WO2006054097A1

WO2006054097A1 - Moulded leaved article

Info

Publication number: WO2006054097A1
Application number: PCT/GB2005/004450
Authority: WO
Inventors: Paul Bagnall
Original assignee: Brite Ip Limited
Priority date: 2004-11-17
Filing date: 2005-11-17
Publication date: 2006-05-26
Also published as: EP1819529A1

Abstract

The present invention relates to a moulded article (10) incorporating an electronic device (28). The article has a first leaf portion (12) and a second leaf portion (14) connected to one another by a flexible spine portion (16). The leaf portions (12, 14) each comprise an injection moulded planar core (18) of plastics material having an outer layer of material (24, 26) integrated on at least one side (20, 22) thereof, wherein said at least one outer layer of material (24, 26) includes an electronic device (28).

Description

Moulded Leaved Article

The present invention relates to a moulded leaved article comprising first and second leaves joined by a flexible spine. Particularly, though not exclusively, the present invention relates to book covers and the like having the aforementioned configuration and more particularly, though not exclusively, to personal identity documents and travel documents such a passports.

A passport is typically provided in the form of a book having front and rear covers and a plurality of pages therebetween. One of the pages is provided with information relating to the bearer of the passport such as their name, date of birth, passport number and photograph. This information bearing page is provided with one or more security features such as, for example, a watermark, or a hologram, however advances in printing and copying technology have made such measures relatively simple to replicate. In a bid to make passports harder to counterfeit, it is now proposed to incorporate electronic data storage means within them.

According to a first aspect of the present invention there is provided a moulded article incorporating an electronic device, the article having a first leaf portion and a second leaf portion connected to one another by a flexible spine portion, the leaf portions each comprising an injection moulded planar core of plastics material having an outer layer of flexible material integrated on at least one side thereof, wherein said at least one outer layer of material includes an electronic device

According to a second aspect of the present invention there is provided a moulded article incorporating an electronic device, the article having a first leaf portion and a second leaf portion connected to one another by a flexible spine portion, the leaf portions comprising a planar core of plastics material having an outer layer of material integrated on opposing sides thereof, wherein the spine portion is formed by both of said layers of material extending between the leaf portions, and wherein further one of said layers of material includes an electronic device. The layers may extend fully over the cores or, alternatively, may extend over the cores only in the regions either side of the spine portion. The portions of the layers forming the spine portion may extend between the covers via an intermediate spine member of the cover. Such a spine member may be of a similar construction to the covers comprising a core sandwiched between the layers.

According to a third aspect of the present invention there is provided a moulded article incorporating an electronic device, the article having a first leaf portion and a second leaf portion connected to one another by a flexible spine portion, the leaf portions comprising a planar core of plastics material having an outer layer of material integrated on opposing sides thereof, wherein the spine portion is formed by one of said layers of material extending between the cover portions, and wherein further one of said layers of material includes an electronic device.

The layers may extend fully over the cores or alternatively, may extend over the cores only in the regions either side of the spine portion. The layer forming the spine portion may extend between the covers via an intermediate spine member of the cover. The spine portion may include a portion of the core material overlaying the layer and extending between the core portions.

According to a further aspect of the present invention there is provided a moulded article incorporating an electronic device, the article having a first leaf portion and a second leaf portion connected to one another by a flexible spine portion, the leaf portions comprising a planar core of plastics material having an outer layer of material integrated on opposing sides thereof, wherein the spine portion is formed by a living hinge of the core material extending between the cover portions, and wherein further one of said layers of material includes an electronic device.

The living hinge may have a thickness substantially equal to that of the cover cores. Alternatively, the living hinge may have a thickness less than that of the cores. In such an embodiment, the living hinge may be waisted. The article may form the cover for a book which is subsequently bound, stapled or otherwise attached to the article. The term book is intended to cover such items as books, booklets, pamphlets, folios and other such like items having two covers flexibly connected to one another by a spine. Alternatively the article may be a stand alone item such as, for example a foldable pass or identity document.

The outer layers are preferably integrated to the cores in a non-adhesive manner which is to say they are integrated therewith without the use of adhesive. For example the layers may be integrated with the cores during a moulding operation to form the article.

The article may be textured. The texture may be decorative in nature, for example providing a raised or recessed pattern in register with a pictures or lettering on the cover. Alternatively the texture may be technical in nature, for example the texture may be configured so as to produce an optical effect. In a alternative embodiment the texture may be provided so as to permit a visual and/or tactile evidence of tampering, wherein the absence of the texture indicates tampering. Preferably the above described instances of texturing are applied to the cover during moulding thereof.

The electronic device is preferably positioned in an inner surface of the layer upon which it is carried such that it faces the core of a leaf portion. The layer including the electronic device may further be provided with an antenna means in communication with the device. The antenna may be positioned on the layer such that it is fully within the bounds of a leaf portion of the moulded article. Alternatively the antenna may extend across the spine portion to the other leaf portion. The antenna means may be formed by a layer of conductive material applied to the layer. The conductive material may comprise a conductive ink. Advantageously the layer including the electronic device is provided with an anti-tamper arrangement so as to affect the operation of the electronic device in the event that an attempt is made to delaminate the cover. The anti-tamper arrangement may be provided by differing the attachment strength of portions of the layer bearing the electronic device to the core. In such an embodiment the differing attachment strengths may be such that during attempted delamination, portions of layer are removable from the core, while other portions remain attached to the core. The differing attachment strengths may be effected by the application of a suitable coating to portions of the layer. For example, a low adhesion coating may be applied to the portions of the layer which are intended to be removed from the core.

The layer may further be adapted to delaminate from the core in a predetermined manner. The layer may be provided with lines of weakness to promote tearing of the layer in the event of delamination. The lines of weakness may comprise, for example, areas of reduced thickness of the layer or one or more perforations. Advantageously the lines of weakness are positioned at or near the aforementioned low adhesion coating. In the embodiment where the layer bearing the electronic device is provided with an antenna, the layer may be configured to tear or otherwise break the antenna during delamination.

A layer of the cover may be provided with an viewing aperture which exposes a portion of one of the cores. Where the material of the core is transparent, the aperture may permit the other of the layers to be viewed through the core. It will thus be understood that information provided on the other of the layers may be viewed. The surface of the exposed core portion within the layer aperture may be textured, contoured or otherwise modified so as to optically enhance any information viewed therethrough. The other of the layers may also be provided with an aperture aligned with the viewing aperture. This other aperture may define a space where information intended to be viewed through the viewing aperture may be subsequently added.

The material forming the or each outer layer may comprise a fabric. The fabric may preferably comprise a woven arrangement of threads or filaments. The threads or filaments may comprise a plastics material such as, for example, polyester. The fabric may be provided with one or more surface coatings which are applied to the fabric before its incorporation into a moulded article. The threads or filaments of the fabric may include a marker arranged to become visible when viewed under certain conditions. For example, the marker may become visible when viewed under certain light conditions. The marker may become visible when, for example, the fabric is subjected to light of a certain wavelength. The marker may be come visible when viewed under ultraviolet (UV) light. In an alternative embodiment, the maker may become visible when the fabric is exposed to a particular type of radiation such as, for example, x-ray radiation.

Where the moulded article includes an antenna, the antenna may be defined by a UV curable ink. The ink may comprise a plurality of electrically conductive particles suspended in a liquid medium. Upon being subjected to UV radiation the liquid medium solidifies. The ink may be applied to the layer via a screen printing operation or, alternatively, by an ink jet printer. During incorporation of the layer bearing the conductive ink into a moulded body or article the ink forming the antenna may be compressed such that the thickness of the ink decreases and the conductive particles of the ink are moved closer to one another.

According to a further aspect of the present invention there is provided method of manufacturing a moulded article incorporating an electronic device, the article having first and second leaf portions connected to one another by a flexible spine portion the method comprising the steps of: providing a flexible layer of material having an electronic device attached thereto; providing a mould having a mould cavity, said mould cavity having first and second cavity portions separated by a third cavity portion, said third cavity portion defining the spine portion and said first and second cavity portions defining said first and second leaf portions; placing said flexible layer in the mould cavity against a face thereof; closing the mould; and injecting plastics material into the first and second cavity portions between the flexible layers.

The step of placing the flexible layer in the mould cavity may comprise positioning the layer such that the layer extends across all three cavity portions. The layer may thus define the flexible spine portion of the article. The spine portion may alternatively be defined by a combination of the layer and plastics material.

In an alternative embodiment first and second flexible layers of material may be provided, with one of said layers having an electronic device attached thereto, and wherein the layers are placed in the mould cavity against opposing faces thereof prior to the injection of plastics material therebetween. The step of placing the flexible layers in the mould cavity may comprise positioning the layers such that each layer extends across all three cavity portions. In such an embodiment the layers may thus define the flexible spine portion of the article. The spine portion amy include plastics material between the layers.

In yet a further embodiment first, second and third flexible layers of material may be provided, one of said layers having an electronic device attached thereto, wherein further the step of placing the layers in the mould cavity comprises the steps of placing one of the layers against a face of the mould cavity such that said layer extends across all three cavity portions, and placing the other of the flexible layers against an opposing face of the mould cavity prior to the injection of plastics material therebetween.

Alternatively, first, second, third and fourth flexible layers of material may be provided, one of said layers having an electronic device attached thereto, wherein further the step of placing the layers in the mould cavity comprises the steps of placing two of the layers against a face of the mould cavity, and placing the other of the flexible layers against an opposing face of the mould cavity prior to the injection of plastics material therebetween.

Embodiments of the present invention will now be described with reference to the accompanying drawings in which:

Figure 1 shows a plan view of a moulded article according to an aspect of the present invention in the from of a book cover;

Figure 2 shows a cross-sectional view of the cover of figure 1;

Figure 3 shows a plan view of an outer cover layer; Figure 4 shows a plan view of an inner cover layer according to an embodiment of the present invention;

Figure 5 shows a partial cross-sectional view of a cover including the layer of figure 4 as indicated by section A-A of figure 4; Figure 6 shows the layer of figures 4 and 5 in a de-laminated state;

Figure 7 shows a partial cross-sectional view of a cover incorporating a viewing aperture;

Figure 8 shows a partial cross-sectional view of an alternative embodiment of a cover incorporating a viewing aperture; Figure 9 shows a partial cross-sectional view of a textured cover incorporating a viewing aperture;

Figure 10 shows a plan view of a moulded article according to a further embodiment of the present invention in the form of a book cover;

Figure 11 shows a cross-sectional view of the book cover of figure 10; Figure 12 shows a plan view of a moulded article according to a further alternative embodiment of the present invention in the form of a book cover;

Figure 13 shows a cross-sectional view of the book cover of figure 12.

Referring firstly to figures 1 and 2 there is shown a moulded article, generally designated 10, according to an aspect of the present invention. The article 10 comprises first and second leaves 12, 14 which are joined by a flexible spine portion 16. The spine portion 16 is of sufficient width and flexibility to allow the leaves 12, 14 to be folded such that one may rest against the other. The spine portion 16 also provides a base to which one or more paper pages may be attached so as to form a number of pages between the leaves 12,14. The pages may be attached to the spine portion 16 by any appropriate means such as, for example, stitching, gluing, welding or a combination thereof.

Each leaf 12,14 comprises a planar core 18 having opposing sides 20,22. The cores 18 are joined to one another by being sandwiched between opposed flexible layers of material 24,26. The layers 24,26 are attached to respective sides 20,22 of the cores 18.

As can be seen from figure 2 the spine portion 16 is formed where the layers 24,26 come into contact with one another between the cores 18. It will be appreciated that the spine portion 16 thus has a thickness substantially equal to that of the combined thickness of the layers 24,26. The cores 18 are preferably formed from a thermoplastic plastics material such as polypropylene, while the flexible layers may each comprise a thin sheet of paper, card, fabric, plastics material such as polypropylene or be of a laminate construction comprising a plurality of layers chosen from the aforementioned materials.

As can be seen in figure 2, the article 10 further includes an electronic device 28 which is provided between a core 18 and one of the flexible layers 24. The electronic device

28 includes a chip within which data may be stored and which may be accessed by an appropriately configured reader means. To assist in the reading of data from the device

28 the flexible layer 24 to which it is attached may be provided with an antenna or aerial. The antenna or aerial may be formed by an appropriately configured layer of conductive ink applied to the layer 24. As the device 28 is provided between the layer 24 and the core 18, it will be appreciated that it is to all intents and purposes concealed internally within the cover. Accordingly its existence and position is not readily identifiable and hence the likelihood of it being disturbed is reduced. In use, a booklet

29 is attached to the article 10, for example by a layer of adhesive. Advantageously the booklet 29 is attached to the layer 24 to which the electronic device 28 is attached. The existence and position of the electronic device 28 is therefore further shielded by the booklet 29.

The article 10 is advantageously manufactured using an injection moulding operation. The flexible layers 24,26, one of which has the electronic device 28 attached thereto, are placed on opposing sides of an appropriately configured mould. Once the mould is closed a plastics material injected between portions of the layers 24,26, with the result that said portions of the layers 24,26 become bonded to the cores 18.

The articles 10 may be moulded individually. Alternatively the mould may be configured to mould multiple articles 10 in a platen from which the articles 10 are subsequently released by, for example, a pressing or stamping operation. Advantageously the layers 24,26 may be pre-printed with information and/or images. Taking the example of providing an article 10 which subsequently is used as a cover for a passport, the layers 24,26 may be pre-printed, foil blocked or otherwise provided with pre-applied information. This information may comprise such items such as the name of the passport issuing authority, heraldic symbols etc. as well as information relating to the person to which passport has been issued and a picture of said person. The mould within which the article 10 is made may advantageously be textured so that it imparts a corresponding texture to the cover 10 during the manufacture thereof. The texture may serve as indication of authenticity of the passport and is discussed in greater detail below.

Figures 3 and 4 show, respectively, outer 26 and inner 24 layers. The outer layer 26 is provided with information related to the particular document it is intended to form part of, in this case a passport. The inner layer 24, on the other hand, is free from information as, in use, it will be covered by the booklet 29 forming the body of the passport. The inner layer 24 is provided with an electronic device 28 and an antenna 31 in electrical connection with the device 28. In the embodiment shown the antenna 31 is formed by a layer of electrically conductive ink applied to the layer 24. The layer 24 is additionally provided with lines of weakness 33 which are positioned adjacent edges of the antenna 31. The lines of weakness 33 form part of an anti-tamper arrangement which is described in greater detail below. The lines of weakness 33 may, for example, comprise perforations through the layer 24 or areas of reduced thickness. In the case of perforations, these are advantageously provided in the layer after the application of the antenna 31 so as to prevent bleed through of the material forming the antenna 31.

The layer 24 of figure 4 may also be provided with an antenna blocking means illustrated by broken lines 39. The blocking means 39 are provided on a portion of the layer which, in use will form part of the leaf portion which does not contain the electronic device 28 and antenna 31. When the article 10 is in an open position the blocking means 39 is spaced from the antenna 31 and hence wireless reading of the device 28 is possible. When article 10 is in a closed position, which is to say the leaf portions 12,14 are folded together, the blocking means 39 overlies the antenna 31 and prevents the operation thereof. The blocking means 39 may be defined by a electrically conductive loop or lattice of material such as, for example, foil or electrically conductive ink. The blocking means 39 may preferably have a similar construction and configuration as the antenna 31.

Figure 5 shows a cross-sectional view of a portion of an article 10 including the inner layer 24 described above. Features common to those described above are identified with like reference numerals. As before, the cover 10 comprises a core 18 which is sandwiched between the inner and outer layers 24,26, with the inner layer 24 being covered by a leaf of a booklet 29. The booklet 29 is attached to the inner layer 24 by a layer of adhesive 35. The inner layer 24 is positioned such that the antenna 31 faces the core 18 with the result that there is no outward bulging of the inner layer 24 which might betray the presence of the antenna 31. In the region of the lines of weakness 33 the antenna is provided with a coating 37 which prevents or, at the very least reduces, the adhesion of the material of the core 18 to the antenna. The coating 37 may comprise a layer of varnish or lacquer.

In the event that a person wishes to tamper with the passport, for example by separating the booklet 29 from the article 10 with a view to possible swapping one or the other with another passport, then the lines of weakness 33 and coating 37 cooperate to disable the antenna 31. Figure 6 shows the result of attempting to separate the booklet 29 from the article 10 of the document shown in figure 5. In peeling the booklet 29 from the article 10 the portion of the antenna 31 provided with the low adhesion coating 37 separates from the core 18. The presence of the lines of weakness 33 result in tearing of the inner layer 24 in the region of the coating 37 with the result that some portions of the inner layer 24 and antenna 31 are removed with the booklet 29, while the remainder of the imier layer 24 and antenna 31 remain attached to the article 10. The antenna 31 is therefore disabled and wireless communication with the electronic device 28 is not possible. In the event that the article 10 and/or booklet 29 are incorporated into another passport then the disabling of the antenna 31 and device 28 will be readily apparent when reading of the device 28 by wireless means is not possible. Referring now to figure 7 there is shown a cross-sectional view of a portion of a leaf generally designated 30. As before, the leaf 30 comprises a core 18 sandwiched between respective layers 24,26. One of the layers 24 is provided with an aperture 32 with the result that the material forming the core 18 can be seen through the aperture 32. It will be appreciated that should the material of the core be transparent, then the inner surface 34 of the other of the layers 26 may be viewed through the aperture. The inner surface 34 may therefore be printed with information intended to be viewed through the aperture 32. The portion 36 of the core 18 which faces the aperture 32 may be provided with a textured, contoured or otherwise modified surface 38 which may serve to enhance information printed on the inner surface 34. For example the surface 38 may be formed so as to magnify the information. Alternatively the surface may be configured so as to create an optical effect such as making the information appear to be presented in three dimensions within the core 18. The particular configuration of the surface 38 may advantageously be formed during moulding by the provision of an appropriately configured portion of the mould.

Figure 8 shows a cross-sectional view of a leaf portion, generally designated 40, which is similar to the leaf portion 30 described with reference to figure 7. As before one of the layers 24 is provided with an aperture 32 within which a surface 38 of the core 18 projects through. In contrast to the embodiment of figure 3 the other of the layers 26 is provided with an aperture 42 aligned with the surface 38. The aperture 42 is provided so as to allow an information bearing sheet or sticker 44 to be attached to the leaf portion 40. The sheet or sticker 44 may, for example, carry personal information relating to the bearer of the passport to which the leaf portion 40 is attached. The provision of the aperture 42, and the subsequent attachment of a sticker or sheet, may be utilised to increase the security surrounding the manufacture of documents such as passports. Articles may be manufactured with the aperture in a relatively low security facility or area before being moved to a higher security facility or area for the subsequent production and attachment of the sticker. Fig 9 shows a cross-sectional view of a portion of a leaf, generally designated 41, which is similar to those described with reference to figures 7 and 8 and common features are identified with like reference numerals. As before, the leaf portion 41 comprises a core 18 sandwiched between respective layers 24, 26. An aperture 32 is provided in one of the layers 26 which may serve as a viewing aperture. The leaf portion 41 is textured and, in the embodiment shown, a rippled surface is provided on either side of the leaf portion 41. The depth of the ripples, i.e. the distance between the peaks and troughs is greater than the thickness of the respective layers 24, 26. In the event that a person tries to remove information provided in one or other of the layers 24, 26, for example by using an abrasive means, then the material of the core 18 will become exposed before the information has been fully removed. This can therefore provide an outward indication of tampering with the leaf 41. Where one or other of the layers 24,26 is provided with an antenna, then abrasion of the relevant layer will result in damage to the antenna and the probable disabling of the wireless reading of an electronic device associated with the antenna.

Figure 9 also shows a portion of a mould 43 which is configured to provide the modified surface 38 of the leaf portion exposed through the aperture 32. The mould portion 43 is provided with a wall 45 which surrounds a mould surface 47 configured to impart the required contour or texture to the core surface 38. The wall 45 serves to both locate the layer 26 relative to the mould as a whole prior to injection of the core material by fitting with a pre-formed aperture 32 of the layer 26, and to prevent the bleeding of the core material to the outer side of the layer 26 during injection. Alternatively the mould portion 43 may comprise a solid projection, indicated by broken line 49, wit the face of the projection being configured to impart the required contour or texture to the core surface 38.

Referring now to figures 10 and 11 there is shown a moulded article, generally designated 110, according to an aspect of the present invention. The article 110 comprises first and second leaf portions 112, 114 which are joined by a flexible spine portion 116. The spine portion 116 is of sufficient width and flexibility to allow the leaf portions 112, 114 to be folded such that one may rest against the other. The spine portion 116 also provides a base to which one or more paper pages may be attached so as to form a number of pages between the leaf portions 112,114. The pages may be attached to the spine portion 116 by any appropriate means such as, for example, stitching, gluing, welding or a combination thereof.

Each leaf portion 112,114 comprises a planar core 118 having opposing sides 120,122. The cores 118 are joined to one another by being sandwiched between opposed flexible layers of material 124a, 124b, 126, one of which 126 extends between the cores 118. The layers 124a, 124b, 126 are attached to respective sides 20,22 of the cores 18. As can be seen from figure 11 the spine portion 116 is formed where one of the layers 126 on one side of the cores 118 extends between the cores 118. The layers 124a, 124b on the opposing side of the cores 118 terminate before the spine portion 116. In the embodiment shown the spine portion 116 is defined by a portion of one layer 126 alone. In an alternative embodiment the spine portion 116 may include a portion of the core material extending between the cores 118 over the layer 126. The cores 118 are formed from a plastics material such as polypropylene, while the flexible layers 124a, 124b, 126 may each comprise a thin sheet of paper, card, fabric, plastics material such as polypropylene or be of a laminate or composite construction comprising a plurality of layers or constituents chosen from the aforementioned materials.

As can be seen in figure 11, the article 110 further includes an electronic device 128 which is provided between a core 118 and one of the flexible layers 124b. The electronic device 128 includes a chip within which data may be stored and which may be accessed by an appropriately configured reader means. To assist in the reading of data from the device 128 the flexible layer 124b to which it is attached may be provided with an antenna or aerial. The antenna or aerial may be formed by an appropriately configured layer of conductive ink applied to the layer 124b as described above with reference to the previously described embodiments. As the device 128 is provided between the layer 124b and the core 128, it will be appreciated that it is to all intents and purposes concealed internally within the article 10. Accordingly its existence and position is not readily identifiable and hence the likelihood of it being disturbed is reduced. In use, a booklet 129 is attached to the article 110, for example by a layer of adhesive. Advantageously the booklet 129 is attached to the layer 124b to which the electronic device 128 is attached. The existence and position of the device is therefore further shielded by the booklet 129.

The article 110 is advantageously manufactured using an injection moulding operation. The flexible layers 124a, 214b, 126, one of which has the electronic device 128 attached thereto, are placed on opposing sides of an appropriately configured mould. Once the mould is closed a plastics material injected between portions of the layers 124a, 124b, 126, with the result that the portions of the layers 124a, 124b, 126 become bonded to the cores 118.

The articles 110 may be moulded individually. Alternatively the mould may be configured to mould multiple articles 110 in a platen from which the articles 110 are subsequently released by, for example, a pressing or stamping operation.

Advantageously the layers 124a, 124b, 126 may be pre-printed with information and/or images. Taking the example of providing an article 110 intended to form a cover for a passport, the layers 124a, 124b, 126 may be pre-printed, foil blocked or otherwise provided with pre-applied information. This information may comprise such items such as the name of the passport issuing authority, heraldic symbols etc. as well as information relating to the person to which passport has been issued and a picture of said person. The mould within which the article 10 is made may advantageously be textured so that it imparts a corresponding texture to the article 10 during the manufacture thereof. The texture may serve as indication of authenticity of the passport. The article 110 of figures 10 and 11 may optionally include the antenna and viewing aperture features of described with reference to figures 4 to 9.

Referring finally to figures 12 and 13 there is shown a moulded article, generally designated 210, according to an aspect of the present invention. The article 210 comprises first and second leaf portions 212, 214 which are joined by a flexible spine portion 216. The spine portion 216 is of sufficient width and flexibility to allow the leaf portions 212, 214 to be folded such that one may rest against the other. The spine portion 216 also provides a base to which one or more paper pages may be attached so as to form a number of leaves between the leaf portions 212,214. The pages may be attached to the spine portion by any appropriate means such as, for example, stitching, gluing, welding or a combination thereof.

Each leaf portion 212,214 comprises a planar core 218 having opposing sides 220,222 which are sandwiched between opposed flexible layers of material 224a, 224b, 226a, 226b. The spine portion 216 is formed by a living hinge 227 extending between the cores 218. The hinge 227 is formed integrally with the cores 218 and in the embodiment shown has a narrowed, waisted configuration. The layers 224a, 224b, 226a, 226b terminate before the spine portion 216 with the result that the material forming the living hinge 227 is exposed. The cores 218 and hinge 227 are formed from a plastics material such as polypropylene, while the flexible layers 224a, 224b, 226a, 226b may each comprise a thin sheet of paper, card, fabric, plastics material such as polypropylene or be of a laminate or composite construction comprising a plurality of layers or constituents chosen from the aforementioned materials.

As can be seen in figure 13, the article 210 further includes an electronic device 228 which is provided between a core 218 and one of the flexible layers 224b. The electronic device 228 includes a chip within which data may be stored and which may be accessed by an appropriately configured reader means. To assist in the reading of data from the device 228 the flexible layer 224b to which it is attached may be provided with an antenna or aerial. The antenna or aerial may be formed by an appropriately configured layer of conductive ink applied to the layer 224b as described in greater detail above. As the device 228 is provided between the layer 224b and the core 228, it will be appreciated that it is to all intents and purposes concealed internally within the cover. Accordingly its existence and position is not readily identifiable and hence the likelihood of it being disturbed is reduced. In use, a booklet 229 is attached to the article 210, for example by a layer of adhesive. Advantageously the booklet 229 is attached to the layer 224b to which the electronic device 228 is attached. The existence and position of the device is therefore further shielded by the booklet 229. The article 210 is advantageously manufactured using an injection moulding operation. The flexible layers 224a, 224b, 226a, 226b, one of which has the electronic device 228 attached thereto, are placed on opposing sides of an appropriately configured mould. Once the mould is closed a plastics material injected between the layers 224a, 224b, 226a, 226b, with the result that the layers 224a, 224b, 226a, 226b become bonded to the cores 218.

The articles 210 may be moulded individually. Alternatively the mould may be configured to mould multiple articles 210 in a platen from which the articles 210 are subsequently released by, for example, a pressing or stamping operation.

Advantageously the layers 224a, 224b, 226a, 226b may be pre-printed with information and/or images. Taking the example of providing an article 210 for use as a cover for a passport, the layers 224a, 224b, 226a, 226b may be pre-printed, foil blocked or otherwise provided with pre-applied information. This information may comprise such items such as the name of the passport issuing authority, heraldic symbols etc. as well as information relating to the person to which passport has been issued and a picture of said person. The mould within which the article 210 is made may advantageously be textured so that it imparts a corresponding texture to the article 210 during the manufacture thereof. The texture may serve as indication of authenticity of the passport. The article 210 of figures 12 and 13 may optionally include the antenna and viewing aperture features of described with reference to figures 4 to 9.

While the above described embodiments relate to a moulded article intended to form the cover for a book or the like, the article may be used without a booklet being attached thereto as, for example, a twin leaf foldable document such as a travel or identity pass. It will be appreciated that the leaves of the article may not be of a uniform thickness as shown in the above described embodiments. For example one leaf may be thicker than the other. Alternatively one or both leaves may be of non uniform thickness, for example one or both leave may be tapered or stepped in cross section.

The electronic device carried by one of the layers may be provided on an outer surface of the layer, which is to say the surface opposite to that which contacts the core, in order that it may, in use, be placed into contact with a read/write device. The moulded article may be provided with a plurality electronic devices.

Claims

1. A moulded article incorporating an electronic device, the article having a first leaf portion and a second leaf portion connected to one another by a flexible spine portion, the leaf portions each comprising an injection moulded planar core of plastics material having an outer layer of flexible material integrated on at least one side thereof, wherein said at least one outer layer of material includes an electronic device.

2. A moulded article as claimed in claim 1 wherein said cores have an outer layer of flexible material on both sides thereof

3. A moulded article as claimed in claim 2 wherein the spine portion has a thickness which is less than that of the leaf portions.

4. A moulded article as claimed in claim 2 or claim 3 wherein the spine portion is formed by one of said outer layers of material extending between the leaf portions.

5. A moulded article as claimed in claim 4 wherein said outer layer of material forming the spine portion extends fully over the core of each leaf portion.

6. A moulded article as claimed in claim 4 wherein said outer layer of material forming the spine portion extends partially over the core of each leaf portion.

7. A moulded article as claimed in any of claims 4 to 6 wherein the outer layer forming the spine portion may extend between the leaf portions via an intermediate spine member of the article.

8. A moulded article as claimed in claim 7 wherein said intermediate spine member comprises a portion of plastics material extending between the cores.

9. A moulded article as claimed in claim 2 or claim 3 wherein the spine portion is formed by both of said outer layers of material extending between the leaf portions.

10. A moulded article as claimed in claim 9 wherein one of said outer layers of material forming the spine portion extends fully over the core of each leaf portion.

11. A moulded article as claimed in claim 9 or claim 10 wherein both of said outer layers of material forming the spine portion extends fully over the core of each leaf portion.

12. A moulded article as claimed in claim 9 wherein both of said outer layers of material forming the spine portion extends partially over the core of each leaf portion.

13. A moulded article as claimed in any of claims 9 to 12 wherein said outer layers of material forming the spine portion extend between the leaf portions via an intermediate spine member of the cover.

14. A moulded article as claimed in claim 13 wherein said intermediate spine member comprises a portion of plastics material extending between the cores.

15. A moulded article as claimed in claim 1 or claim 2 wherein the spine portion is formed by a living hinge of the core material extending between the leaf portions.

16. A moulded article as claimed in any preceding claim wherein the electronic device is a data storage device.

17. A moulded article as claimed in claim 16 wherein the data storage device is positioned on an inner surface of the outer layer such that it faces the core.

18. A moulded article as claimed in any preceding claim wherein at least one surface of the article is textured.

19. A moulded article as claimed in any preceding claim wherein the outer layer having the electronic device is provided with an antenna means in communication with the device.

20. A moulded article as claimed in claim 19 wherein the antenna means is positioned on the layer such that it is fully within the bounds of a leaf portion of the moulded article.

21. A moulded article as claimed in claim 19 wherein the antenna means extend across the spine portion to the other leaf portion.

22. A moulded article as claimed in any of claims 19 to 21 wherein the antenna means is formed by a layer of conductive material applied to the layer.

23. A moulded article as claimed in claim 22 wherein the conductive material comprises a conductive ink.

24. A moulded article as claimed in any preceding claim wherein the outer layer having the electronic device is provided with an anti-tamper arrangement so as to affect the operation of the electronic device in the event that an attempt is made to delaminate the cover.

25. A moulded article as claimed in claim 24 wherein the anti-tamper arrangement is provided by differing the attachment strength of portions of the outer layer bearing the electronic device to the core.

26. A moulded article as claimed in claim 25 wherein the differing attachment strengths effected by the application of a suitable coating to portions of the outer layer.

27. A moulded article as claimed in any of claims 24 to 26 wherein the outer layer is adapted to delaminate from the core in a predetermined manner.

28. A moulded article as claimed in claim 26 wherein the outer layer is provided with lines of weakness to promote tearing of the layer in the event of delamination.

29. A moulded article as claimed in any preceding claim wherein at least one of the outer layers comprises a flexible sheet of plastics material.

30. A moulded article as claimed in claim 29 wherein the plastics material is polypropylene.

31. A moulded article as claimed in any of claims 1 to 28 wherein at least one of the outer layers comprises a flexible sheet of paper or card.

32. A moulded article as claimed in any of claims 1 to 28 wherein at least one of the outer layers comprises a flexible sheet of fabric.

33. A moulded article as claimed in claim 32 wherein the fabric comprises a woven arrangement of threads or filaments.

34. A moulded article as claimed in claim 33 wherein the threads or filaments of the fabric include a marker arranged to become visible when viewed under certain conditions.

35. A moulded article as claimed in claim 34 wherein the marker is arranged become visible when viewed under certain light conditions, is exposed to a particular type of radiation such as, for example, x-ray radiation.

36. A moulded article as claimed in any preceding claim wherein one of the outer layers of material is provided with an viewing aperture which exposes a portion of the core.

37. A moulded article as claimed in claim 36 wherein the surface of the exposed core portion within the outer layer aperture is textured, contoured or otherwise modified.

38. A moulded article as claimed in claim 37 wherein the surface of the exposed core portion is shaped so as to define a lens.

39. A moulded article as claimed in any preceding claim wherein one of the outer layers is provided with a wireless blocking means arranged to prevent wireless access to the electronic device when the leaf portions are folded together.

40. A moulded article as claimed in claim 38 wherein the wireless blocking means is defined by a an electrically conductive portion of said outer layer.

41. A method of manufacturing a moulded article incorporating an electronic device, the article having first and second leaf portions connected to one another by a flexible spine portion the method comprising the steps of: providing a flexible layer of material having an electronic device attached thereto; providing a mould having a mould cavity, said mould cavity having first and second cavity portions separated by a third cavity portion, said third cavity portion defining the spine portion and said first and second cavity portions defining said first and second leaf portions; placing said flexible layer in the mould cavity against a face thereof; closing the mould; and injecting plastics material into the first and second cavity portions between the flexible layers.

42. A method as claimed in claim 41 wherein the step of placing the flexible layer in the mould cavity comprises positioning the layer such that the layer extends across all three cavity portions.

43. A method as claimed in claim 41 wherein first and second flexible layers of material are provided, one of said layers having an electronic device attached thereto, and wherein the layers are placed in the mould cavity against opposing faces thereof prior to the injection of plastics material therebetween.

44. A method as claimed in claim 43 wherein the step of placing the flexible layers in the mould cavity comprises positioning the layers such that each layer extends across all three cavity portions.

45. A method as claimed in claim 41 wherein first, second and third flexible layers of material are provided, one of said layers having an electronic device attached thereto, wherein further the step of placing the layers in the mould cavity comprises the steps of placing one of the layers against a face of the mould cavity such that said layer extends across all three cavity portions, and placing the other of the flexible layers against an opposing face of the mould cavity prior to the injection of plastics material therebetween.

46. A method as claimed in claim 41 wherein first, second, third and fourth flexible layers of material are provided, one of said layers having an electronic device attached thereto, wherein further the step of placing the layers in the mould cavity comprises the steps of placing two of the layers against a face of the mould cavity, and placing the other of the flexible layers against an opposing face of the mould cavity prior to the injection of plastics material therebetween.

47. A method as claimed in claim 46 wherein said layers are positioned against opposing faces of the first and second cavity portions of the mould cavity.