Patent ID: 8926779
Filing Date: 2015-01-06
Classification: B32B,B42D,Y10T

Abstract:
1. A method for making a hard laminate sheet with a flexible hinge extending there from for binding the laminate sheet into a security document, the method comprising the steps: (a) overlaying layers of a hard synthetic material with a flexible material layer there between, whereby a hinge portion of the flexible material layer is located in a hinge side of the overlaid layers and an affixing portion of the flexible material layer is located in a hard synthetic material side of the overlaid layers, the affixing portion configured to affix to the hard synthetic material layers upon lamination of the overlaid layers and the hinge portion configured to be separable from the hard synthetic material layers upon lamination of the overlaid layers; (b) laminating the overlaid layers, thereby forming a laminate sheet having an embedded hinge on a hinge side of the laminate sheet which is affixed to the hard synthetic material side of the laminate sheet; (c) making score cuttings along a score line coinciding with an inner hinge edge on top and bottom surfaces of the hinge side of the laminated sheet having an embedded hinge; (d) flexing the hinge side of the laminate sheet having an embedded hinge until the hard synthetic material layers break along the inner hinge edge, whereby the hard synthetic material layers on the hinge side form residual laminate layers which are separable from the hinge portion; and, (e) separating the residual laminate layers from the hinge side to expose the hinge portion of the flexible material, thereby forming the hard laminate sheet with a flexible hinge extending there from.