The present invention relates to a moulded body which may be inserted into a leaved article such as a book. More particularly, though not exclusively, the present invention relates to a moulded body which may be inserted into and permenantly retained in a personal identity document or travel document such a passport.

A passport is typically provided in the form of a book having front and rear covers and a plurality of pages there between. 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 the present invention there is provided a moulded body incorporating an electronic device which is insertable into a leaved article, the moulded body comprising a body portion and a flexible attachment portion along an edge of said body portion, the body portion comprising a planar injection moulded core of plastics material having an outer layer of material integrated on at least one side thereof, wherein said outer layer of material includes an electronic device.

The attachment portion may be formed by a portion of said outer layer of material extending beyond an edge of said core. The outer layer may extend fully over the core or alternatively, may extend over the core only in the region of the body portion adjacent to the attachment portion. The outer layer may be of a uniform construction, for example having a substantially common thickness throughout. In an alternative embodiment the outer layer may be of non-uniform construction, for example the portion of the outer layer forming the attachment portion may have a greater flexibility than the portion of the outer layer overlying the core. In an alternative embodiment the

attachment portion may be formed by a portion of the core extending beyond the outer layer of material. In yet a further embodiment the attachment portion may be formed by the combination of a portion of the outer layer and a portion of the core. The attachment portion may be provided with one or more apertures extending therethrough to increase the flexibility thereof. The attachment portion may be provided with an extension which may be folded back upon itself and secured to the attachment portion. The folding of the extension in this manner may be used to cover fixing means, such as staples or stitches, used to attach the moulded body to a leaved article such as a book. The extension may extend across the full extent of the attachment portion. Alternatively there may be provided a plurality of spaced extensions. The length of the or each extension may be such that when folded in the manner described above the or each extension overlies both the attachment portion ant at least a portion of the body portion.

The attachment portion is preferably thinner than the body portion. The electronic device is preferably an electronic data storage device. The electronic data storage device is preferably positioned on an inner surface of said outer layer, which is to say the surface of the outer layer which faces and is attached to the core, such that the device is positioned intermediate the core and outer layer. The outer layer is preferably integrated to the core without the use of adhesive. For example the outer layer may be integrated with the core during a moulding operation.

The moulded body 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 insert. 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 moulded body during moulding thereof.

The outer layer may further be provided with an antenna means in communication with the electronic data storage device. 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 outer layer 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 body by separation of the outer layer from the core. The anti-tamper arrangement may be provided by differing the attachment strength of portions of the outer layer to the core. In such an embodiment the differing attachment strengths may be such that during attempted delamination, portions of the outer 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 outer layer. For example, a low adhesion coating may be applied to the portions of the outer layer which are intended to be removed from the core.

The outer layer may further be adapted to delaminate from the core in a predetermined manner. The outer layer may be provided with lines of weakness to promote tearing of the outer layer in the event of delamination. The lines of weakness may comprise, for example, areas of reduced thickness of the outer 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 outer layer is provided with an antenna, the outer layer may be configured to tear or otherwise break the antenna during delamination.

The material forming the 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 the moulded body. 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 body 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.

The planar core may be provided with an outer layer on each side thereof. In such an embodiment the attachment portion may be defined by portions of said outer layers of material which extend beyond an edge of said core.

A layer of the insert may be provided with an viewing aperture which exposes a portion of the core. Where the material of the core is transparent, the aperture may permit the other of the layers, where present, 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, where present, 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.

According to another aspect of the present invention there is provided a method of manufacturing a moulded body incorporating an electronic device which is insertable into a leaved article, the moulded body having a body portion and a flexible attachment portion along an edge of said body 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, said first cavity portion defining the body portion of the moulded body and the second cavity portion defining the flexible attachment portion of the moulded body; placing the flexible layer in the mould cavity against a face thereof; closing the mould; and injecting plastics material into the mould cavity to form the moulded body.

The flexible attachment portion of the moulded body may be defined by a portion of the flexible layer, a portion of the injected plastics material, or a combination of the two.

Two flexible layers may be provided. In such an embodiment the layers are placed on opposing sides of the mould cavity and the plastics material is injected between the layers. In such an embodiment the plastics material may be injected through one of the layers. Where two layers are provided, the flexible attachment portion may by defined by one or both of the flexible layers, a portion of the injected plastics material comprising the core, or a portion of the injected plastics material comprising the core and one or both of the flexible layers.

According to a further aspect of the present invention there is provided a multi leaved article such as a book into which there is incorporated a moulded body having an electronic device, the moulded body comprising a body portion and a flexible attachment portion along an edge of said body portion, the body portion comprising a planar core of plastics material having outer layers of material integrated on opposing sides thereof, wherein one of said outer layers of material includes an electronic device and wherein further said outer layers of material are formed from a single piece of material which extends between opposing sides of the core around an edge thereof, said attachment portion being formed in a portion of said single piece of material which extends around an edge of the core.

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

Figure 1 shows a partial cross-sectional view of a moulded body or insert according to the present invention;

Figure 2 shows a plan view of the insert of figure 1; Figures 3 to 6 show partial cross-sectional views of inserts according to the present invention;

Figure 7 shows a plan view of a outer layer including an antenna;

Figures 8 and 9 show partial cross-sectional views of an insert including the outer layer of figure 7; Figure 10 shows a partial cross-sectional view of an insert incorporating a viewing aperture;

Figure 11 shows a partial cross-sectional view of an alternative embodiment of an insert incorporating a viewing aperture;

Figure 12 shows a partial cross-sectional view of a textured insert incorporating a viewing aperture;

Figure 13 shows a plan view of a further embodiment of an insert according to the present invention; and

Figure 14 shows a cross-sectional view of an insert according to an aspect of the present invention.

Referring firstly to figures 1 and 2 there is shown a partial cross-sectional view of an insert for a document generally designated 10. The insert 10 comprises a moulded body having a body portion 12 and an attachment portion 14. The body portion 12 comprises a core 16 sandwiched between opposed flexible layers of material 18,20. The layers 18,20 are attached to respective sides 22,24 of the core 16. The attachment portion 14 is formed by portions of the flexible layers 18,20 which extend beyond and join along an edge of the core 16. The attachment portion 14 allows the insert 10 to be attached to an identity document, such as a passport, by stitching and/or gluing. The insert 10 includes an electronic device 26 which is positioned on an inner surface of one of the layers 18 such that it is positioned between the layer 18 and the core 16. The insert 10 is formed by a moulding operation whereupon the layers 18,20 are inserted into a mould and held in a spaced apart relationship to one another. A molten plastic material is

subsequently injected between the layers 18,20 to form the core 16. The layers 18, 20 are integrated with the core 16 as a result of the injection moulding procedure.

The core 16 comprises a plastics material such as polypropylene, while the flexible layers 18,20 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 1, the electronic device 26 which is provided between the core 16 and one of the flexible layers 18. The electronic device 26 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 26 the flexible layer 18 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 18 as will be described in greater detail below. As the device 26 is provided between the layer 18 and the core 16, it will be appreciated that it is to all intents and purposes concealed internally within the insert 10. Accordingly its existence and position is not readily identifiable and hence the likelihood of it being disturbed is reduced. In an alternative embodiment the device 26 may be provided on the outer surface of the layer 18 or, alternatively may be visible through an aperture of the layer 18

Advantageously the layers 18,20 may be pre-printed with information and/or images. Taking the example of providing an insert 10 for a passport, the layers 18,20 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 layers 18,20 may also be printable with additional information after their attachment to the core 16.

The mould within which the insert 10 is made may advantageously be textured so that it imparts a corresponding texture to the insert 10 during the manufacture thereof. The texture may serve as indication of authenticity of the passport.

Figure 3 shows an alternative embodiment of an insert, generally designated 52, where features common to the embodiment of figure 1 are identified with like reference numerals. The insert 28 of figure 3 is provided with an attachment portion 14 formed by only one of the layers 18. Figure 4 shows yet a further embodiment of an insert, generally designated 30, where again features common to the embodiments of figures 1 and 2 are identified with like reference numerals. As with the embodiment of figure 2, the attachment portion 14 is comprised of only one of the layers 18 extending beyond the core 16. The layer 18 comprises a first portion 32 which forms the attachment portion 14 of the insert 30, and a second portion 34 which is attached to the core 18 to form the body portion 12. This two part construction for the layer 18 is advantageous where different characteristics of the layer 18 are required. For example, the body portion 12 may be required to be transparent, thereby necessitating that the core 16 and layers 18,20 are formed form a transparent material. The transparent layer material may, however, not have the required characteristics for the attachment portion 14. The layer 18 may therefore be formed by connecting two materials having the required material characteristics to one another. It will be appreciated that the connection of the materials is achieved prior to the layer 18 being attached to the core 16.

Figure 5 shows an alternative embodiment of an insert generally designated 36. Features common to the previously described inserts are identified with like reference numerals. The attachment portion 14 is formed by a portion of the core 16 which extends beyond the layers 18,20. The extended portion of the core 16 is significantly thinner than the body portion 12 of the insert 36. Figure 6 shows a further embodiment of an insert generally designated 38. The insert 38 is similar to the embodiment shown and described with reference to figure 3. The attachment portion 14 of the insert 38 is provided with an extension 40 which may be folded back upon itself in the manner shown and fixed to the attachment portion 14 by, for example, adhesive or where the material of the layer 18 is suitable, by a plastics welding operation. The folding of the extension 40 in this manner may be employed after the insert 38 has been inserted into a leaved article such as a book to enclose fixing means, such as stitching or staples, utilised to attach the insert 38. The extension 40 may extend fully over the attachment portion 14 and over an edge of the body portion 12 as indicated by broken lines 39. In

such an embodiment the body portion 12 mat be provided with a step or recess within which the extension 40 may be received in order that it lies flush with the layer 20 of the body portion 12.

The various examples of inserts described with reference to figures 1 to 6 comprise a core 16 having flexible layers 18,20 incorporated on opposing sides thereof. It will be appreciated that an insert according to the present invention may equally be formed from a core having a flexible layer on one side thereof. In such an embodiment the attachment portion many be formed by a portion of the layer, core or a combination of the two.

Figure 7 shows a plan view a flexible layer 18 is provided with an electronic device 26 and an antenna 42 in electrical connection with the device 26. In the embodiment shown the antenna 42 is formed by a layer of electrically conductive ink applied to the layer 18. The layer 18 is additionally provided with lines of weakness 44 which are positioned adjacent edges of the antenna 42. The lines of weakness 44 form part of an anti-tamper arrangement which is described in greater detail below. The lines of weakness 44 may, for example, comprise perforations through the layer 18 or areas of reduced thickness. In the case of perforations, these are advantageously provided in the layer 18 after the application of the antenna 42 so as to prevent bleed through of the conductive ink forming the antenna 42.

Figure 8 shows a cross-sectional view of a portion of an insert 46 including the layer 18 described above. Features common to the previously described inserts are identified with like reference numerals. As before, the insert 46 comprises a core 16 which is sandwiched between respective layers 18,20. The layer 18 bearing the device 26 is positioned such that the device 26 and antenna 42 faces the core 16 with the result that there is no outward bulging of the layer 18 which might betray the presence of the device 26 and antenna 42. In the region of the layer 18 around of the lines of weakness 44 there is provided a coating 48 which reduces the adhesion of the material of the core 16 to the layer 18. The coating 48 may comprise a layer of varnish or lacquer.

In the event that a person wishes to tamper with the insert 46, for example by separating the layer 18 from the core 16 with a view to possibly swapping one or the other with another insert, then the lines of weakness 44 and coating 48 cooperate to disable the antenna 42. Figure 9 shows the result of attempting to separate the layer 18 from the core 16 of the insert 46 shown in figure 8. In peeling the layer 18 from the core 16 the portion of the layer 18 provided with the low adhesion coating 48 separates relatively easily from the core 16 while the non-coated portions of the layer 18 remain tenaciously attached. The presence of the lines of weakness 44 result in tearing of the layer 18 with the result that some portions of the layer 18 and antenna 42 are removed from the core 16, while the remainder of the layer 18 and antenna 42 remain attached to the core 16. The antenna 42 is therefore disabled and wireless communication with the electronic device 26 is no longer possible.

Referring now to figure 10 there is shown a cross-sectional view of a portion of an insert generally designated 70. As before, the insert 70 comprises a core 16 sandwiched between respective layers 18,20. One of the layers 20 is provided with an aperture 72 with the result that the material forming the core 16 can be seen through the aperture 72. It will be appreciated that should the material of the core 16 be transparent, then the inner surface 22 of the other of the layers 18 may be viewed through the aperture 72. The inner surface 22 may therefore be printed with information intended to be viewed through the aperture 72. The portion 74 of the core 18 which faces and is surrounded by the aperture 72 may be provided with a textured, contoured or otherwise modified surface 76 which may serve to enhance information printed on the inner surface 22. For example the surface 76 may be formed so as to magnify the information. Alternatively the surface 76 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 16. The particular configuration of the surface 76 may advantageously be formed during moulding by the provision of an appropriately configured portion of the mould.

Figure 11 shows a cross-sectional view of an insert, generally designated 78, which is similar to the insert 70 described with reference to figure 10. As before one of the layers 24 is provided with an aperture 72 within which a surface 76 of the core 16

projects through. In contrast to the embodiment of figure 10 the other of the layers 28 is provided with an additional aperture 80 aligned with the first aperture 72. The aperture 80 is provided so as to allow an information bearing sheet or sticker 82 to be attached to the insert 78. The sheet or sticker 82 may, for example, carry personal information relating to the bearer of the document to which the insert 78 is attached. The provision of the aperture 80, and the subsequent attachment of a sticker or sheet 82, may be utilised to increase the security surrounding the manufacture of documents such as passports. Inserts may be manufactured with the apertures 72,80 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 82.

Fig 12 shows a cross-sectional view of a portion of an insert generally designated 84, which is similar to those described with reference to figures 10 and 11 and common features are identified with like reference numerals. As before, the insert 84 comprises a core 16 sandwiched between respective layers 18, 20. An aperture 72 is provided in one of the layers 20 which may serve as a viewing aperture. The insert 84 is textured and, in the embodiment shown, a rippled surface is provided on either side of the insert 84. The depth of the ripples, i.e. the distance between the peaks and troughs is greater than the thickness of the respective layers 18, 20. In the event that a person tries to remove information provided in one or other of the layers 18, 20, for example by using an abrasive means, then the material of the core 16 will become exposed before the information has been fully removed. This can therefore provide an outward indication of tampering with the insert 84. Where one or other of the layers 18,20 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 12 also shows a portion of a mould 86 which is configured to provide the modified surface 76 of the core 16 of the insert 84 exposed through the aperture 72. The mould portion 86 is provided with a wall 88 which surrounds a mould surface 90 configured to impart the required contour or texture to the core surface 76. The wall 88 serves to both locate the layer 20 relative to the mould as a whole prior to injection of

the core material by fitting with a pre-formed aperture 72 of the layer 20, and to prevent the bleeding of the core material to the outer side of the layer 20 during injection. Alternatively the mould portion 86 may comprise a solid projection, indicated by broken line 92, with the face of the projection 92 being configured to impart the required contour or texture to the core surface 76.

Figure 13 shows a plan view of a further insert according to the present invention and generally designated 50. In common with the previously described examples the insert 50 includes a body portion 12 and an attachment portion 14. The attachment portion 14 is provided with a plurality of spaced apertures 52 along its length which increase the flexibility of the attachment portion 14. Where the attachment portion 14 is formed by one or more outer layers of the insert 50 the apertures 52 may be pre-cut into the or each layer prior to their integration to the core 16 or, alternatively may be made after moulding of the insert 50 by a subsequent cutting or stamping operation. Where the attachment portion 14 is formed by an extension of the core material the apertures 52 may be formed during moulding of the insert 50 by using an appropriately configured mould or, alternatively may be made after moulding of the insert 50 by a subsequent cutting or stamping operation.

Figure 14 shows an alternative configuration for an insert generally designated 54. The insert 54 comprises a body portion 12 and an attachment portion 14. The body portion 12 comprises a core 16 sandwiched between opposed outer flexible layers of material 18,20. An electronic device 26 is provided between one of the layers 18 and the core 16. The flexible layers 18,20 are formed from a single sheet of flexible material 56 which is looped around an edge 66 of the core 16 to form the attachment portion 14. The insert 54 is shown connected to a booklet 58 comprising a plurality of pages 60 by the provision of stitching 62. The single sheet of flexible material 56 with the electronic device 26 pre-attached is initially stitched into the booklet 58 so as to form the centre pages thereof. The portions of the sheet 56 which are intended to be integrated with the core 16 to form the layers 18,20 are inserted into an appropriately shaped mould and a plastics material injected therein to define the core 16. It will be appreciated that by forming the insert 54 in this manner from a sheet 16 stitched into a

booklet 58, then a portion of the stitching 62 is enclosed within the attachment portion in a space 64 defined between an edge 66 of the core 16 and portion 68 of the single sheet which extends between each outer layer 18,20.