Security Document Data Page Gap Integration
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Solution Overview
Problem
Existing methods for producing book-shaped security and/or value documents restrict the selection of cover flap materials and often result in protruding areas due to the integration of the cover flap during data sheet production, limiting flexibility and leading to suboptimal document design.
Innovation Solution
A method involving at least two layers of organic polymer materials, where a gap or step is created between the layers using a non-laminatable shim, allowing for independent production of the data sheet before integrating the cover flap, enabling free material choice and secure connection through mechanical or material bonding methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the cover flap is integrated into the datasheet during its production, then the production process is simplified, but the choice of materials for the cover flap is limited and bulky areas are created within the datasheet
Solution Approach 1:
The patent divides the production process into separate stages: first producing the datasheet without the cover flap, then integrating the cover flap in a subsequent step. This segmentation allows independent optimization of each component and enables free material selection for the cover flap without being constrained by the datasheet lamination process.
Solution Approach 2:
The datasheet is produced completely independently before the cover flap integration. This preliminary production of the datasheet without the cover flap allows for streamlined manufacturing while preserving the ability to choose appropriate materials for the cover flap in a later stage.
2Productivity
If the cover flap is laminated simultaneously with the datasheet layers, then the production process is streamlined, but the material choices are restricted to laminate-compatible materials
Solution Approach 1:
The patent separates the lamination process from the cover flap integration process. The datasheet layers are laminated first, then the cover flap is integrated in a subsequent step using appropriate connection methods. This eliminates the constraint of requiring cover flap materials to be compatible with the lamination process while maintaining production efficiency.
3Ease of manufacture
If the integrated cover flap is produced as part of the datasheet, then manufacturing is simplified, but protruding areas and bulky regions are created within the datasheet
Solution Approach 1:
The datasheet is produced to its final precise dimensions and surface quality before the cover flap is added. This preliminary completion of the datasheet ensures that no protruding areas are created during the datasheet manufacturing process itself.
Solution Approach 2:
The datasheet area of the cover flap is inserted into a gap or step formed by layers of different sizes in the datasheet structure. This nesting approach allows the cover flap to be integrated without creating protruding areas, as it fits within the existing dimensional variations of the datasheet layers.
Data Source
Figure 1a~1e
Figure 2a~2e
Figure 3
AI summary
The invention relates to a method for producing a security document and/or value document (1) in book form, said method comprising the following steps: A) at least two layers (2, 3, 4) of a data page (5) formed from organic polymer materials are brought together, wherein one layer (3) is of smaller dimensions than at least one adjacent layer (2, 4), wherein the layers (2, 3, 4) are brought together with the proviso that the data page (5) forms a gap (7a) or a step (7b) along one edge (6), wherein the gap (7a) or the step (7b) is filled out with a spacer (8) of a thickness that essentially corresponds to the thickness D1 of the smaller dimensioned inner layer (3), wherein the spacer (8) is formed from a material which cannot be laminated with the layers (2, 3, 4); B) the stack from step A) is subjected to a lamination method step, wherein all layers (2, 3, 4) are laminated with each other, but not with the spacer (8); C) the spacer (8) is removed; D) a data page region (9) of a binding tab (10) is introduced into the gap (7a) or into the step (7b) in the data page (5) and joined to the data page (5) in an interlocking, friction-locking or material bonding manner; E) a binding region (11) of the binding tab (10) is bound into the binding (12) of the security document and/or value document.