure strong cohesion and easy release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manufacturing methods (punching, drilling, stitching) are used to create passport inserts, then the structural integrity can be maintained, but the manufacturing process becomes complex and time-consuming with multiple separate steps
Solution Approach 1:
The patent combines multiple separate manufacturing operations (punching, drilling, stitching) into a single integrated die-cutting process. The die simultaneously performs all cutting, punching, and creasing operations in one stamping action, eliminating the need for multiple sequential steps and significantly improving manufacturing efficiency while reducing process complexity
Solution Approach 2:
The patent segments the insert design into modular components (main body, pockets, flaps, pockets) that are all created from a single sheet through strategic die-cutting paths. This segmentation allows complex functionality to be achieved through one integrated process rather than assembling multiple pre-manufactured parts
2Ease of manufacture
If multiple separate manufacturing steps are used for punching, drilling and stitching, then each operation can be optimized independently, but the overall manufacturing time and resource consumption increase
Solution Approach 1:
The die is pre-configured with all necessary cutting edges, punching elements, and creasing features before the manufacturing process begins. This preliminary preparation allows all operations to be executed simultaneously in a single stamping action, eliminating the need for sequential operations and significantly reducing manufacturing cycle time
Solution Approach 2:
The single die performs multiple functions simultaneously: it cuts the outer perimeter, punches internal shapes, creates pockets, forms flaps, and scores crease lines. This multi-functionality consolidates what would traditionally require multiple specialized tools and operations into one universal manufacturing step
Data Source
Figure 1A~3
Figure 4~6
AI summary
The invention relates to a method for producing a data page (10) for a passport booklet, which page is formed of a multilayer complex comprising a central core (2) made of plastic ending on one side with at least one metallic strip intended to form a hinge (5), where the data page (10) is intended to be stitched or stapled into a passport booklet, and outer layers (1, 3) made of plastic applied to each face of said core (2), this method comprising steps consisting in: superposing the central core (2) and the outer layers (1, 3) and laminating them together by applying a predetermined lamination temperature and pressure; freeing the metal hinge (5) by weakening and removing an excess part (14) of each outer layer (1, 3) situated in line with said at least one metallic strip (5); characterized in that, in order to remove said excess part, it comprises a step involving making a pre-cut (6) in each outer layer (1, 3) so as to obtain a weakened zone (14) in each outer layer (1, 3), followed by a step of removing said weakened zone (14) along said pre-cut (6).