A METHOD OF MANUFACTURING A WEB-SHAPED MONOLITHIC FOIL WITH INCORPORATED SECURITY FEATURES AND A MANUFACTURING MACHINE

Abstract

 The present invention relates to a method of manufacturing a web-shaped monolithic foil (20) with incorporated security features (22) from a web-shaped multi-layered foil (10), wherein the method comprises the steps of separating the carrier layer (16) from the liner (14), separating the cover layer (12) from the liner (14), applying at least one security feature (22) to a first surface (15) of the carrier layer (16), arranging the cover layer (12) on the first surface (15) of the carrier layer (16), and inseparably connecting the carrier layer (16) with the cover layer (12), wherein a web-shaped monolithic foil (20) with at least one incorporated security feature (22) is generated. The present invention furthermore relates to a machine (40) configured to manufacture the monolithic foil (20) with incorporated security features (22).

Description

Technical Field

[0001] The present invention relates to a method of manufacturing a web-shaped monolithic foil with incorporated security features as well as to a machine configured to manufacture the foil.

Background

[0002] In the manufacturing process of datapages for passports or other security-related documents, it is desired to provide security features not only for the datapage itself but also for the hinge, which connects the datapage to a booklet. In particular, there is a desire to embed security features within the interior of the hinge. Certain security features include three dimensional topographies, such as printing, fibers, planchettes, or other known security feature, However, these security features increase the complexity of the manufacturing process because creating a smooth hinge layer generally requires the application of overlying layers, making the process complex.

[0003] From a manufacturer's point of view, however, the manufacturing process should be flexible to a variety of applied security features, including three dimensional topographies on surfaces of layers, while large quantities of hinges should be generated at low cost.

[0004] Document WO 2016/177681 A1 relates to a data carrier suitable for inserting into a notebook- or book-shaped object, wherein the data carrier comprises a datapage and a connecting element, and the datapage and the connecting element are connected to one another in an overlap region. In the overlap region, a security feature is formed by means of laser processing, and the information components of the security feature are in part developed in the datapage and in part in the connecting element.

[0005] Document DE 10 2012 016 329 A1 relates to the production of a joint sheet, the production comprising the steps of forming a layer using a base material and coating one side of the base material with a thermoplastic plastic composition, to obtain a primary-coated film with the base material and a thermoplastic plastic layer. Furthermore, the method comprises the step of compression bonding, where a pair of the primary coated films are arranged using a pair of primary coated films and a textile sheet, such that the thermoplastic plastic layers face each other and a textile sheet is arranged between the pair of primary coated films.

[0006] Document FR 3 043 015 relates to a method of manufacturing a hinge to be placed along a binding line of a security document in the form of a booklet, the hinge being intended to be integral with an additional datapage of the document of security. This method comprises the steps of forming a first polycarbonate layer having a first window and laminating so that the first window is partially filled with polyurethane and a part of the first window being disposed along at least a portion of the binding line of said hinge.

[0007] In order to enhance the reliability and security of security documents there is a need for hinges in which a variety of different security features, including three dimensional topographies, can be incorporated. The manufacturing of such enhanced security documents and of the corresponding base material, respectively, should be flexible and at low cost.

[0008] Thus, for the present invention arises the problem to provide a flexible and efficient method of manufacturing a foil for identification with an improved reliability, a security document with an improved reliability and a machine for manufacturing the foil.

Summary of the Disclosure

[0009] The above-mentioned problem is solved by a method of manufacturing a web-shaped monolithic foil with incorporated security features from a web-shaped multi-layered foil, where-in the multi-layered foil at least comprises a carrier layer, a cover layer and a liner disposed between the carrier layer and the cover layer. The method comprises a step of separating the carrier layer from the liner, and a step of separating the cover layer from the liner. Furthermore, the method comprises the step of applying at least one security feature to a first surface of the carrier layer, and a step of arranging the cover layer on the first surface of the carrier layer. Moreover, the method comprises the step of inseparably connecting the carrier layer with the cover layer, wherein a web-shaped monolithic foil with at least one incorporated security feature is generated.

[0010] A web-shaped foil is strictly speaking a piece of foil comprising a predetermined width in a lateral direction and a very long length in a longitudinal direction. Both directions are orthogonal to each other. Because of the very long length of the foil the foil is usually wound up onto a coil or folded into stacks for practical reasons. Other appropriate storage options are also possible. The processing of web-shaped materials allows for fast processing of large volumes of material.

[0011] A monolithic foil cannot be separated into its original individual elements without being destroyed. The original individual elements may include layers and additional elements like security features applied onto one or more of the layers. In case a separation of parts of the monolithic foil is carried out, a subsequent assembly of the separated parts of the monolithic foil into the monolithic foil as it was prior to the separation is not possible. The monolithic foil forms a single structure. The separation refers to physical as well as to chemical procedures. Due to the above characteristics, a monolithic foil complies with the requirements for security documents in that the original layers forming the foil cannot be separated again without destroying the foil. As a result, the foil with incorporated security features cannot be altered. The arrangement of a liner between the carrier layer and the separate cover layer allows for an easy storage and separation of both layers. The incorporation of a variety of security features enhances the security and reliability of the generated foil and the foil is suitable for use in security related documents, for example, as a hinge.

[0012] In an exemplary embodiment, the web-shaped multi-layered foil is made by co-extrusion of the cover layer, the carrier layer, and the liner at the same time. Preferably the carrier layer and the cover layer are made of thermoplastic polyurethane (TPU). In particular, the step of manufacturing the web-shaped multi-layered foil by co-extrusion of the cover layer, the carrier layer, and the liner at the same time, takes place before separating the carrier layer from the liner or separating the cover layer from the liner. The co-extrusion of all three layers is the most economic way to manufacture the multi-layered foil. The cost for manufacturing the three-layered foil is comparable to the cost of the presently available one layer foil. A TPU foil can be manufactured at low cost and has high adhesive properties when adhered and/or laminated. In the case where both the carrier and the cover layer are made of TPU, the generated monolithic foil will be made of TPU as well.

[0013] In an exemplary embodiment, the step of inseparably connecting the carrier layer with the cover layer includes laminating both layers together. The process of laminating layers includes the application of pressure and/or heat to the plastic layers causing the layers to melt together and form an inseparable connection between the layers. Moreover, the lamination process creates a uniform surface, because the lamination process dispenses the molten plastic uniformly and compensates for irregular surfaces, such as from the inclusion of security features on the first surface of the carrier layer. As a result, the generated foil with incorporated security features always comprises a planar outer surface such that the foil can be used with different additional applications, e.g. the application of additional layers or other desired surface treatments, irrespective of the shape and dimension of the incorporated security features.

[0014] In an exemplary embodiment, the step of applying at least one security feature to the first surface of the carrier layer includes at least one of printing a liquid, etching engravings, dispersing fibres and/or planchettes, and/or laying at least one security thread. The large variety of possible applicable security features enables a broad range of combinations of security features. The inclusion of these embedded security features improves the security and reliability of the generated foil, as well as the datapage created with the foil. Moreover, the application of a certain security feature can be adapted easily to customer's needs. The security features named above represent a selection only and can be extended to other security features as well.

[0015] In an exemplary embodiment, the method further comprises the step of applying at least one additional layer on the carrier and/or cover layer, after inseparably connecting the carrier layer with the cover layer, wherein the additional layer preferably includes a polycarbonate layer. With the application of an additional layer further properties can be included in the generated foil. For example, a polycarbonate layer reinforces the foil and provides more mechanical and/or chemical resistance to the foil.

[0016] In an exemplary embodiment, the steps of separating the carrier layer from the liner and separating the cover layer from the liner are carried out at the same time. The simultaneous separation saves processing time. Moreover, potentially occurring separation forces may be balanced by separating the layers in opposite or mirrored directions at the same time.

[0017] In an exemplary embodiment, the security features protrude from and/or form notches on the first surface of the carrier layer, wherein the maximum thickness of the protrusions and/or notches is preferably less than 30%, more preferred less than 20%, even more preferred less than 10% and most preferred less than 5% of the thickness of the cover layer. In particular, the security features may at least comprise a first group of security features protruding from the first surface of the carrier layer and/or comprise a second group of security features forming notches on the first surface of the carrier layer. The formation of protrusions and/or notches provides a large variety of applied security features. Any security feature with a large thickness provides good contrast and is easy to be recognized in a later verification process. On the other hand, a smaller thickness of the protrusion and/or notch provides for a less irregular first surface of the carrier layer and facilitates the connection of the cover layer with the carrier layer.

[0018] In an exemplary embodiment, the security features form a predetermined pattern on the first surface of the carrier layer. The predetermined pattern refers to a portion of the carrier layer. The length of the portion may vary. A certain predetermined pattern may be formed on a plurality of portions of the carrier layer. In such a case large quantities of foil with the same security features incorporated can be manufactured. In case each portion of the carrier layer comprises a different predetermined pattern large quantities of foil with unique security features incorporated can be manufactured.

[0019] In an exemplary embodiment, the carrier layer and the cover layer each comprise a thickness of 75-125µm, preferably of 80-120µm, more preferred of 90-110µm and most preferred of 95-100µm, and preferably both layers comprise the same thickness. A cover layer comprising a larger thickness allows for the application of security features with a larger thickness. In case notches are provided as security features, a larger thickness of the carrier layer allows for the application of notches with a larger thickness and depth respectively. In case the carrier and the cover layer comprise the same thickness both layers can be easily generated by co-extrusion with the same parameters for each layer which facilitates the generation of the layers.

[0020] In an exemplary embodiment, the method of manufacturing further comprises the steps of providing a coil with the web-shaped multi-layered foil wound up, unwinding the coil and continuously providing the web-shaped multi-layered foil for processing. Furthermore, the method comprises the steps of continuously separating the carrier layer from the liner and continuously separating the cover layer from the liner. Moreover, the method comprises the steps of continuously applying at least one security feature to a first surface of the carrier layer, continuously arranging the cover layer on the first surface of the carrier layer, and inseparably connecting the carrier layer with the cover layer in a continuous process, wherein the monolithic foil with at least one incorporated security feature is continuously generated.

[0021] In that the manufacturing process is formed as a continuous process large quantities of the multi-layered foil can be processed and corresponding large quantities of monolithic foil can be generated in a short period of time. In an exemplary embodiment the application of different security features can be changed without stopping the manufacturing process, thus, a continuous and fast process is feasible. Here, the term continuous also includes virtual continuous processing wherein only necessary interruptions of the process occur, e.g. during change of a coil at the feeding or storage device.

[0022] The problem above is also solved by a security document comprising a hinge, wherein the hinge incorporates the web-shaped monolithic foil produced by the method described above. The security document comprises an improved reliability because the hinge cannot be altered. For example the security features inside the hinge or a datapage connected to the hinge cannot be changed without detection of the manipulation.

[0023] The problem above is also solved by a machine configured to manufacture a web-shaped monolithic foil with incorporated security features from a web-shaped multi-layered foil, wherein the multi-layered foil at least comprises a carrier layer, a cover layer and a liner disposed between the carrier layer and the cover layer. The machine comprises a separation unit for separating the carrier layer from the liner and the cover layer from the liner, at least one application device which is configured to apply a security feature to a first surface of the carrier layer, and a connecting device for inseparably connecting the carrier layer and the cover layer.

[0024] In an exemplary embodiment, the machine further comprises a first processing line for transporting the web-shaped carrier layer from the separation unit via at least one application device to the connecting device, and a second processing line for transporting the web-shaped cover layer from the separation unit to the connecting device and aligning the cover layer on the first surface of the carrier layer comprising the security features. Each processing line enables a fast transport and continuous processing of the carrier and cover layer, wherein large quantities of material are processed in short time. Furthermore, the cover layer can be easily aligned to the first surface of the carrier layer by a timely and dimensional synchronization of the first and second processing line.

[0025] In an exemplary embodiment, the machine further comprises a feeding device for continuously providing the web-shaped multi-layered foil to the separation unit, wherein the feeding device preferably includes a coil of the web-shaped multi-layered foil. Thereby, the coil may include a plurality of coils configured to provide a web-shaped multi-layered foil with a continuous or virtual continuous length, for example by means of an automatic coil change, to the separation unit. The web-shaped multi-layered foil with a continuous length allows for a continuous and fast processing of large quantities of material.

[0026] In an exemplary embodiment, the machine further comprises a storage device for buffering and/or storing the web-shaped monolithic foil, wherein the storing device preferably includes a coil for winding the web-shaped monolithic foil. The storage of monolithic foil may be a temporary storage for short period of time in case the monolithic foil is directly further processed. In that case the storage device may solely comprise an additional transport line. The storage device including a coil is advantageous in case the generated monolithic foil is to be transported somewhere else. The coil enables storage of a generated monolithic foil with a very long length in a small space.

[0027] In an exemplary embodiment, the machine further comprises an optional storage device for storing the web-shaped liner, wherein the optional storage device preferably includes a coil for winding the liner. The optional storage device provides for a storage of the liner which is separated from the carrier and cover layer. The stored liner could be re-used, for example, or could be removed compactly on the coil.

[0028] Other features and aspects of this disclosure will be apparent from the following description and the accompanying drawings.

Brief Description of the Drawings

[0029] In the following a short description with reference to the accompanying figures is given. Thereby, it shows:

Fig. 1 an exemplary embodiment of a machine to manufacture a web-shaped monolithic foil with incorporated security features from a web-shaped multi-layered foil;

Fig. 2 an exemplary embodiment of the web-shaped multi-layered foil of Fig. 1; and

Fig. 3 an exemplary embodiment of an enhanced web-shaped monolithic foil with incorporated security features.

Detailed Description

[0030] In the following exemplary embodiments are described with reference to the accompanying figures.

[0031] Fig. 1 shows an exemplary embodiment of a machine 40 to manufacture a web-shaped monolithic foil 20 with incorporated security features 22 from a web-shaped multi-layered foil 10. The processing of web-shaped material enables a continuous and fast processing of large quantities of material. Moreover, the manufacturing machine 40 in Fig. 1 is arranged in a modular concept, thus, a change in the arrangement and/or additional processing steps can be implemented easily due to the fact that each processing step does not interfere with another processing step.

[0032] In the embodiment of Fig. 1 the web-shaped multi-layered foil 10 is provided on a coil as a feeding device 41 for providing a multi-layered foil 10 with a continuous or virtual continuous length to a separation unit 48. Besides the provision by a coil 41, the multi-layered foil 10 can also be provided by a different arrangement, e.g. a plurality of coils 41 which are arranged accordingly.

[0033] The speed of rotation to unwind the coil 41 is at least synchronized with the processing speed, i.e. in this embodiment the speed of rotation of the coil, of a storage device 43 in order to continuously and steadily provide a foil 10, 20 through the manufacturing machine 40.

[0034] A separation unit 48 is arranged to receive the multi-layered foil 10. Furthermore, the separation unit 48 is configured to separate each single layer 12, 14, 16 of the multi-layered foil 10. Thereby, the separation can be carried out in a single process step or in consecutive steps at different times and/or locations. In the exemplary embodiment of Fig. 1 the separation of the carrier layer 16, the cover layer 12 and the liner 14 is performed simultaneously.

[0035] The carrier layer 16 is subsequently to the separation transported from the separation unit 48 by means of rollers 47 onto a first processing line 44. The cover layer 12 is at the same time transported from the separation unit 48 by means of rollers 47 onto a second processing line 45, which is separate from the first processing line 44. The total length of both processing lines 44, 45 is, however, the same, such that the cover layer 12 can be aligned in a later step onto the carrier layer 16, 17 again. In Fig. 1, the carrier layer 16 comprising the security features 22 at its first surface 15 is denoted by reference sign 17. At the separation unit 48, the liner 14 is wound onto an optional storage coil 42 in the exemplary embodiment of Fig. 1. By winding the liner 14 onto a coil 42 the liner 14 may be re-used again or can be stored economically. In other embodiments the liner 14 may be discarded in a waste container or carried away somewhere else.

[0036] In the exemplary embodiment of Fig. 1 at least one application device 46a, b, c, is arranged at the first processing line 44. In other embodiments the at least one application device 46a, b, c may also or additionally be arranged at the second processing line 45. A first application device 46a may be a printing device for printing a liquid, i.e. an ink, onto the first surface 15 of the carrier layer 16.

[0037] A second application device 46b may apply fibres, so called security fibres, or planchettes to the first surface 15 of the carrier layer 16. Optionally, the fibres can be fluorescent fibres. The second application device 46b can be arranged in addition to the first application device 46a or instead of the first application device 46a.

[0038] Moreover, a third application device 46c may be arranged at the processing line 44 wherein the third application device 46c is configured to apply a security thread to the first surface 15 of the carrier layer 16. The security thread can include at least one of a holographic, metallized or de-metallized security thread.

[0039] The selection and order of the application devices 46a, b, c is freely selectable and adaptable to actual requirements for the monolithic foil 20. The numbering of the application devices 46a, b, c is solely provided to better distinguish the application devices 46a, b, c. Furthermore, additional application devices may be arranged as well at the processing line 44 in order to apply further different security features to the carrier layer 16, for example by etching a gravure to the first surface 15 of the carrier layer 16.

[0040] A connecting device 49 is furthermore provided in the exemplary embodiment of Fig. 1. The connecting device 49 is configured to inseparably connect the carrier layer 17, i.e. the carrier layer 16 comprising the security features 22 at its first surface 15, to the cover layer 12. In a preferred embodiment the connection is provided by a lamination of the two layers 12, 17 together. Thereby, heat and/or pressure, for example applied by hot rollers 49, are applied to the surfaces of the carrier and cover layer 12, 17 and both layers 12, 17 are inseparably connected, wherein a monolithic foil 20 is formed. An inseparable connection and monolithic foil 20, respectively, means that the foil 20 is destroyed in trying to separate both layers 12, 17 again. The lamination is also compatible with stack lamination and in-line lamination processes. In other embodiments different connection methods, leading to the same result of the monolithic foil 20, can be applied as well.

[0041] Furthermore, the outer surfaces of the generated monolithic foil 20 each comprise a planar face. Hence, any further processing is facilitated in that always a uniform surface shape of the monolithic foil 20 is provided. As a consequence, the generated monolithic foil 20 can be further processed without knowledge about the security features 22, i.e. the shape, dimension, arrangement, pattern etc. of the security features incorporated in the foil 20.

[0042] Afterwards, in the embodiment of Fig. 1, the generated monolithic foil 20 is wound onto a storage device 43 in form of a coil. In another embodiment is it possible that, instead of winding the monolithic foil 20 to a coil 43, the foil 20 can be transported to a further processing unit for further processing, for example for applying additional layers 32, 34 to the monolithic foil 20. In still another embodiment the storage can be performed by different storage means, e.g. by folding up the monolithic foil 20.

[0043] In Fig. 2, an embodiment of a multi-layered foil 10 is shown. The multi-layered foil 10 is manufactured in a web process and is continuously provided. In the shown embodiment the multi-layered foil 10 comprises a carrier layer 16, a cover layer 12 and a liner 14 in between the carrier and cover layer 12, 16. However, in other embodiments, the multi-layered foil 10 may comprise additional layers, preferably also separated by a liner 14 in order to easily separate all layers of the multi-layered foil 10.

[0044] In order to achieve an easy separation of the layers, the properties of the liner 14 are as such that the surfaces of the liner 14 and of the cover and carrier layer 12, 16 are easily separable, i.e. comprising only slight adhesive properties. Slight means that all three layers 12, 14, 16 adhere together to form the multi-layered foil 10 but can be easily separated again, preferably by simply pulling the layers 12, 14, 16 away from each other.

[0045] Furthermore, the carrier and cover layer 12, 16 are manufactured by co-extrusion, i.e. at the same time and are each preferably made of a thermoplastic polyurethane (TPU) layer. Additionally, the liner 14 is coextruded, i.e. generated and aligned in the center between the carrier and cover layer 12, 16 during the co-extrusion process, as well, because otherwise the cover and carrier layer 12, 16 would become inseparable. Moreover, no extra pass on the extrusion line is required and the cost is kept low. Altogether, the co-extrusion in combination with the disclosed method steps of a separation of the multi-layered foil 10, the application of security features 22 to the carrier layer 16 and the inseparable connection of the carrier and the cover layer 12, 16 provides for a very efficient and low cost manufacturing process in order to provide the base material for a passport hinge made from TPU including diverse security features.

[0046] Typical thicknesses H1, H3 of the carrier and/or cover layer 12, 16 are in the range of 75-125µm. It is preferred that both layers 12, 16 comprise the same thickness H1, H3. A typical thickness H2 of the liner 14 is in the range of 40-70µm, preferably about 55µm. Thereby, the thickness H2 of the liner 14 should be 95% of the thickness H1, H3 of one of the carrier and cover layer 12, 16 at a maximum.

[0047] In Fig. 3 an embodiment of an enhanced monolithic foil 30 is shown. Thereby, the monolithic foil 20 comprises a first additional layer 32 and a second additional layer 34 at the upper and lower side, respectively. The additional layers 32, 34 may include the same material, such as polycarbonate, or are made of different materials. Preferably, at least one of the additional layers 32, 34 is transparent to electromagnetic waves, i.e. light in the visible, UV or IR spectrum, in order to enable an identification of the security features 22 inside the monolithic foil 20.

[0048] By applying the additional layers 32 and 34, the mechanical and chemical properties of the monolithic foil 20 can be altered, for example in case the additional layers 32, 34 are made of polycarbonate, the generated enhanced monolithic foil 30 will comprise an increased mechanical and chemical resistance compared to the monolithic foil 20 without the additional layers 32, 34. Alternatively, at least one of the additional layers 32, 34 may be made of TPU. Moreover, further additional layers may be applied to the enhanced monolithic foil 30 as well.

[0049] The thicknesses H4, H6 of the additional layers 32, 34, are preferably in the range of 30-50µm, and may be adjusted to the actual needs regarding the desired properties of the enhanced monolithic foil 30. The thickness H5 of the monolithic foil 20 is about the sum of the thicknesses H1 and H3 of the carrier and cover layer 12, 17. The term about means that there might occur slight differences due to the thickness and depth, respectively, of the applied security features 22. In general, the smaller the maximum thickness H7 of the security features 22 the smaller the slight differences.

[0050] Moreover, in Fig. 3, the first surface 15 is only shown as a dotted line for visualization purposes, because actually the first surface 15 as such does not exist anymore after the connection of the carrier layer 17 and the cover layer 12.

[0051] The security features 22 applied onto the first surface 15 of the carrier layer 16 in the embodiment of Fig. 3 form a predetermined pattern in longitudinal direction of the foil 20, 30. The sequence of security features 22 may repeat after a predetermined length in longitudinal direction of the foil 20, 30. The pattern may relate to the thickness, kind, group or longitudinal length of a security feature or the distance between adjacent or specific security features.

[0052] Moreover, the security features 22 in Fig. 3 comprise different lengths, however, in other embodiments the security features may, instead or additionally, comprise different thicknesses H7. As already explained above each security feature 22 may be made of one of the group including an ink, a gravure, a fibre, a planchette, a security thread or something else suitable as a security feature. Moreover, optical variable elements like holograms can be used as security features. Layers may be embedded as security features that are or can be laser engraved. Small electronic devices like an RFID element or portions thereof may be used as security features. Generally, the security features may be active and/or passive elements, i.e. they provide an identification on their own or in response to some identification process or inquiry. Thereby, different kinds of security features 22 may be applied adjacent to one another. This increases variation possibilities and, thus, enhances security and reliability at least of the monolithic foil 20.

[0053] The generated monolithic foil 20, with or without additional layers 32, 34, may then be used as a base material for a hinge used in security related documents, such as passports.

List of reference signs

[0054] 

10

multi-layered foil

12

cover layer

14

liner

15

first surface

16

carrier layer

20

monolithic foil

22

security features

30

enhanced monolithic foil

32

first additional layer

34

second additional layer

40

manufacturing machine

41

feeding device

42

optional storage device

43

storage device

44

first processing line

45

second processing line

46a, b, c

application device

47

transport device

48

separation unit

49

connecting device

H1

thickness of cover layer

H2

thickness of liner

H3

thickness of carrier layer

H4

thickness of first additional layer

H5

thickness of monolithic foil

H6

thickness of second additional layer

H7

maximum thickness of security features

Claims

1. A method of manufacturing a web-shaped monolithic foil (20) with incorporated security features (22) from a web-shaped multi-layered foil (10), wherein the multi-layered foil (10) at least comprises a carrier layer (16), a cover layer (12) and a liner (14) disposed between the carrier layer (16) and the cover layer (12), the method comprising the following steps:

separating the carrier layer (16) from the liner (14);

separating the cover layer (12) from the liner (14);

applying at least one security feature (22) to a first surface (15) of the carrier layer (16);

arranging the cover layer (12) on the first surface (15) of the carrier layer (16); and

inseparably connecting the carrier layer (16) with the cover layer (12), wherein a web-shaped monolithic foil (20) with at least one incorporated security feature (22) is generated.

2. The method of claim 1, further comprising the step of manufacturing the web-shaped multi-layered foil (10) by co-extrusion of the cover layer (12), the carrier layer (16) and the liner (14) at the same time, wherein preferably the carrier layer (16) and the cover layer (12) are made of thermoplastic polyurethane (TPU).

3. The method of claim 1 or 2, wherein the step of inseparably connecting the carrier layer (16) with the cover layer (12) includes laminating both layers (12, 16) together.

4. The method of any one of claims 1 to 3, wherein the step of applying at least one security feature (22) to the first surface (15) of the carrier layer (16) includes at least one of the steps of:

printing a liquid;

etching engravings;

dispersing fibres and/or planchettes; and/or

laying at least one security thread.

5. The method of any one of claims 1 to 4, further comprising the step of applying at least one additional layer (32, 34) on the carrier (16) and/or cover layer (12), after inseparably connecting the carrier layer (16) with the cover layer (12), wherein the additional layer (32, 34) preferably includes a polycarbonate layer.

6. The method of any one of claims 1 to 5, wherein the steps of separating the carrier layer (16) from the liner (14) and separating the cover layer (12) from the liner (14) are carried out at the same time.

7. The method of any one of claims 1 to 6, wherein the security features (22) protrude from and/or form notches on the first surface (15) of the carrier layer (16), wherein the maximum thickness (H7) of the protrusions and/or notches (22) is preferably less than 30%, more preferred less than 20%, even more preferred less than 10% and most preferred less than 5% of the thickness (HI) of the cover layer (12).

8. The method of any one of claims 1 to 7, wherein the security features (22) form a predetermined pattern on the first surface (15) of the carrier layer (16).

9. The method of any one of claims 1 to 8, wherein the carrier layer (16) and the cover layer (12) each comprise a thickness (HI, H3) of 75-125µm, preferably of 80-120µm, more preferred of 90-110µm and most preferred of 95-100µm, and preferably both layers (12, 16) comprise the same thickness (HI, H3).

10. The method of any one of claims 1 to 9, further comprising the steps of:

providing a coil (41) with the web-shaped multi-layered foil (10) wound up;

unwinding the coil (41) and continuously providing the web-shaped multi-layered foil (10) for processing;

continuously separating the carrier layer (16) from the liner (14);

continuously separating the cover layer (12) from the liner (14);

continuously applying at least one security feature (22) to a first surface (15) of the carrier layer (16);

continuously arranging the cover layer (12) on the first surface (15) of the carrier layer (16); and

inseparably connecting the carrier layer (16) with the cover layer (12) in a continuous process, wherein the monolithic foil (20) with at least one incorporated security feature (22) is continuously generated.

11. A security document comprising a hinge, wherein the hinge incorporates the web-shaped monolithic foil (20) produced by the method of any one of claims 1 to 10.

12. A machine (40) configured to manufacture a web-shaped monolithic foil (20) with incorporated security features (22) from a web-shaped multi-layered foil (10), wherein the multi-layered foil (10) at least comprises a carrier layer (16), a cover layer (12) and a liner (14) disposed between the carrier layer (16) and the cover layer (12), the machine (40) comprising:

a separation unit (48) for separating the carrier layer (16) from the liner (14) and the cover layer (12) from the liner (14);

at least one application device (46a, b, c) which is configured to apply a security feature (22) to a first surface (15) of the carrier layer (16); and

a connecting device (49) for inseparably connecting the carrier layer (16) and the cover layer (12).

13. The machine of claim 12, further comprising a first processing line (44) for transporting the web-shaped carrier layer (16) from the separation unit (48) via at least one application device (46a, b, c) to the connecting device (49), and a second processing line (45) for transporting the web-shaped cover layer (12) from the separation unit (48) to the connecting device (49) and aligning the cover layer (12) on the first surface (15) of the carrier layer comprising the security features (17).

14. The machine of claim 12 or 13, further comprising a feeding device (41) for continuously providing the web-shaped multi-layered foil (10) to the separation unit (48), wherein the feeding device (41) preferably includes a coil of the web-shaped multi-layered foil (10).

15. The machine of any one of claims 12 to 14, further comprising a storage device (43) for buffering and/or storing the web-shaped monolithic foil (20), wherein the storing device (43) preferably includes a coil for winding the web-shaped monolithic foil (20).

16. The machine of any one of claims 12 to 15, further comprising an optional storage device (42) for storing the web-shaped liner (14), wherein the optional storage device (43) preferably includes a coil for winding the liner (14).

Drawing