GB2543053A

GB2543053A - A security document

Info

Publication number: GB2543053A
Application number: GB1517558.1A
Authority: GB
Inventors: Charles Sugdon Matthew; George Prachar Michael
Original assignee: De la Rue International Ltd
Current assignee: De la Rue International Ltd
Priority date: 2015-10-05
Filing date: 2015-10-05
Publication date: 2017-04-12
Anticipated expiration: 2035-10-05
Also published as: GB201517558D0; EP3359390A1; GB2543053B; WO2017060684A1

Abstract

A security document 10 comprising a security sheet 11 formed from a plastic substrate (20, figure 3) and an adjacent page 16 of fibrous substrate 15, which are connected by a hinge 14. The security sheet is for displaying personal data. The adjacent page comprises a first security device 75 having at least one exposed region 18 at the surface 19. The security sheet comprises a second security device 76, which is located at least partially in at least one window 27 of the plastic substrate, and it may be a filter or lens. The first and second security element may also be a thread; the thread may have a fusing and a tactile layer for soft touch. When the security sheet and adjacent page are arranged to overlie one another the first and second security devices are visible in the at least one window when the security sheet is viewed in reflected light. The present invention is further directed to a plurality of such security documents and a method of manufacturing the security document. The method comprising embedding the security elements into a plurality of layers by applying heat and pressure (figure 8).

Description

A SECURITY DOCUMENT

The present invention is directed towards a security document comprising a security sheet formed from a plastic substrate and an adjacent page of fibrous substrate. The present invention is further directed to a plurality of such security documents and a method of manufacturing the security document. The present invention is yet further directed to a security thread, a security sheet comprising the security thread and a method of manufacturing the security sheet.

Security documents and booklets, such as passports, passbooks, identification documents, certificates, licences, cheque books and the like, commonly comprise one or more security pages on which information is provided. A passport booklet typically comprises a cover and a plurality of internal visa pages therebetween. Typically the visa pages are made from paper having a grammage of around 85 gsm and are sewn together along a stitch line. The cover is adhered to the outside of the visa pages and thereby protects the stitch line.

At least one security sheet or data page is provided in the booklet and is usually the second or the penultimate page, typically located between one of the visa pages and the cover. The security sheet usually contains personal data and is generally overlaid by a layer of polymer laminate, usually applied as a film or lacquer. This layer helps protect the data and prevent counterfeiting and fraudulent alteration. The security sheet may be formed from a fibrous substrate and may comprise security features, such as watermarks, laser perforations, security fibres, security threads, security print and the like.

Alternatively, the security sheet may be formed from a sheet comprising a plastic, which is typically polycarbonate. Plastic sheets are more durable than fibrous substrate security sheets and are resistant to delamination by a counterfeiter. During manufacture a number of thin plastic layers are laid over one another and fused together, thereby forming a thicker plastic sheet. The most common method of fusing the thinner plastic layers together involves placing them in between a “sandwich” of steel or brass laminating plates. A number of such sandwiches are stacked on top of each other and heat is applied to the top and bottom of the stack. The heat is transferred through the thinner plastic layers and laminating plates such that the thinner plastic layers fuse together, thereby forming a plastic sheet within each sandwich. A low temperature is then applied to the top and bottom of the stack to cool and harden the plastic sheets. However, such a method is relatively time inefficient as each heating and cooling cycle lasts for around thirty minutes. Furthermore, it can lead to uneven fusing and quality of the plastic sheets due to varying temperature and pressure distribution throughout the stack. This is caused by the laminating plates closer to the top and bottom of the stack usually being hotter (during heating) or colder (during cooling) than those in the middle of the stack.

An alternative, semi-continuous, method of manufacturing plastic security sheets for security documents is disclosed in US-B-6669813. The thin plastic layers are brought together before being incrementally conveyed between two opposing continuous belts through a series of heating and cooling devices. A section of the thin plastic layers is initially kept stationary by the continuous belts and the layers are heated and pressed together under pressure by the heating devices such that they fuse into a plastic sheet. After a certain amount of time, typically less than a minute, the continuous belts move the section to between the cooling devices where it is cooled and pressure is again applied, typically for less than a minute. The resulting plastic sheets are substantially uniform in quality. A plastic security sheet may comprise various security features, such as UV responsive arrangements, optically variable features, windowed or transparent features, laser-perforations, laser markings and tactile features. EP-B-2611622 discloses the introduction of a security thread in between the plastic layers before they are laminated together. US-A-2014/0138444 discloses a data carrier card in which a security thread is coextruded in the form of a thread strip in one of the plastic layers before they are laminated together.

An object of the present invention is to provide a security document having at least one security thread with improved security features. A further object is to provide an improved method of manufacture such a security document.

The present invention therefore provides a security document comprising a security sheet for displaying personal data attached to an adjacent page along a hinge, wherein: the adjacent page comprises a fibrous substrate and a first security device, said first security device comprising at least one exposed region at a surface of the substrate; the security sheet comprises a plastic substrate and a second security device, said second security device being located at least partially in at least one window of the plastic substrate; and when the security sheet and adjacent page are arranged to overlie one another the first and second security devices are visible in the at least one window when the security sheet is viewed in reflected light.

The first security device preferably comprises at least a first pattern visible in the at least one exposed region and the second security device comprises a second pattern, the first and second patterns being visible in the at least one window when the security sheet and adjacent page overlie one another and the security sheet is viewed in reflected light. In an embodiment the first and second patterns are substantially identical. In an alternative embodiment, the first and second patterns combine to form a third pattern visible when the security sheet and adjacent page overlie one another in the at least one window when the security sheet is viewed in reflected light, the third pattern being different to the first and second patterns.

In one embodiment, the second security device overlies the first security device when the security sheet and adjacent page overlie one another, the second security device being at least partially transparent such that the at least one exposed region of the first security device is visible through the second security device. The second security device is preferably arranged to adjust the visible image of the first security device when viewed through the at least one window. As such, the second security device preferably comprises a filter or a lens.

In a further embodiment, the first and second security devices are located in the security sheet and adjacent page such that when the security sheet and adjacent page overlie one another the first and second security devices are visible adjacent to one another in the at least one window.

Preferably the security document further comprises a plurality of visa pages such that it forms a passport.

In a preferred embodiment the first and second security devices comprise first and second security threads respectively. The first and second security threads are preferably the same. The first security device alternatively comprises at least one of printed ink, security fibres, holograms, foils, hot foils, laser perforations, microtext, fine line patterns, latent images, Venetian blind devices, lenticular devices, moire interference devices and moire magnification devices. The second security device alternatively comprises at least one of printed ink, laser markings holograms, foils, hot foils, UV responsive features, optically variable features, windowed or transparent features, antenna, electronic chips, laser perforations, microtext, fine line patterns, latent images, Venetian blind devices, lenticular devices, moire interference devices and moire magnification devices. Alternatively, the second security device may comprise a printed ink located within the plastic substrate in the form of a substantially opaque stripe extending between edges of the security sheet.

The present invention further provides a plurality of the aforementioned security documents wherein the first and second security devices have the same registration to one another other in each security document.

The present invention yet further provides a method of manufacturing a security document comprising a security sheet attached to an adjacent page along a hinge, said method comprising the steps of: forming the adjacent page from a fibrous substrate with a first security device at least partially embedded therein to form at least one exposed region; forming the security sheet in a process comprising: feeding a plurality of plastic layers into a laminator, the plurality of plastic layers forming at least one window; applying heat and pressure to the plurality of plastic layers in the laminator to form a plastic substrate; and incorporating a second security device at least partially in the at least one window during the feeding and/or applying steps; and attaching the security sheet and adjacent page to one another along the hinge, wherein when they are arranged to overlie one another the first and second security devices are visible in the at least one window when the security sheet is viewed in reflected light.

Preferably the first security device comprises a first security thread and the adjacent page is formed by a process comprising: depositing fibres on to a support surface to form a layer of the fibrous substrate; contacting the first security thread with raised regions and/or drainage restriction regions of the support surface to partially embed the first security thread in the fibrous substrate and form the at least one exposed region; couching the fibrous substrate layer and first security thread from the support surface; and drying the layer of fibrous substrate. Preferably the plurality of plastic layers comprises a substantially transparent insert for forming the window. The insert preferably comprises the second security device. The second security device is preferably incorporated into, or located between, one or more of the plurality of plastic layers. Alternatively, the second security device may be applied to at least one outer surface of the plastic substrate.

The present invention yet further provides a security thread for fusing to an outer surface of a plastic substrate of a security sheet, the security thread comprising a fusing layer for fusing with the outer surface of the plastic substrate and a tactile layer attached to the fusing layer, wherein the tactile layer comprises a soft touch material. The tactile layer and/or fusing layer preferably comprises a thermoplastic polymer. The soft-touch material preferably has a Shore hardness in the range of from approximately 30A to approximately 95A on the Shore A scale and up to approximately 65 on the Shore D scale.

The present invention yet further provides a security sheet for displaying personal data comprising: a plastic substrate having first and second outer surfaces; and the aforementioned security thread embedded at least partially in the first or second outer surface such that the tactile layer comprises at least one exposed region, the tactile layer having a different tactility to a surrounding region of the first outer surface. Preferably the tactile layer has a substantially continuous surface texture which is softer than the surface texture of the surrounding region. The at least one exposed region preferably comprises at least one raised element, the at least one raised element extending above the first outer surface such that the at least one raised element has a different tactility to the surrounding region. Preferably the security thread at the at least one exposed region is substantially transparent and print is located on an opposing side of the security thread to the at least one exposed region, the print being visible through the security thread when the first outer surface is viewed in reflected light.

The present invention yet further provides a method of manufacturing such a security sheet, the method comprising: feeding a plurality of plastic layers and the security thread into a laminator; and applying heat and pressure to the plurality of plastic layers in the laminator to form the plastic substrate with the security thread located on the first outer surface.

By way of example only, embodiments of a security document, a security sheet, methods of manufacture and a security thread in accordance with the present invention are now described with reference to, and as shown in, the accompanying drawings, in which:

Figure 1 is a perspective view of a passport according to the present invention in an open configuration;

Figure 2 is a plan view of the passport of Figure 1 opened between a security sheet and an adjacent page;

Figure 3 is a cross-sectional side elevation of the security sheet of Figure 2 through section A-A;

Figure 4 is a plan view of the passport of Figure 2 opened between the security sheet and a cover;

Figure 5 is a plan view of an embodiment of first and second security threads of the security document according to the present invention;

Figure 6 is a plan view of a further embodiment of first and second security threads of the security document according to the present invention;

Figure 7 is a plan view of yet a further embodiment of first and second security threads of the security document according to the present invention;

Figure 8 is a cross-sectional side elevation of an apparatus for use in a method of manufacturing the security sheet of the passport of Figure 1;

Figure 9 is a cross-sectional side elevation of a plurality of plastic layers prior to being laminated into a plastic substrate by the apparatus of Figure 8;

Figure 10 is a cross-sectional side elevation of a section of a paper-making machine for use in a method of manufacturing an adjacent page of the security document of the present invention;

Figure 11 is a detailed cross-sectional side elevation of a cylinder mould cover section of the paper-making machine of Figure 10;

Figure 12 is a detailed cross-sectional side elevation of a cylinder mould cover section of the paper-making machine of Figure 10 in use;

Figure 13 is a plan view of a further embodiment of a passport opened between a security sheet and an adjacent page;

Figure 14 is a cross-sectional side elevation of the security sheet of Figure 13 through section B-B;

Figure 15 is a plan view of yet a further embodiment of a passport opened between a security sheet and an adjacent page; and

Figure 16 is a cross-sectional side elevation of the security sheet of Figure 15 through section C-C.

Figures 1 to 4 illustrate a security document 10, in this case a passport, comprising a security sheet 11, in this case a data page, a plurality of visa pages 12 and a cover 13 attached along a hinge 14. The hinge 14 may comprises stitches or the like. The plurality of visa pages 12 are typically made from a fibrous substrate 15, such as paper, and may include a number of security features, such as security fibres and watermarks. The plurality of visa pages 12 includes an adjacent page 16 which is adjacent to the security sheet 11.

The adjacent page 16 comprises a first security device 75, in this case a first security thread 17, incorporated in or applied to the fibrous substrate 15 and having at least one exposed region 18 at a surface 19, which opposes the security sheet 11. In the illustrated embodiment the first security thread 17 is partially embedded, so that parts thereof are covered by a plurality of bridges 28 in the fibrous substrate 15, for example as disclosed in WO-OO/39391, EP-A-0059056 and WO-A-2004/001130. The first security thread 17 may, alternatively, be continuously exposed at one surface, so the exposed region 18 extends across the entire adjacent page 16. In this embodiment the first security thread 17 may be attached to the fibrous substrate 15 by an adhesive.

The first security device 75 comprises a security feature suitable for incorporation into the fibrous substrate 15 and which is at least partially exposed on the surface 19 of the adjacent page 16. For example, the first security device 75 may comprise at least one of printed ink, security fibres, patches, holograms, foils, hot foils, laser perforations, microtext, fine line patterns, latent images, Venetian blind devices, lenticular devices, moire interference devices and moire magnification devices. Typically the first security device 75 is in the form of an elongate thread, stripe or patch of a defined area comprising a carrier substrate with one or more of these security features on it.

The security sheet 11 comprises a plastic substrate 20 having a first outer surface 21 and a second outer surface 22. Each of the first and second outer surfaces 21,22 is preferably substantially flat and planar. The plastic substrate 20 is formed from a plurality of layers which are fused together into a substantially non-laminar or unitary structure. The plastic from which the plastic substrate 20 is formed may be a thermoplastic polymer such as polycarbonate, polyester, polyethylene, polypropylene or polyvinyl chloride. Polycarbonate is particularly suitable due to its high durability, its ease of manufacture and the ease with which security features can be incorporated within it.

The security sheet 11 may be substantially rigid or at least semi-rigid, particularly by virtue of the thickness of the plastic substrate 20. The thickness of the plastic substrate 20, which is the distance between the first and second outer surfaces 21,22, is preferably at least approximately 150 pm and more preferably at least approximately 300 pm. In particular, the plastic substrate 20 may be between approximately 300 pm and 1000 pm thick and, for example, may be approximately 800 pm thick.

The plastic substrate 20 preferably comprises a substantially opaque region 23 within its thickness and separated from the first and second outer surfaces 21,22 by first and second substantially transparent regions 24, 25. The opaque region 23 at least partially borders at least one third substantially transparent region 26. The first, second and third transparent regions 24, 25, 26 form at least one window 27 through the plastic substrate 20. In the illustrated embodiment a single, square window 27 extends through the thickness of the plastic substrate 20. The at least one window 27 may, alternatively, be of another shape, such as a pattern, indicia, symbol, logo or the like. The at least one window 27 is substantially transparent such that light can pass through it and objects can be seen through it. The at least one window 27 may be clear, coloured or the like. A series of laser markings 60 may be located within the plastic substrate 20 in the first transparent region 24 between the opaque region 23 and the first outer surface 21.

The laser markings 60 may provide personal data of the holder of the security document 10. Such personal data is known as “variable data” or “biographical data” and is provided in the security sheet 11 to identify the specific holder of the security document 10. The Seventh Edition (2015) of Document 9303 (“Machine Readable Travel Documents”) issued by the International Civil Aviation Organization (ICAO) describes such biographical data and its contents are incorporated herein by reference. Typically, no two security documents 10 issued by an issuing authority contain the same variable data. The personal data may include, for example, the holder’s portrait 61, text 62 providing the holder’s name, nationality and date of birth and a machine readable zone 63 containing data for machine reading. The personal data may be applied to the plastic substrate 20 by any suitable method, such as printing, as an alternative to, or in addition to, the series of laser markings 60.

The laser markings 60 are preferably visible when the first outer surface 21 is viewed in reflected light incident upon the first outer surface 21 by virtue of the first transparent region 24 in which they are located. The plastic substrate 20 may also comprise any other suitable security feature, such as a hologram in the form of nonvariable data, UV responsive features, optically variable features, windowed or transparent features, antenna, electronic chips and laser-perforations.

The security sheet 11 further comprises a second security device 76, in this case a second security thread 65, disposed in the plastic substrate 20 and at least partially in the at least one window 27. In the illustrated embodiment the second security thread 65 is located in the first transparent region 24 between the opaque region 23 and the first outer surface 21. As a result, the second security thread 65 is visible along its entire length across the security sheet 11 when the first outer surface 21 is viewed in reflected light. When the second outer surface 22 of the security sheet 11 is viewed in reflected light, only the portion of the second security thread 65 in the at least one window 27 is visible. The opaque region 23 blocks the rest of the second security thread 65 from view. In an alternative embodiment the second security thread 65 is located in the second transparent region 25 such that it is visible along its entire length on the second outer surface 22 and only visible in the at least one window 27 on the first outer surface 21. In yet a further embodiment the plastic substrate 20 comprises a plurality of windows 27 and the second security device 76 is located in each window 27 such that it is visible at a plurality of locations.

The second security device 76 may comprise any security feature suitable for incorporation into the plastic substrate 20 and which is visible through the at least one window 27. The second security device 76 comprises at least one of printed ink, laser markings, patches, holograms, foils, hot foils, UV responsive features, optically variable features, windowed or transparent features, antenna, electronic chips and laser perforations, microtext, fine line patterns, latent images, Venetian blind devices, lenticular devices, moire interference devices and moire magnification devices. Depending upon the particular application the security feature of the second security device 76 may or may not be applied to a carrier substrate, such as a thread, stripe or patch, prior to incorporation into the plastic substrate 20. The second security device 76 may be located at the first or second outer surface 21,22, for example by being adhered thereto, or it may be at least partially embedded within the plastic substrate 20, for example by being fused therewith.

As illustrated in Figure 4, the first outer surface 21 of the security sheet 11 and the opposing surface 19 of the adjacent page 16 may be brought together about the hinge 14. The adjacent page 16 is visible through the at least one window 27 when viewed in reflected light incident upon the second outer surface 22 of the security sheet 11. The reflected light may be visible or non-visible light. The first and second security devices 75, 76 comprise suitable security features, such as first and second security threads 17, 65, which are visible together in the at least one window 27. The at least one window 27 and at least one exposed region 18 of the first security thread 17 are located on the security sheet 11 and adjacent page 16 respectively such that the at least one exposed region 18 is visible through the at least one window 27. In the illustrated embodiment one of the exposed regions 18 extends across a width of the window 27 adjacent to the second security thread 65. As a result, the first and second security devices 75, 76 can be viewed side-by-side for comparison.

In order to reproduce such a security document 10 a counterfeiter needs to embed the first and second security devices 75, 76 in both the fibrous substrate 15 and the plastic substrate 20. As will become apparent from the following description, very different machinery may be required for the different materials, thereby increasing the costs to the counterfeiter and the level of skill required. A counterfeiter would also need to ensure that the first and second security devices 75, 76 and at least one window 27 are accurately located relative to one another such that the first and second security devices 75, 76 are visible through the at least one window 27.

The security of the security document 10 can be further improved by incorporating visible elements or the like into each of the first and second security devices 75, 76 or by forming patterns with the visible elements and/or outer shapes of the first and second security devices 75, 76. In particular, the first and second security devices 75, 76 may be registered to each other in that they are at the same predetermined relative position in a plurality of security documents 10. Therefore, a user can easily detect if the first and second security devices 75, 76 are out of register, for example due to counterfeiting.

Figures 5 to 7 illustrate exemplary embodiments in which the second outer surface 22 of the security sheet 11 is viewed in incident light when the first outer surface 21 is in contact with the adjacent page 16. The following description is focussed upon the first and second security devices 75, 76 comprising first and second security threads 17, 65, although the features are equally applicable for any other type of first and second security device 75, 76 disclosed herein, such as foils in the form of patches or stripes.

In Figure 5 the first security thread 17 comprises at least one element 66 thereupon which is identical to at least one element 67 of the second security thread 65. The authenticity of the security document 10 can therefore be easily verified by checking that the elements 66, 67 are identical when viewed through the window 27. As illustrated, the elements 66, 67 may form a shape, but in other embodiments may form other patterns, indicia, words, logos, symbols or the like.

In Figure 6 the first security thread 17 comprises at least one element 68 forming a first pattern (“United”) and the second security thread 65 comprises at least one element 69 forming a second pattern (“Kingdom”). The authenticity of the security document 10 can be verified as the first and second patterns combine to form a third pattern (“United Kingdom”) which is different to the first and second patterns when viewed in the window 27. This embodiment poses further problems for a counterfeiter as they would need to produce two different types of thread to form the security document 10.

In Figure 7 the second security thread 65 overlies the first security thread 17 (shown in dashed lines) when viewed in the window 27. In the illustrated embodiment the second security thread 65 is at least partially transparent and is wider than the first security thread 17 to ensure that it covers the first security thread 17. As a result, the second security thread 65 will still overlie the first security thread 17 if the first and second security threads 17, 65 are not located accurately in the adjacent page 16 and security sheet 11 during manufacture. The first security thread 17 comprises at least one element 70 which forms “De La Rue” in the illustrated embodiment. The second security thread 65 is arranged to adjust the visible image of the at least one element 70 when viewed through the window 27. For example, the second security thread 65 may comprise a colour filter which makes the at least one element 70 appear a different colour when viewed through the window 27 to the colour it appears when viewed directly.

In alternative embodiments the second security thread 65 may comprise a polarising filter, a lens or the like. In a particular embodiment the first and second security threads 17, 65 comprise first and second patterns respectively. The first and second patterns each comprise a series of fine lines which combine to form a Moire pattern as a third pattern when the second security thread 65 overlies the first security thread 17.

The first and second security thread 17, 65 may comprise the same material, and preferably comprise a thermoplastic polymer such as polycarbonate. Suitable materials for forming the first security thread 17 include polyethylene terephthalate (PET), oriented polypropylene (OPP), polyethylene (PE) or polyketone (PK). The first and second security threads 17, 65 are preferably between approximately 2 mm and 20 mm wide.

The security sheet 11 and adjacent page 16 are generally formed separately before being attached along the hinge 14. The security sheet 11 is generally manufactured by forming an insert 42, forming a plurality of plastic layers 32 (shown in Figure 8) including the insert 42 and second security device 76 therein and laminating the plurality of plastic layers 32 together in a laminator 33 (shown in Figure 9) to form the plastic substrate 20.

Figure 9 illustrates a suitable structure for the plurality of plastic layers 32 prior to entering the laminator 33 and after being positioned to overlie one another. The plurality of plastic layers 32 is preferably capable of forming a plurality of security sheets 11, although only a portion of the plurality of plastic layers 32 for forming a single security sheet 11 is shown. In particular, the plurality of plastic layers 32 comprises first and second opaque layers 34, 35, which are typically white and/or opaque, and an inlay 36 therebetween. Graphical information, colours and/or patterns may be printed on the outer surfaces of the first and second opaque layers 34, 35. Electronic chips and antenna or the like may be located within the inlay 36 or first and second opaque layers 34, 35.

Substantially transparent first and second overlays 37, 38 are located at the outer most sides of the plurality of plastic layers 32 and form the first and second outer surfaces 21,22 of the plastic substrate 20. First and second intermediate layers 39, 40 for holding security features are located between the first opaque layer 34 and the first overlay 37. In particular, the first intermediate layer 39 may be substantially opaque and located adjacent to the first opaque layer 34. The second intermediate layer 40 is located between the first overlay 37 and the first intermediate layer 39 and is substantially transparent. In other embodiments any suitable number of intermediate layers, on either side of the first and second opaque layers 34, 35, may be used in order to provide different security features. A strip of substantially transparent plastic may initially be cut by a punching tool to form a plurality of inserts 42 before or during the arrangement of the plurality of plastic layers 32. The shape of the perimeter of each insert 42 forms the shape of the perimeter of each window 27. Each insert 42 is located in an aperture 43 through the first and second opaque layers 34, 35, the inlay 36 and the first intermediate layer 39. The opposing outer surfaces of each insert 42 are overlaid by the second overlay 38 and second intermediate layer 40. Alternatively, each aperture 43 may be formed in, and each insert 42 located in, only one or two of the first opaque layer 34, the second opaque layer 35, the inlay 36 and/or the first intermediate layer 39.

Preferably the aperture 43 and insert 42 are formed and brought together in line, as is disclosed in WO-A-2015/104011. In particular, a single punch tool may be operated to form an aperture 43. The punch tool then cuts or punches an insert 42 from the strip and places the insert 42 into the aperture 43. The shape of the aperture 43 matches the outer shape of the insert 42 such that their edges are substantially adjacent to and substantially in contact with one another. The insert 42 is preferably friction fitted into the aperture 43, although they may be loosely fitted and held in place by adhesive or by friction in the plurality of plastic layers 32.

Each of the plurality of plastic layers 32 may be between approximately 0.05 mm thick and approximately 3 mm thick and is comprised of the plastic forming the plastic substrate 20, such as polycarbonate, although they may be formed of different plastics provided that they are able to fuse together. Each insert 42 may have a thickness of between approximately 0.1 mm and approximately 0.4 mm and may be the same plastic from which the plurality of plastic layers 32 are formed, such as polycarbonate or the like.

As illustrated in Figure 9 the second security device 76, in this case the second security thread 65, may be located between the first and second intermediate layers 39, 40. Alternatively, as discussed below, one of the first and second intermediate layers 39,40 may comprise the second security device 76 embedded in it.

Figure 8 illustrates an embodiment of an apparatus 30 suitable for manufacturing the security sheet 11 from the plurality of plastic layers 32. The apparatus 30 is similar to the devices disclosed in US-B-6669813 and US-A-2011/022408, the contents of which are incorporated herein by reference. The apparatus 30 comprises a plurality of feeders 31 for feeding the plurality of plastic layers 32 laid over one another into the laminator 33. The laminator 33 fuses the plurality of plastic layers 32 together by the application of heat and pressure to form the plastic substrate 20.

The laminator 33 comprises first and second continuous belts 45, 46 which rotate in opposite directions. The first continuous belt 45 comprises a first support surface 47 extending around first inlet and outlet drums 48, 49 and the second continuous belt 46 comprises a second support surface 50 extending around second inlet and outlet drums 51,52. The first and second support surfaces 47, 50 are substantially adjacent to one another over an elongate laminating region 53 for receiving and pressurising the plurality of plastic layers 32 therebetween. Opposing heating devices 54, 55 are located adjacent to the first and second inlet drums 48, 51 within each of the first and second continuous belts 45, 46. Opposing cooling devices 56, 57 are located between the heating devices 54, 55 and the first and second outlet drums 49, 52. The heating and cooling devices 54, 55, 56, 57 are operable to move towards and away from the first and second support surfaces 47, 50 and apply pressure to the plurality of plastic layers 32 between them.

At least one of the first and second continuous belts 45, 46 is intermittently driven to draw the plurality of plastic layers 32 into the laminator 33 through a nip 58 between the first and second inlet drums 48, 51. Initially a region of the plurality of plastic layers 32 is moved into between the heating devices 54, 55. The heating devices 54, 55 move towards the first and second support surfaces 47, 50 to heat and apply pressure to the region of plurality of plastic layers 32 to form the plastic substrate 20. After a set period of time, typically less than a minute, the heating devices 54, 55 move away from the first and second support surfaces 47, 50 and the first and/or second continuous belt 45, 46 is driven to move the region to between the cooling devices 56, 57. The cooling devices 56, 57 move towards the first and second support surfaces 47, 50 and cool and apply pressure to the plastic substrate 20 in order to maintain its structure. This heating, cooling and pressure application process is repeated along the plurality of alternating heating and cooling devices 54, 55, 56, 57 until the fully formed plastic substrate 20 exits the laminator 33.

The second security device 76 may be incorporated into the plurality of plastic layers 32 either before or during entry into the laminator 33. For example, the second security device 76 may be positioned on one of the plurality of plastic layers 32 or the insert 42. Alternatively, the second security device 76 may be fed into the plurality of plastic layers 32 at the nip 58. In particular, the second security thread 65 is introduced into the plastic substrate 20 by being fed in between two of the plurality of plastic layers 32 from a bobbin 71 via at least one roller 72. The surfaces of the second security thread 65 may be coated in an adhesive to secure it within the plastic substrate 20. The second security thread 65 may be adhered to one of the plurality of plastic layers 32 prior to entering the laminator 33, as disclosed in EP-B-2611622. Alternatively, the second security thread 65 may comprise one or more outer layers formed of a plastic (such as polycarbonate) which, during the lamination process, fuses with the plastic of one or more of the adjacent plurality of plastic layers 32. In yet a further alternative, the second security thread 65 may be coextruded with a plastic such that it is integrally formed with one of the plurality of plastic layers 32, as disclosed in US-A-2014/0138444.

During the heating process each of the plurality of plastic layers 32 and insert 42 become at least softened or semi-molten (i.e. a liquid of relatively high viscosity) so that the plastic flows and mixes together across the interfaces between them. The first overlay 37 and second intermediate layer 40 form the first transparent region 24. The first and second opaque layers 34, 35, the inlay 36 and the first intermediate layer 39 form the opaque region 23. The second overlay 38 forms the second transparent region 25. The insert 42 forms the third transparent regions 26 and window 27. The plastic substrate 20 comprises mixed material regions formed at positions that correspond to the interfaces between neighbouring layers of the plurality of plastic layers 32 and the insert 42. The mixed regions comprise varying concentrations of plastic from neighbouring layers of the plurality of plastic layers 32 and insert 42.

In order to achieve such fusing the heating devices 54, 55 may be suitably controlled to raise the temperature and pressure applied to the plurality of plastic layers 32 to reach the softening point of the plastic. A temperature at which deformation and therefore fusion is possible at a certain pressure can be ascertained using the Vicat softening point test of any of the methods of the ASTM D 1525 and ISO 306 standards.

The Vicat softening point may be the temperature at which a specimen is penetrated to a depth of 1 mm by a flat-ended needle with a 1 mm2 circular or square cross-section. In a particular example, the Vicat softening point for polycarbonate can be determined using a heating rate of 50°C/hr and a load of 50 N. In a further example for polycarbonate, the heating devices 54, 55 may apply a temperature of approximately 180 °C at approximately 8 MPa to the plurality of plastic layers 32 and the cooling devices 56, 57 may apply a temperature of approximately 20 °C to 30 °C and a pressure of 10 MPa to the plurality of plastic layers 32. In yet a further example for polycarbonate, the heating devices 54, 55 may apply a temperature of approximately 180 °C at approximately 1.6 N/mm2 to the plurality of plastic layers 32 and the cooling devices 56, 57 may apply a temperature of approximately 20 °C to 30 °C at a pressure of 3.2 N/mm2 to the plurality of plastic layers 32. This latter example is particularly appropriate where the region of the plurality of plastic layers 32 between the heating or cooling devices 54, 55, 56, 57 has a surface area of 130 mm by 190 mm.

After the plastic substrate 20 has exited the laminator 33 it may be subjected to further processing, such as the addition of further security features to the first and second outer surfaces 21,22. If located on the first or second outer surface 21,22, the second security device 76 may be applied thereto. The plastic substrate 20 is also cut into a plurality of security sheets 11.

In order to incorporate the first security device 75 in the form of the first security thread 17 into the fibrous substrate 15, the adjacent page 16 is preferably produced in a similar manner to the method disclosed in EP-A-0059056, the contents of which are incorporated herein by reference. As illustrated in Figures 10 to 12, a cylinder mould papermaking machine 80 comprises a cylinder mould 81 rotating in a vat of aqueous fibrous stock 82. The cylinder mould 81 is covered with a porous support surface, such as a porous wire mesh, which forms a cylinder mould cover 83. As the cylinder mould 81 rotates, the liquid within the fibrous stock 82 passes through the porous support surface of the cylinder mould cover 83. The fibres are deposited on the support surface and the layer of fibrous substrate 15 is thereby formed.

The cylinder mould cover 83 may comprise a plurality of raised regions 84. The raised regions 84 may be formed by, as illustrated in Figures 10 to 12 and disclosed in EP-A-0059056, embossed regions of the cylinder mould cover 83. A guide 85 directs the first security thread 17 into contact with each raised region 84 as the raised region 84 enters the fibrous stock 82 so that the first security thread 17 is lying over the raised region 84 as fibres begin to deposit on the cylinder mould cover 83. Fibres are deposited above and below the first security thread 17, but substantially none are deposited where the first security thread 17 contacts the raised regions 84, thereby forming the at least one exposed region 18. The bridges 28 are formed by the deposition of fibres between adjacent raised regions 84 on the cylinder mould cover 83.

Alternatively the at least one exposed region 18 may be formed by creating drainage restrictive regions on the cylinder mould cover 83, for example in the form of electrotypes attached to the cylinder mould cover 83. Such an arrangement is disclosed in WO-A-2005/069231, the contents of which are incorporated herein by reference. Drainage restrictive regions can also be formed by using polymer resins to fill in drainage channels in the cylinder mould cover 83.

An adhesive layer or other appropriate coating with adhesive properties may be applied to at least one side of the first security thread 17 prior to its contact with the raised regions 84. The adhesive, as discussed in WO-A-OO/39291, assists in the formation of the fibres around the first security thread 17 to form the appropriate pattern of exposed regions 18 and bridges 28 shown in Figures 1 and 2.

As the layer of fibrous substrate 15 is formed, it is couched from the cylinder mould cover 83 as a continuous web, for example by a couch roll 86. The couch roll 86 is used to transfer the layer of fibrous substrate 15 from the cylinder mould cover 83 to a felt 87 (formex) which carries the web from the wet end of the papermaking machine 80 to a press section (not shown in the drawings). Water is extracted from the wet fibrous web and the web of paper undergoes a drying process. Water jets or the like may be used to remove fibres from the exposed regions 18. The dried web is initially cut along cutting lines to form a plurality of interim sheets, which are stacked in reams of typically 500 sheets. These interim sheets are typically printed and cut into individual smaller sheets, each of which may form the adjacent page 16 and/or the visa pages 12.

Each of the plurality of security sheets 11 is bound along the hinge 14, for example by stitching, with an adjacent page 16, other visa pages 12 and cover 13 to form the passport or other security document 10. The personal data relating to the holder of the security document 10 may also be applied to each security sheet 11.

Various alternatives to those described above also fall within the scope of the present invention. The security document 10 may be of any suitable type having both the security sheet 11 and adjacent page 16, such as an identity document, particularly a booklet, or the like. Where the first security device 75 is of a different form to the first security thread 17 it may be applied and adhered to the surface 19 or it may be at least partially embedded therein in any manner known in the art.

In one embodiment the second security device 76 comprises printed ink forming an opaque stripe on the first intermediate layer 39 which extends between edges of the security sheet 11 such that it is laid out in a similar manner to the second security thread 65 as shown in Figure 2. As such, it may be difficult for a naked eye to distinguish it from a true security thread, such as the second security thread 65.

In a further embodiment, as illustrated in Figures 15 and 16, the second security device 76 may comprise printed ink located initially printed on the insert 42 and, after lamination, located within the window 27 of the plastic substrate 20. The first security device 75 may also comprise a printed ink of substantially the same colour. The first security device 75 is in the form of a first pattern, in this case a circle, and the second security device 76 is in the form of a second pattern, in this case an annulus. When the security sheet 11 and adjacent page 16 overlie one another the first and second patterns combine to form a third pattern, which will be a larger circle.

In yet a further embodiment, the first security device 75 comprises a series of patterns, indicia, symbols, logos or the like, laser perforated through the fibrous substrate 15. The second security device 76 is formed by laser marking a markable additive located in the insert 42 in the form of the same patterns, indicia, symbols, logos or the like. The similarity between the two can be checked through the at least one window 27. In a particular embodiment the first and second security devices 75, 76 form indicia in the form of a serial number of the security document 10.

The security sheet 11 may comprise further windows located at and extending along the edge of the security sheet 11. The opaque region 23 may comprise a shape or the like along its edge such that the at least one window forms a predefined shape. The further window(s) may be formed according to the method disclosed above or in WO-A-2015/104011. Alternatively, the further window(s) may be formed by providing transparent portions of the first and second opaque layers 34, 35, the inlay 36 and/or the first intermediate layer 39.

The opaque region 23, particularly around the at least one window 27, preferably forms a uniform colour when viewed in the first and second outer surface 21,22. In an embodiment the opaque region 23 is visible as a first colour at the first outer surface 21 and as a second colour at the second outer surface 22 when viewed in reflected light. For example, the second opaque layer 35 and first intermediate layer 39 may comprise different additives to form the different colours. Fluorescent additives may be selected such that the different colours are only apparent when the first and/or second outer surfaces 21, 22 are viewed in reflected UV light. The different colours may also be visible in the thickness of the security sheet 11, particularly if the additives are included in the first opaque layer 34 and the inlay 36 and/or if the first and second opaque layers 34, 35, the inlay 36 and/or the first intermediate layer 39 are sufficiently thick.

Figures 13 and 14 illustrate a further security document 90, in this case a passport, in which the second security thread 91 is located at the first outer surface 21 of the security sheet 11 and has a different tactility to a surrounding region of the first outer surface 21. Although not essential, the security document 90 may comprise substantially similar features to those described in respect of the passport illustrated in Figures 1 to 7 and 15 and 16. Therefore, the same features and reference numerals are shown in Figures 13 and 14. In addition, the security document 90 is manufactured in a substantially similar method to that described in respect of Figures 8 and 9.

In the embodiment of Figures 13 and 14 the second security thread 91 comprises a tactile layer 92 at the first outer surface 21 and a fusing layer 93 between the tactile layer 92 and the plastic substrate 20. The tactile layer 92 is preferably a continuous soft-touch material which is substantially softer than the surrounding region of the first outer surface 21. In particular, the soft-touch material may have a Shore hardness in the range of from approximately 30A to approximately 95A on the Shore A scale and up to approximately 65 on the Shore D scale. More preferably the soft-touch material may have a Shore hardness in the range of from approximately 30 to approximately 80 on the Shore A scale. The plastic substrate 20 may comprise polycarbonate, which has a typical Shore hardness of 80D on the Shore D scale. The hardness may be determined according to the test set out it ASTM D2240. Suitable materials include thermoplastic polyurethane, polyethylene, polypropylene. The surrounding region may be defined as an area of the first outer surface 21 up to approximately 1 mm, approximately 5 mm or approximately 10 mm from any part of the tactile layer 92. As a result, when a user touches the second security thread 91 it will have substantially softer, continuous texture than the surrounding region. In other embodiments the tactile layer 92 may comprise any other suitable tactile feature, such as at least one raised element which extends above the first outer surface such that the at least one raised element has a different tactility to the surrounding region.

The fusing layer 93 fuses the second security thread 91 to the plastic substrate 20 during the aforementioned lamination process. In particular, the bobbin 71 and at least one roller 72 are arranged to direct the second security thread 91 onto the first overlay 37 of the plurality of plastic layers 32. Preferably the fusing layer 93 is the same material as the plastic substrate 20, such as polycarbonate, but may be any material capable of fusing with the plastic substrate 20, such as another thermoplastic polymer. The fusing layer 93 may be adhered, fused or otherwise suitably attached to the tactile layer 92. In the laminator 33 the plastic will diffuse across the boundary of the fusing layer 93 and first overlay 37 such that they become a single structure (although this is not shown in Figure 14).

At least one printed element 94 may be deposited on the fusing layer 93 prior to lamination and in the security sheet 11 the at least one printed element 94 is located between the fusing layer 93 and the plastic substrate 20. The tactile layer 92 and fusing layer 93 are preferably transparent such that the at least one printed element 94 is visible when viewed in reflected light incident upon the security sheet 11. The illustrated at least one printed element 94 forms the repeated element “UK”, although it may form any suitable shape, pattern, indicia, symbol, logo or the like. In embodiments in which the security document 90 comprises the adjacent page 16 and the security sheet 11 comprises the at least one window 27, the at least one printed element 94 may form at least one of the elements 67, 69 discussed in respect of Figures 5 and 6.

Furthermore, in any of the examples above machine readable materials could be included in any of plurality of plastic layers 32, the insert 42, the fibrous substrate 15 or any other material. Alternatively, they could comprise further machine readable layers or materials. The machine readable materials may contain detectable materials that react to an external stimulus, which may include but are not limited to fluorescent, phosphorescent, infrared absorbing, thermochromic, photochromic, magnetic, electrochromic, conductive and piezochromic materials.

Claims

CLAIMS:

1. A security document comprising a security sheet for displaying personal data attached to an adjacent page along a hinge, wherein: the adjacent page comprises a fibrous substrate and a first security device, said first security device comprising at least one exposed region at a surface of the substrate; the security sheet comprises a plastic substrate and a second security device, said second security device being located at least partially in at least one window of the plastic substrate; and when the security sheet and adjacent page are arranged to overlie one another the first and second security devices are visible in the at least one window when the security sheet is viewed in reflected light.

2. A security document as claimed in claim 1 wherein the first security device comprises at least a first pattern visible in the at least one exposed region and the second security device comprises a second pattern, the first and second patterns being visible in the at least one window when the security sheet and adjacent page overlie one another and the security sheet is viewed in reflected light.

3. A security document as claimed in claim 2 wherein the first and second patterns are substantially identical.

4. A security document as claimed in claim 2 wherein the first and second patterns combine to form a third pattern visible when the security sheet and adjacent page overlie one another in the at least one window when the security sheet is viewed in reflected light, the third pattern being different to the first and second patterns.

5. A security document as claimed in any one of the preceding claims wherein the second security device overlies the first security device when the security sheet and adjacent page overlie one another, the second security device being at least partially transparent such that the at least one exposed region of the first security device is visible through the second security device.

6. A security document as claimed in claim 5 wherein the second security device is arranged to adjust the visible image of the first security device when viewed through the at least one window.

7. A security document as claimed in claim 6 wherein the second security device comprises a filter or a lens.

8. A security document as claimed in any one of claims 1 to 4 wherein the first and second security devices are located in the security sheet and adjacent page such that when the security sheet and adjacent page overlie one another the first and second security devices are visible adjacent to one another in the at least one window.

9. A security document as claimed in any one of the preceding claims further comprising a plurality of visa pages such that it forms a passport.

10. A security document as claimed in any one of the preceding claims wherein the first and second security devices comprise first and second security threads respectively.

11. A security document as claimed in claim 10 wherein the first and second security threads are the same.

12. A security document as claimed in any one of claims 1 to 9 wherein the first security device comprises at least one of printed ink, security fibres, holograms, foils, hot foils, laser perforations, microtext, fine line patterns, latent images, Venetian blind devices, lenticular devices, moire interference devices and moire magnification devices.

13. A security document as claimed in any one of claims 1 to 9 or 12 wherein the second security device comprises at least one of printed ink, laser markings holograms, foils, hot foils, UV responsive features, optically variable features, windowed or transparent features, antenna, electronic chips, laser perforations, microtext, fine line patterns, latent images, Venetian blind devices, lenticular devices, moire interference devices and moire magnification devices.

14. A security document as claimed in any one of claims 1 to 9 wherein the second security device comprises a printed ink located within the plastic substrate in the form of a substantially opaque stripe extending between edges of the security sheet.

15. A plurality of security documents as claimed in any one of the preceding claims wherein the first and second security devices have the same registration to one another other in each security document.

16. A method of manufacturing a security document comprising a security sheet attached to an adjacent page along a hinge, said method comprising the steps of: forming the adjacent page from a fibrous substrate with a first security device at least partially embedded therein to form at least one exposed region; forming the security sheet in a process comprising: feeding a plurality of plastic layers into a laminator, the plurality of plastic layers forming at least one window; applying heat and pressure to the plurality of plastic layers in the laminator to form a plastic substrate; and incorporating a second security device at least partially in the at least one window during the feeding and/or applying steps; and attaching the security sheet and adjacent page to one another along the hinge, wherein when they are arranged to overlie one another the first and second security devices are visible in the at least one window when the security sheet is viewed in reflected light.

17. A method as claimed in claim 16 wherein the first security device comprises a first security thread and the adjacent page is formed by a process comprising: depositing fibres on to a support surface to form a layer of the fibrous substrate; contacting the first security thread with raised regions and/or drainage restriction regions of the support surface to partially embed the first security thread in the fibrous substrate and form the at least one exposed region; couching the fibrous substrate layer and first security thread from the support surface; and drying the layer of fibrous substrate.

18. A method as claimed in claim 16 or claim 17 wherein the plurality of plastic layers comprise a substantially transparent insert for forming the window.

19. A method as claimed in claim 18 wherein the insert comprises the second security device.

20. A method as claimed in any one of claims 16 to 18 wherein the second security device is incorporated into, or located between, one or more of the plurality of plastic layers.

21. A method as claimed in any one of claims 16 to 18 wherein the second security device is applied to at least one outer surface of the plastic substrate.

22. A security thread for fusing to an outer surface of a plastic substrate of a security sheet, the security thread comprising a fusing layer for fusing with the outer surface of the plastic substrate and a tactile layer attached to the fusing layer, wherein the tactile layer comprises a soft touch material.

23. A security thread as claimed in claim 22 wherein the tactile layer and/or fusing layer comprises a thermoplastic polymer.

24. A security thread as claimed in claim 22 or claim 23 wherein the soft-touch material has a Shore hardness in the range of from approximately 30A to approximately 95A on the Shore A scale and up to approximately 65 on the Shore D scale.

25. A security sheet for displaying personal data comprising: a plastic substrate having first and second outer surfaces; and a security thread according to any one of claims 22 to 24 embedded at least partially in the first or second outer surface such that the tactile layer comprises at least one exposed region, the tactile layer having a different tactility to a surrounding region of the first outer surface.

26. A security sheet as claimed in claim 25 wherein the tactile layer has a substantially continuous surface texture which is softer than the surface texture of the surrounding region.

27. A security sheet as claimed in claim 25 or claim 26 wherein the at least one exposed region comprises at least one raised element, the at least one raised element extending above the first outer surface such that the at least one raised element has a different tactility to the surrounding region.

28. A security sheet as claimed in any one of claims 25 to 27 wherein the security thread at the at least one exposed region is substantially transparent and print is located on an opposing side of the security thread to the at least one exposed region, the print being visible through the security thread when the first outer surface is viewed in reflected light.

29. A method of manufacturing a security sheet according to any one of claims 25 to 28, the method comprising: feeding a plurality of plastic layers and the security thread into a laminator; and applying heat and pressure to the plurality of plastic layers in the laminator to form the plastic substrate with the security thread located on the first outer surface.

30. A security document as hereinbefore described and with reference to the attached drawings.

31. A security sheet as hereinbefore described and with reference to the attached drawings.

32. A method of manufacturing as hereinbefore described and with reference to the attached drawings.

33. A security thread as hereinbefore described and with reference to the attached drawings.

34. A plurality of security documents as hereinbefore described and with reference to the attached drawings.