Ultrasonic bonding for preventing the safety device from being used in the acquisition process from adhering to the substrate.

Abstract

A security document (200) includes a substrate (205) having a first surface and a second surface opposite to the first surface, the first surface being made of a cellulose material. The security document also includes an optical security device (220) having an optical mark indicating the authenticity of the security document and a third surface having a thermoplastic polymer. The security document further includes an ultrasonic weld (225) forming an adhesive portion between a segment of the first surface and a segment of the third surface.

Description

Technical Field

[0001] This disclosure relates to enhancing the security of documents against acquisition security devices to create resistance to document forgery. More specifically, this disclosure relates to ultrasonic bonding of the acquisition security device to the substrate. Background Technology

[0002] Reinforcing passports, banknotes, and other documents (referred to herein as “secure documents”) remains a persistent source of technical challenges and opportunities for improvement in the field of secure document design, whose structural features include difficult-to-replicate markings that ensure the document’s authenticity against counterfeiting. “Collection,” a mechanism by which malicious actors can destroy (e.g., by immersing the document in water or another solvent for an extended period) genuine secure documents to remove these difficult-to-replicate components intact, provides a means by which they can obtain material to produce counterfeit secure documents. If removed substantially intact, these difficult-to-replicate components of the secure document, such as optical security features (e.g., security strips and patches), can be used to create counterfeits, for example, to create upgraded cycles (e.g., counterfeits by incorporating a security thread from a low-denomination banknote into a high-denomination banknote), or multiple counterfeits (e.g., using fragments of an embedded security thread from a genuine banknote to create two counterfeit banknotes). While central banks and security document professionals can generally identify counterfeit security documents generated from collected components, such forgeries are of usable quality to malicious actors as long as they provide visible authenticity markers that are substantially similar to genuine documents, because they can easily pass genuine security documents to ordinary users. Summary of the Invention

[0003] This disclosure relates to an embodiment for preventing the acquisition safety device from ultrasonically bonding to the substrate.

[0004] In a first embodiment, the security document includes a substrate having a first surface and a second surface opposite to the first surface, the first surface comprising a cellulose material. The security document also includes an optical security device having an optical mark indicating the authenticity of the security document and a third surface comprising a thermoplastic polymer. Additionally, the security document includes an ultrasonic weld forming an adhesive portion between a segment of the first surface and a segment of the third surface.

[0005] In a second embodiment, a method for creating a security document includes positioning an optical security device on a first surface of a substrate, wherein the substrate has a first surface and a second surface opposite to the first surface, and the first surface comprises a cellulose material. Furthermore, the optical security device has an optical mark indicating the authenticity of the security document and a third surface, the third surface comprising a thermoplastic polymer. The method includes clamping the optical security device and the substrate together under a predetermined clamping pressure applied by an ultrasonic probe and a mold, and while the optical security device and the substrate are clamped together, applying vibrational energy through the ultrasonic probe for a predetermined welding time to create an ultrasonic weld that bonds a segment of the first surface to a segment of the third surface.

[0006] Other technical features may be apparent to those skilled in the art from the following figures, description and claims.

[0007] Before proceeding with the detailed embodiments below, it may be advantageous to define certain words and phrases used throughout this patent document. The term “connection” and its derivatives refer to any direct or indirect communication between two or more elements, regardless of whether these elements are physically in contact with each other. The term “comprising” and its derivatives mean including but not limited to. The term “or” is inclusive, indicating and / or. The phrase “associated with” and its derivatives mean including, comprising, interconnected with, containing, contained within, connected or linked to, coupled or connected to, communicable with, cooperating with, interleaved, juxtaposed, proximate, bound or bound to, having, possessing the attributes of, having a relationship with, etc. When used with a list of items, the phrase “at least one of” means that different combinations of one or more of the listed items may be used, and only one item from the list may be required. For example, “at least one of A, B, and C” includes any of the following combinations: A, B, C, A and B, A and C, B and C, and A and B and C.

[0008] Definitions of certain other words and phrases are provided throughout this patent document. Those skilled in the art will understand that, in many (if not most) instances, such definitions apply to both prior and future uses of the words and phrases defined herein. Attached Figure Description

[0009] To more fully understand this disclosure and its advantages, reference is now made to the following description in conjunction with the accompanying drawings, in which the same reference numerals denote the same parts:

[0010] Figure 1 As background, two examples of forged security documents with applicable qualities are shown, which incorporate embedded security devices into genuine security documents to generate malicious actors.

[0011] Figure 2A and Figure 2B Two examples of security documents according to various embodiments of this disclosure are shown;

[0012] Figure 3 An example of a segment of an optical safety device incorporated into a safety document according to certain embodiments of this disclosure is shown;

[0013] Figure 4A and Figure 4B Examples of security documents according to certain embodiments of the present disclosure are shown, as well as examples of methods for producing security documents according to certain embodiments of the present disclosure;

[0014] Figure 5A , Figure 5B and Figure 5C Aspects of ultrasonic welding between an optical safety device according to various embodiments of the present disclosure and one or more cellulose surfaces of a substrate formed in the optical safety device are shown.

[0015] Figure 6A , Figure 6B and Figure 6C Examples of tactile features formed in an optical safety device by ultrasonic welding according to certain embodiments of the present disclosure are shown; and

[0016] Figure 7 Operations of methods for creating security documents according to various embodiments of this disclosure are shown. Detailed Implementation

[0017] The following discussion Figures 1 to 7 The various embodiments used to describe the principles of this disclosure are merely examples and should not be construed as limiting the scope of this disclosure in any way. Those skilled in the art will understand that the principles of this disclosure can be implemented in any suitably arranged security document.

[0018] While this disclosure has been described with reference to various embodiments, various changes and modifications will be made to those skilled in the art. It is intended that this disclosure cover such changes and modifications that fall within the scope of the claims.

[0019] With the help of the background and description of at least one technical problem solved according to certain embodiments of this disclosure, Figure 1 Example 100 of a mechanism is shown, through which the security features of a genuine security document 105 (in this example, a banknote) are collected and used to generate two counterfeit security documents with applicable qualities for malicious actors.

[0020] refer to Figure 1The example provided is a security document 105. As shown in the figures, the security document 105 includes a substrate 107 that incorporates a plurality of construction features of visible and invisible markings that provide authenticity of the security document 105. Examples of construction features of invisible markings that provide authenticity of the document include, but are not limited to, magnetic ink or machine-readable features (e.g., radio frequency identification (“RFID”) antennas) attached to or embedded in the substrate 107.

[0021] Examples of construction features providing authenticity for visible markings include watermarks, printing effects, specialty inks, and security devices formed, applied, or embedded in substrate 107. In this illustrative example, construction features of visible markings providing authenticity for security document 105 include a watermark 109, which in some embodiments is formed using a patterned pressure roller during the manufacture of the paper on substrate 107. Further examples of construction features of visual markings providing authenticity for security document 105 include an intaglio design 111 comprising a line pattern that is difficult to reproduce, producing a distinctive moiré interference effect and a unique surface texture due to the fine resolution of the pattern and the use of intaglio printing techniques. In this illustrative example, construction features of visual markings providing document authenticity for security document 105 include an area 113 printed with a specialized, hard-to-obtain ink (such as angle-changing ink or color-changing ink), the appearance of which changes in response to a change in the angle of incidence of light reaching the ink. Construction features of visible markings providing authenticity for security document 105 may also include a security device 115. In some embodiments, the security device 115 includes a segment of a thin material (e.g., a narrow band of a polymer substrate) supporting one or more arrays of micron or nanometer-scale optical structures (e.g., lenses, icon structures, or diffraction gratings) that collectively produce unique optical effects. Examples of such optical effects include, but are not limited to, moiré magnification (sometimes referred to as “synthetic magnified image” or “synthetic image”), color shift, or holograms.

[0022] Improvements in imaging and printing technologies, along with the cunning of criminals, have provided malicious actors with the ability and materials to create counterfeit security documents that embody many of the aforementioned structural features, providing visible markers of authenticity, with the primary exception of security device 115. Given the small-scale optical structure of security device 115 and the institutional control over certain tools, materials, and techniques involved in its production, most malicious actors currently lack the means or technical knowledge to produce counterfeits of security device 115.

[0023] As a workaround for preventing the duplication of security device 115, malicious actors seeking to create forged security files may "extract" security devices from genuine files and incorporate them into one or more forged security files. (See reference) Figure 1 As an illustrative example, security device 115 is a micro-optical filament spanning the width of security document 100. As shown in the figures, security device 115 is embedded in substrate 107 such that portions of security device 115 are visible through windows 117 in the substrate, while other portions of security device are hidden by bridges 119.

[0024] refer to Figure 1 As an illustrative example, in some cases, a malicious actor could remove the security device 115 substantially intact by immersing the security document 100 in a solvent (e.g., water or bleach) for an extended period to release the adhesive bond between the security device 115 and the substrate 107 or to damage the substrate 107. Once substantially intact, the security device 115 can be carefully cut 130 into fragments, which can be adhered to the surfaces of multiple counterfeit substrates 140a and 140b, or alternatively, attached to the surfaces of embedded carrier filaments, to create a large number of counterfeit documents from an initial number of genuine security documents. While not perfect copies of the security document 105, these counterfeit documents carry sufficient visual markings of authenticity to be easily disseminated by many users and mistaken for genuine documents.

[0025] Although Figure 1 While not discussed in the explanatory examples, other methods for generating counterfeit security documents can be enabled by capturing the security device 115 substantially intact. For example, once captured, the security device 115 can be upgraded to produce counterfeit banknotes with a higher denomination than the security document 105, or, in some cases, multiple counterfeit banknotes with the same denomination. Alternatively, capturing the security device 115 substantially intact can facilitate the creation of counterfeit security documents associated with unauthorized actors (e.g., creating fake passports) where the security document is an identity document or otherwise associated with an authorized actor.

[0026] Figure 2A and Figure 2B Two examples of security documents according to various embodiments of this disclosure are shown. For convenience, Figure 2A and Figure 2B The common structural elements in the examples are numbered similarly.

[0027] Such as about Figure 1As discussed in the illustrative examples, one of the operational prerequisites behind acquiring a security device from a genuine security document is that the security device can not only be separated from the substrate of the genuine document, but also can be separated under substantially intact conditions suitable for reuse in a forged document. Advantageously, and as further discussed herein, certain embodiments of this disclosure undermine this operational prerequisite by strengthening the adhesion between the security device and the substrate (thus reducing the likelihood of successful separation) and by strategically altering or damaging parts of the security device (thus increasing the likelihood that the security device, if acquired, would be unsuitable for use in a forged document).

[0028] refer to Figure 2A The following is a non-limiting example illustrating an example of a security document 200 according to various embodiments of the present disclosure. According to some embodiments, the security document 200 includes a substrate 205 comprising a first surface and a second surface. In some embodiments (e.g., embodiments without windows and bridge regions in the substrate), the first surface comprises the outer side of the substrate 205. In some embodiments (e.g., embodiments without windows and bridge regions in the substrate 205), the first surface is the outer surface of the substrate 205.

[0029] According to various embodiments, the first surface 201 comprises a cellulose material. In some embodiments, the cellulose material of the first surface 201 is the same cellulose material used to form the entire substrate 205. For example, the substrate 205 may be made of paper formed on a fourdrinier paper machine, and the cellulose material on the first surface 201 is derived from pulp or fiber pulp used to make the substrate. In some embodiments, the first surface comprises a cellulose outer layer of a multilayer substrate structure. According to various embodiments, the cellulose material is, but is not limited to, one or more of the following: wood pulp, cotton fiber, flax fiber, linen fiber, sisal fiber, hemp fiber, Abaca fiber, Kozo fiber, Mitsumata fiber, bamboo fiber, or Kenaf fiber.

[0030] like Figure 2A As shown in the non-limiting example, the structural features of security document 200 include one or more elements that provide visual markers of authenticity for the security document. In this illustrative example, the elements providing visual markers of authenticity include, but are not limited to, print design 210 (e.g., Figure 1 The intaglio design 111), and the area 215 printed with corner-specific color ink (OVI) (e.g., Figure 1 Region 113) and optical safety device 220 (e.g., Figure 1 Safety device 115 or Figure 3 (Optical safety device 300 in the middle).

[0031] refer to Figure 2AIn a non-limiting example, the optical security device 220 is a thin, continuous strip comprising microscale structures of optical markings that provide authenticity for the security document 200. In this illustrative example, the optical security device 220 is embedded and adhered to a substrate 205 and is visible on the surface in one or more window regions (e.g., window region 221) and not visible on the surface in one or more bridge regions (e.g., bridge region 223). In some embodiments, the optical security device 220 includes a third surface comprising a thermoplastic polymer. Examples of suitable thermoplastic polymers include, but are not limited to, polyesters, polypropylenes, and polyethylene terephthalate (“PET”).

[0032] In some embodiments, the third surface of the optical safety device 220 is a sealing layer of the micro-optical safety device (e.g., Figure 3 (The sealing layer 340 in the middle). In various embodiments (e.g., micro-optical systems without a sealing layer), the third surface is a focusing element (e.g., Figure 3 (An array of focusing elements 305 in the image). In some embodiments, the third surface is an image icon layer (e.g., Figure 3 The arrangement of image icons 320 in the image). In one or more embodiments, the third surface is the substrate of the optical safety device 220 (e.g., Figure 3 (Second substrate 330 in the substrate). According to various embodiments, the optical safety device 220 is embedded in the substrate 205 as part of a roll-to-roll papermaking process for forming the substrate 205 from fiber pulp. In some embodiments, at least one side of the optical safety device 220 is bonded to the inner or outer surface of the substrate 205 with an adhesive.

[0033] Surprisingly and advantageously, the inventors of this disclosure have discovered that certain optical security devices (e.g., micro-optical filaments) suitable for use in security documents can be ultrasonically welded to a cellulose material on one or more surfaces of a security document substrate. To this end, in certain embodiments according to this disclosure, ultrasonic welds (e.g., ultrasonic weld 225) bond one or more thermoplastic surfaces of the optical security device 220 to one or more surfaces of a substrate 205 comprising the cellulose material. As discussed in detail elsewhere in this disclosure, such ultrasonic welds resist forgery in at least the following ways: First, they provide another mechanism for attaching the optical security device 220 to the substrate 205, making it more difficult to separate the optical security device 220 from the substrate 205. Second, the process of ultrasonically welding the optical security device 220 to the substrate 205 can be performed in such a way that even when separated from the substrate 205, the optical security device 220 is significantly altered in a manner that makes it unsuitable for forging security documents.

[0034] Figure 2BExamples of security documents 250 according to various embodiments of this disclosure are shown.

[0035] refer to Figure 2B A non-restrictive example, security file 250 is structurally similar to... Figure 2A The difference between the security file 200 and the one described above is that the optical security device 220 is not embedded in the bridge region of the substrate 205, but rather surface-mounted on the outer first surface 201 of the substrate 205. As noted elsewhere in this disclosure, depending on certain welding parameters (e.g., the clamping pressure applied to the security file by the ultrasonic probe and the mold), the optical security device can be altered or damaged during the creation of the ultrasonic weld (in the sense that the ability of the device to provide optical effects in the region of the ultrasonic weld is degraded or negated). Reference Figure 2B In a non-limiting example, the optical security device 220 includes an image region (e.g., image region 255) containing small-scale optical structures (e.g., ridges of microlenses or diffraction gratings) that produce one or more optical effects that provide the authenticity of the security document 250. As shown in this illustrative example, the optical security device 220 includes a transition region 265, which in some embodiments does not contain small-scale optical structures that produce the optical effects that provide the authenticity of the security document 250. Although not shown in the non-limiting example of Figure 2, in some embodiments, the transition region 265 includes micro-optical structures that provide a “white space” only in the optical effects provided by the optical security device 220. Figure 2B In the illustrative example, the ultrasonic weld (e.g., ultrasonic weld 225) is aligned with the transition region, as discussed elsewhere herein, which helps to apply a higher clamping force during ultrasonic welding. Depending on the implementation and the welding equipment used, applying a higher clamping force can produce a stronger adhesion between the substrate 205 and the optical security device 220, and enhance the functionality of the security document 250 by creating tactile markings (e.g., raised or Braille text) that reflect realism in the security document.

[0036] Figure 3 An example of a segment of an optical safety device 300 incorporated in security document 360 according to certain embodiments of the present disclosure is shown.

[0037] refer to Figure 3As a non-limiting example, the optical security device 300 includes a plurality of focusing elements 305 (including, for example, focusing element 307) and an arrangement of image icons 320 (including, for example, image icons 321). According to various embodiments, each of the plurality of focusing elements 305 has a coverage area in which one or more image icons of the arrangement of image icons 320 are positioned. Commonly, the focusing elements of the plurality of focusing elements 305 magnify portions of the image icons 320 to produce a moiré magnification effect (also known as a “synthetic magnified image” or more simply a “synthetic image”), wherein individual microscopic image icons are collectively magnified by the plurality of focusing elements 305 to produce an image that dynamically reacts to a movement of the viewing angle (e.g., by appearing to move or change color). Given the small scale and tight manufacturing tolerances of the constituent structures of the optical security device providing the moiré magnification effect, many malicious actors cannot produce counterfeit versions of the optical security device 300. Therefore, in many cases, the optical security device 300 is a credible visual marker of the authenticity of a security document (e.g., security document 360).

[0038] According to some embodiments, the plurality of focusing elements 305 comprises a planar array of micro-optical focusing elements. In some embodiments, the focusing elements of the plurality of focusing elements 305 comprise micro-optical refractive focusing elements (e.g., plano-convex or GRIN lenses). In some embodiments, the refractive focusing elements of the plurality of focusing elements 305 are made of a photocurable resin with a refractive index ranging from 1.35 to 1.7 and have a diameter ranging from 5 μm to 200 μm. In various embodiments, the focusing elements of the plurality of focusing elements 305 comprise reflective focusing elements (e.g., very small concave mirrors) with a diameter ranging from 5 μm to 50 μm. Although the focusing elements of the plurality of focusing elements 305 are shown in this illustrative example as comprising circular plano-convex lenses, other refractive lens geometries (e.g., cylindrical lenses) are also possible and within the scope of this disclosure.

[0039] like Figure 3As illustrated in the illustrative example, the arrangement of image icons 320 includes a set of image icons (including image icon 321) positioned at predetermined locations within the coverage area of ​​the focusing elements of a plurality of focusing elements 305. According to various embodiments, individual image icons of the arrangement of image icons 320 include a region of photocurable material associated with the focal path of structured light (e.g., collimated UV light), which extends from a protrusion associated with one or more predetermined ranges of viewing angle through the plurality of focusing elements 305. In some embodiments, individual image icons of the arrangement of image icons 320 are not provided within a structured image icon layer. As used herein, the term "structured image layer" encompasses a layer of material (e.g., a photocurable resin) that has been embossed or otherwise formed to include structures (e.g., recesses, pillars, grooves, or platforms) for positioning and retaining the image icon material. According to various implementation schemes, individual image icons of the arrangement of image icons 320 are provided within a structured image layer, which includes one or more of voids, mesas, or pillars, acting as micron and nanoscale volumes that retain the structure to hold the colored material in place.

[0040] like Figure 3 As illustrated in the illustrative examples, in some embodiments, the optical safety device 300 includes an optical spacer 310. According to various embodiments, the optical spacer 310 comprises a thin film of a substantially transparent material, said film operating to position the arrangement of image icons 320 within or around the focal plane of the focusing elements of the plurality of focusing elements 305. In some embodiments according to this disclosure, the optical spacer 310 includes a fabrication substrate on which one or more layers of photocurable material may be applied to form the arrangement of image icons 320 or one or more of the plurality of focusing elements 305.

[0041] According to various embodiments, the optical safety device 300 includes one or more areas of a photocurable protective material that occupy the space between the image icons of the arrangement of image icons 320. In some embodiments, the arrangement of image icons 320 is first formed (e.g., by selectively curing and removing a liquid photocurable material on optical spacers 310), and then a layer of transparent photocurable material is applied to fill the space between the image icons of the arrangement of image icons 320, and then flood-cured to create a protective layer that protects the image icons from movement from their position within the coverage area of ​​the focusing elements of a plurality of focusing elements 305. In some embodiments, the photocurable material used to form the arrangement of image icons 320 is a colored, ultraviolet (UV)-curable polymer.

[0042] In some embodiments, the arrangement of image icons 320 is adhered to a second substrate 330, which functions to protect and secure the arrangement of image icons 320 and provides an interface for attaching the optical safety device 300 to a substrate 350 (e.g., Figure 2A The substrate 205 in the document is part of the security file 360.

[0043] In some embodiments of the present disclosure, the optical safety device 300 includes a sealing layer 340. According to some embodiments, the sealing layer 340 comprises a thin (e.g., a layer from 2 μm to 50 μm thick) substantially transparent material that interfaces with the focusing elements of a plurality of focusing elements 305 on its lower surface and includes an upper surface with less curvature variation compared to the plurality of focusing elements 305 (e.g., by smoothing the upper surface or by having a radius of curvature larger than that of the focusing elements, exhibiting local undulations). According to various embodiments, the upper surface of the sealing layer 340 is formed of a thermoplastic material that can be ultrasonically welded to a surface comprising a cellulose material.

[0044] like Figure 3 As shown in a non-limiting example, in some embodiments, the optical security device 300 may be attached to a substrate 350 to form a security document 360. According to various embodiments, the substrate 350 includes a sheet of material, at least one surface of which comprises a cellulosic material such as wood pulp, cotton fiber, flax fiber, linen fiber, sisal fiber, hemp fiber, Abaca fiber, Kozo fiber, Mitsumata fiber, bamboo fiber, or Kenaf fiber.

[0045] Although Figure 3 An example of an optical security device 300 according to various embodiments is provided, but this disclosure is not limited thereto. Other optical security devices are also within the scope of this disclosure, including at least one surface having a thermoplastic polymer and including micron and nanoscale optical structures that are difficult to replicate (e.g., holograms, devices providing thin-film effects, devices generating diffraction-based optical effects), which provide a target for malicious actors.

[0046] Figure 4A and Figure 4B Aspects of examples of security documents according to certain embodiments of the present disclosure are shown, as well as examples of methods for creating security documents according to certain embodiments of the present disclosure. For convenience, Figure 4A and Figure 4B The common elements in the examples are similarly numbered in the accompanying drawings.

[0047] Certain security documents, including but not limited to banknotes and identification documents, are mass-produced on high-capacity roll-to-roll machines (such as paper machines and printing presses) with roll speeds of approximately 500 (500) feet per minute. Advantageously, ultrasonic welds (e.g., according to certain embodiments of this disclosure) are used to enhance the resistance of security documents to acquisition security devices. Figure 2A and Figure 2B The ultrasonic weld (225) can be formed in the sub-second time range. Because the ultrasonic welding according to some embodiments of the present disclosure can be performed within a limited time range of a section of a roll-to-roll processing machine as the paper roll is passed through at high speed, the method of ultrasonically bonding a safety device to a substrate according to the present disclosure is compatible with the high-speed manufacturing technology used in the production of safety documents.

[0048] refer to Figure 4A An illustrative example is provided, showing a front view of a section of safety file 400 being passed between ultrasonic probe 405 and mold 410 of ultrasonic welding machine. As indicated by coordinate axis 420, in some embodiments, safety file 400 is part of a moving roll of paper (in this case, the roll of paper moves toward the observer along the z-axis of coordinate axis 420).

[0049] According to some implementations, security document 400 includes a bridge region (e.g., bridge region 223 in FIG. 2), wherein optical safety device 415 (e.g., Figure 3 The optical safety device 300 in the optical safety device 415 is attached to the substrate 417 (e.g., on both the top side 413 and the bottom side 411 of the substrate). Figure 3 The substrate 350 is connected.

[0050] like Figure 4AAs illustrated in the explanatory examples, the ultrasonic probe 405 includes an ultrasonic stack configured to convert electrical signals into high-frequency mechanical vibrations of the lower surface 407 at ultrasonic frequencies. Examples of ultrasonic frequencies according to various embodiments of the present disclosure include frequencies between 15 kHz and 40 kHz. In some embodiments according to the present disclosure, the mold 410 includes a patterned anvil having one or more raised features 419 defining clamping points that form an ultrasonic weld between the substrate 417 and one or more sides 411 and 413 of the optical security device. According to various embodiments, the security document 400 is clamped between the bottom surface 407 and the mold 410 under a predetermined clamping pressure (e.g., by a hydraulic press (not shown in the figures)). When clamped, the ultrasonic probe 405 applies vibrational energy to the clamped portion of the security document 400 for a predetermined time. According to various embodiments, the predetermined time is between 0.5 seconds and 1.0 seconds. In some embodiments, the predetermined time is between 0.3 seconds and 0.5 seconds. In some implementations, the scheduled time is between 0.1 seconds and 0.3 seconds. In various implementations, the scheduled time is 0.2 seconds or less.

[0051] As shown in Figure 5 of this disclosure and Figures 6A-6C The clamping pressure applied to hold the security document 400 between the ultrasonic probe 405 and the mold 410, as discussed, is a parameter that can be fine-tuned to reflect the overall design and manufacturing objectives of the security document 400. In some embodiments, the design and manufacturing objectives of the security document may specify that making the outer surface of the security document as smooth as possible is more important than maximizing the likelihood that the acquired security document is unsuitable for malicious reuse. Therefore, in such embodiments, the predetermined clamping pressure can be reduced to decrease the likelihood that the ultrasonic weld will cause the end product to "dent". In some embodiments, ensuring that the security device, even if successfully acquired, is so significantly altered by the ultrasonic weld that it is unsuitable for malicious reuse is a higher priority than achieving perfect smoothness of the end product. In some embodiments, the design and manufacturing objectives require a visible alteration of the security device by the ultrasonic weld, and simultaneously specify that the surface "dent" of the end product should be minimized by applying a predetermined clamping force during ultrasonic welding.

[0052] In some embodiments according to this disclosure, the design and manufacturing objectives of the end product may be to meet a predetermined clamping pressure of 10 psi or even less. In some embodiments, the design and manufacturing objectives of the end product may be to meet a predetermined clamping pressure between 10 psi and 20 psi. In various embodiments, the design and manufacturing objectives of the end product may be to meet a predetermined clamping pressure between 20 psi and 30 psi. Those skilled in the art will understand that some experimentation is required to find a suitable clamping pressure for a given set of manufacturing and design parameters, because the geometry of feature 419 of die 410 will affect how clamping forces are applied and distributed over the area of ​​security document 400. For example, a die with multiple closely spaced “points” may produce a “bed of nails” effect, where the clamping pressure is distributed over a large number of points, and the clamping force at any one of the raised features of the die is insufficient to cause significant indentation of the end product. Similarly, other die feature geometries, such as extrusions with a trapezoidal shape having a high aspect ratio (e.g., shaped like a kit), may also be affected. The mold features of the separation section of the strip may cause deformation of the substrate or safety device under relatively low clamping pressure.

[0053] refer to Figure 4A In a non-limiting example, the combined action of applying vibrational energy to the clamped section of the security document 400 causes the formation of an ultrasonic weld that bonds the optical security device 415 to one or more of the bottom side 411 or top side 413 of the substrate 417. According to various embodiments, the action of ultrasonically welding the optical security device 415 to the substrate 417 significantly alters the structure of the optical security device 415, thereby reducing its suitability for reuse. In some embodiments, the ultrasonic weld crushes or otherwise structurally damages the micro-optical elements of the optical security device 415, causing a portion of the security device to no longer provide the optical effect of serving as a visual mark or marker of the authenticity of the security document 400. In various embodiments, a predetermined clamping force is used to deform or separate the portion of the optical security device 415 in a manner suitable for reuse (e.g., by causing reference to this disclosure). Figures 5A to 5C (Description of the "punched ticket" effect).

[0054] Although Figure 4A Various aspects of ultrasonically welding the optical safety device 415 to the bridge region of the substrate are shown, but embodiments according to this disclosure are not limited thereto. Specifically, Figure 4B Examples of various aspects of creating an ultrasonic weld in security document 450 are shown, wherein an optical safety device 415 is disposed on the surface of substrate 417 in the region of the ultrasonic weld. Reference Figure 4B In some embodiments, as an illustrative example, the equipment used to create ultrasonic welds in the bridge region can be used in areas where safety devices are located (including, for example,...) Figure 2A An ultrasonic weld is formed in the window area 221, and the safety device surface is mounted in this area or otherwise includes the outer surface of the safety document.

[0055] In some embodiments, the design and manufacturing parameters of the end product require that the ultrasonic welding alters the optical security device 415 without affecting the micro-optical structures that produce the markings used as the authenticity of the security document 450. Therefore, in some embodiments, the optical security device 415 includes an image region 451 and a transition region 453, the image region containing optical microstructures (e.g., focusing elements and image icons) that may be damaged by ultrasonic welding, and the transition region excluding optical structures associated with the signature optical effects of the optical security device 415. In some embodiments, ultrasonic welding is performed in the transition region 453 to achieve the combined goal of securing the optical security device 415 to the substrate 417 in a manner that reduces the applicability of the optical security device 417 to malicious reuse, while simultaneously not negatively impacting the performance of the micro-optical structures in the image region 451.

[0056] Although Figure 4B An example of ultrasonically welding an optical safety device 415 to a substrate 417 is shown, wherein a safety document 450 is passed through an ultrasonic welding apparatus such that the optical safety device 415 faces a mold 410 and the substrate 417 faces the lower surface 407 of an ultrasonic probe 405, but embodiments according to this disclosure are not limited thereto. In some embodiments, the safety document 450 may be “flipped” relative to the ultrasonic probe 405 and the mold 410 such that a feature 419 of the mold 410 contacts the substrate 417 and the ultrasonic probe 405 contacts the optical safety device 415. According to various embodiments, and depending on the profile of the mold 410, the application of a predetermined clamping pressure creates a “bulge” or raised feature in the optical safety device 417. In some embodiments, the “bulge” or raised feature created by applying the predetermined clamping pressure provides a tactile mark of authenticity for the safety document 450. According to some embodiments, the tactile mark created by the clamping portion of the ultrasonic welding process may be one or more of the following: stripes (e.g., as in this disclosure). Figure 6B and Figure 6C As shown), alphanumeric characters (e.g., as in this disclosure). Figure 6A (as shown) or Braille characters (e.g., as shown) Figure 6A (as shown in the image).

[0057] Figure 5A , Figure 5B and Figure 5C Aspects of ultrasonic welding between an optical safety device according to various embodiments of the present disclosure and one or more cellulose surfaces of a substrate are illustrated. For convenience, common elements in the various figures are similarly numbered.

[0058] refer to Figure 5A As a non-limiting example, the accompanying drawings show an intact section of the surface of the optical safety device 500. According to certain embodiments, when incorporated into a security document (e.g., Figure 2A In the security document 200, some or all of the visible portion of the optical safety device 500, as described in the document, refers to... Figure 5A As shown in the illustration. Specifically, in some embodiments, the visible portion of the optical security device 500 includes a first undamaged edge 501A and a second undamaged edge 501B, as well as an undamaged image region 503 that provides a distinctive optical effect, which, when incorporated into a security document, provides an optical marker of the document's authenticity. As shown in this disclosure... Figure 1 As mentioned in the discussion, for many malicious actors, obtaining as many intact optical security devices as possible is a primary goal of their acquisition efforts. For example... Figure 5B and Figure 5C As illustrated in the explanatory examples, certain embodiments of this disclosure help prevent malicious actors from achieving this objective, particularly by reducing the length of the intact optical security device 500 that can be used for acquisition.

[0059] Figure 5B Substrate 510 is provided (e.g., Figure 3 A surface view of one side of a segment of the substrate 350, where a segment of the optical safety device 520 has been ultrasonically welded to the opposite side of the substrate. In some embodiments, Figure 5B The section of substrate 510 shown corresponds to the substrate in an embedded optical security device (e.g., such as...). Figure 2A The bridge area shown in the figure (e.g., Figure 2A A portion of the bridge region 223. In some implementations, Figure 5B The section of substrate 510 shown corresponds to the bottom surface of the security document, where the security device has been surface-mounted (e.g., as shown in the image). Figure 2B (as shown in the diagram) to the opposite side.

[0060] refer to Figure 5BAs a non-limiting example, the surface appearance of the section of substrate 510 covering the ultrasonic weld formed according to embodiments of the present disclosure can be finely tuned by adjusting the predetermined clamping pressure used during the ultrasonic welding process. It should be noted that the specific number of pounds of clamping pressure associated with a particular surface appearance on a section of the substrate covering the ultrasonic weld can depend on a variety of variables, including but not limited to the thickness of the section of substrate covering, the thickness of the optical safety device, and the surface area and shape of the welding die (e.g., die 410 in FIG. 4). According to some embodiments, when using a lower predetermined clamping pressure (in some embodiments, a clamping pressure of ~10 p.si), the area of ​​substrate 511 directly covering the ultrasonic weld exhibits minimal (if any) deformation from the ultrasonic welding process. In various embodiments according to the present disclosure, when an intermediate clamping pressure (in some embodiments, ~20 p.si) is applied during the welding process, the area of ​​substrate 513 directly covering the ultrasonic weld exhibits moderate surface deflection. According to various embodiments, the surface deflection is a function of the pattern height of the welding die. In some embodiments of this disclosure, under high clamping pressure (~30 p.si according to various embodiments of this disclosure), the substrate region directly covering the ultrasonic weld exhibits a significant (according to safety documentation standards) deflection relative to the surrounding region of the substrate 510 (e.g., a deflection greater than or equal to the thickness of the optical safety device 520).

[0061] Figure 5C Provided Figure 5B The corresponding view shows a view of the opposite sides of a segment of substrate 510, showing the relationship with... Figure 5B An optical safety device 520 in the region associated with an ultrasonic weld performed under different clamping pressures, as in a non-limiting example. Figure 5C As shown in the non-limiting example, in some embodiments using a lower predetermined clamping pressure, the surface profile of the optical safety device 520 is deformed in the region 521 of the optical safety device 520 that directly covers the ultrasonic weld. However, in this illustrative example, the ultrasonic weld remains confined to a single surface of the optical safety device 520. According to some embodiments, a “recess” or unilateral deformation of a portion of the optical safety device 520 in region 521 can be advantageously employed to provide tactile features (e.g., Braille letters or shape patterns) in the safety document.

[0062] According to some embodiments, under intermediate clamping pressure, the region 523 of the optical safety device 520 near the ultrasonic weld seam is significantly altered so that it appears different from the intact section of the optical safety device 500 or ceases to function. Depending on the shape of the mold used, the alteration of the optical safety device manifests as a "punched ticket" effect, where previously continuous boundaries (e.g., Figure 5AThe second unbroken edge 501B in the ultrasonic weld is broken. In some embodiments, the clamping action may leave “dangling debris” 524 of material in the area around the ultrasonic weld. In such embodiments, it is believed that the ultrasonic weld can extend to the second surface of the optical security device, since the effect of the welding process is visible on the welded side of the optical security device 520 at the interface between the optical security device and the substrate 510. According to various embodiments, the aforementioned “punched ticket” and “dangling debris” effects created by increasing the clamping pressure can be hidden from the viewing surface of the security document (e.g., in the bridge area) and simultaneously advantageously reduce the number of optical security devices 520 that, if successfully obtained, are suitable for malicious reuse.

[0063] like Figure 5C As illustrated in the illustrative example, the "punched ticket" or "dangling debris" effect shown in region 523 can be amplified by increasing the clamping pressure during ultrasonic welding (e.g., to further ensure that fewer optical security devices 520 are suitable for recycling in counterfeit security documents). According to various embodiments, by applying greater clamping pressure, the region 525 of the optical security device near the ultrasonic weld, and portion 526 of the optical security device 520, can be loosened or completely separated from the rest of the optical security device 520, thereby denying counterfeiters the opportunity to attempt to repair the optical security device 520 to make it appear intact.

[0064] As discussed elsewhere in this disclosure, in addition to providing a bonding portion between the optical security device and the cellulose surface of the substrate and a mechanism to make the parts of the optical security device less suitable for reuse, ultrasonic welding of the optical security device according to certain embodiments of this disclosure can also enhance the functionality of the security document by providing tactile markings to supplement the visual features of the security document.

[0065] Figures 6A to 6C Examples of tactile features formed in an optical safety device by ultrasonic welding according to certain embodiments of the present disclosure are shown.

[0066] refer to Figure 6A A non-limiting example, the accompanying drawings provide an optical safety device 600 (e.g., Figure 3 The illustration shows a section of the optical safety device 600 (601a and 601b) that appears after ultrasonic welding to the cellulose surface. In this non-limiting example, the figures show two regions (601a and 601b) of the optical safety device 600, which include a raised portion of the optical safety device 600 on the surface of the ultrasonic weld adjacent to the cellulose surface formed according to certain embodiments of the present disclosure.

[0067] refer to Figure 6AAn illustrative example is that by clamping the optical security device 600 and the cellulose surface of the substrate between a mold and an ultrasonic probe, while applying vibrational energy to form an ultrasonic weld, a raised patterned form based on the shape of the mold can be formed in the optical security device. Depending on the placement of the ultrasonic weld and the mold used, these raised patterned forms can provide tactile markings of identity (e.g., the denomination of banknotes) or the authenticity of security documents. According to some embodiments, and as shown in region 601a, the raised features created during ultrasonic welding include one or more alphanumeric characters, such as the number "100". According to embodiments, the tactile features formed by ultrasonic welding can have a scale (e.g., on the order of 50-100 micrometers) such that the feature feels like a single "bump" or "dot" when touched, but appears as a number or patterned feature when viewed under a magnifying glass. In some embodiments, creating this level of microscopic detail provides further marking of the authenticity of security documents and a technical challenge to potential counterfeiters. In some implementations, and as shown in region 601b, the raised features created during ultrasonic welding are spaced apart and formed to provide different features that can be distinguished by the user's touch, such as Braille letters.

[0068] Figure 6B Various embodiments of the present disclosure are shown in the optical safety device 610 (e.g., during ultrasonic welding to a cellulose surface). Figure 3 Examples of tactile features provided on the surface of the optical security device 610 (300 in the document). According to some embodiments, the optical security device 610 includes microstructures (e.g., microlenses, diffraction gratings, or other structures of similar scale) that produce distinctive optical effects. Given the size and precise positioning of such microstructures, ultrasonically welding the optical security device to the cellulose surface according to some embodiments of this disclosure may damage or destroy the appearance of the distinctive optical effects in the area surrounding the ultrasonic weld. In some embodiments (e.g., embodiments where the ultrasonic weld is formed in the bridge region of the security document), such damage may be advantageous because it reduces the length of the potentially reusable segment of the optical security device. In some embodiments, the design parameters of the security document (e.g., where the ultrasonic weld will be provided in the area of ​​the security document where the optical security device 610 is mounted to the surface) may make it undesirable for the ultrasonic weld to significantly damage the microstructures supporting the optical effects.

[0069] refer to Figure 6B As a non-limiting example, the visible surface of the optical safety device 610 includes one or more effect regions (e.g., effect region 615) and one or more transition regions (e.g., transition region 620). According to various embodiments, effect region 615 includes a region within the optical safety device 610 that includes microstructures that contribute to providing a distinctive optical effect (e.g., Figure 3 The array of focusing elements 305 in the image). In some embodiments according to this disclosure, the transition region 620 includes a section of the optical safety device 610 in which no microstructure is provided, or alternatively, a section of the optical safety device 610 in which microstructure is present but which is highlighted in the design of the optical safety device as a white space, and thus the optical effect provided by the optical safety device 610 is not detected to be damaged during the ultrasonic welding process. According to some embodiments, the transition region 620 is formed by ultrasonic welding to an optical spacer (e.g., ...) onto the cellulose surface. Figure 3 The optical safety device 610 consists of optical spacers 310. In some embodiments, in addition to the ultrasonic weld, the optical safety device 610 is adhered to the cellulose surface using an adhesive such as an acrylic, thermoplastic, or thermosetting adhesive. According to some embodiments, an ultrasonic weld is formed in the transition region 620 to create a tactile feature (e.g., tactile feature 625) in one or more shapes, including but not limited to stripes, dots, circles, and their patterns. Figure 6C Another illustrative example is provided of a raised tactile feature 630 formed in the transition region 635 of an optical security device according to some embodiments of the present disclosure.

[0070] Although Figures 6A to 6C An example of a tactile feature protruding relative to the viewing surface of an optical security device, created by ultrasonic welding, is shown, but embodiments according to this disclosure are not limited thereto and cover tactile features that are reduced relative to the viewing surface of the optical security device (e.g., depressions or dents in the surface of the optical security device).

[0071] Figure 7 Operation of a method 700 for creating security documents according to various embodiments of the present disclosure is shown.

[0072] refer to Figure 7 In a non-limiting example, at operation 705, an optical safety device (e.g., Figure 5A The optical safety device 500 or a segment thereof is positioned on a first surface of the substrate. In some embodiments, the first surface of the substrate comprises a cellulose material, such as wood pulp or cotton fiber. According to some embodiments, the first surface of the substrate may be an outer surface of the substrate (e.g., the location for surface mounting of the optical safety device) or an inner surface of the substrate, such as a surface formed by bridge regions (e.g., Figure 2A The bridge region 223 in the middle is provided. In some embodiments, the optical security device is positioned by a station within a larger device used to perform the roll-to-roll process for manufacturing security documents, such as a paper machine or printing press (e.g., (The machine). In some embodiments, the optical safety device is positioned at the wet end of the paper machine and held in place with adhesive during substrate formation, followed by subsequent ultrasonic welding. In some embodiments, the optical safety device is positioned on the substrate at the dry end of the paper machine.

[0073] like Figure 7 As shown in the illustrative example, at operation 710, once positioned, the optical safety device and the substrate are clamped together with a predetermined clamping pressure, said predetermined clamping pressure being exerted by an ultrasonic probe (e.g., Figure 4A The ultrasonic probe 405 and the mold (e.g., Figure 4A The mold 410 is applied. In some embodiments according to this disclosure, the mold has one or more features (e.g., feature 419) that concentrate contact pressure to create a tactile structure (e.g., in one or more of a substrate or optical safety device near the ultrasonic weld) Figure 6A (Braille letters in region 601b). According to some embodiments, a predetermined clamping pressure is selected in the region close to the ultrasonic weld (e.g., Figure 5C Visible changes occur in region 525. In some embodiments, the optical safety device is clamped in the transition region (e.g., Figure 6B The transition region 620 is used to avoid altering the distinctive visual effects produced by the microstructure in the optical safety device.

[0074] refer to Figure 7 In a non-limiting example, at operation 715, when the optical safety device and the substrate are clamped together, vibrational energy is applied via an ultrasonic probe for a predetermined time to form an ultrasonic weld. In some embodiments according to this disclosure, the predetermined time is greater than 0.25 seconds. In various embodiments, the predetermined time is 0.25 seconds or less. In at least one embodiment according to this disclosure, the predetermined welding time is 0.15 seconds or less. In various embodiments according to this disclosure, the predetermined welding time is 0.1 seconds or less.

[0075] Examples of security documents according to certain embodiments of this disclosure include a security document comprising: a substrate including a first surface and a second surface opposite to the first surface, the first surface comprising a cellulose material; an optical security device including an optical mark for the authenticity of the security document and a third surface comprising a thermoplastic polymer; and an ultrasonic weld forming an adhesive portion between a segment of the first surface and a segment of the third surface.

[0076] Examples of safety documents according to certain embodiments of this disclosure include safety documents in which the cellulose material includes at least one of the following: wood pulp, cotton fiber, flax fiber, flax cloth fiber, sisal fiber, hemp fiber, Abaca fiber, Kozo fiber, Mitsumata fiber, bamboo fiber, or Kenaf fiber.

[0077] Examples of security documents according to certain embodiments of this disclosure include security documents in which the thermoplastic polymer includes at least one of polyester, polyethylene terephthalate (PET), polypropylene, polyethylene, or nylon.

[0078] Examples of security documents according to certain embodiments of this disclosure include security documents in which an ultrasonic weld contacts the second surface of a substrate.

[0079] Examples of security documents according to certain embodiments of this disclosure include a security document that further includes: a window region; and a bridge region, wherein a first portion of the optical security device is embedded within the bridge region, wherein an ultrasonic weld is disposed within the bridge region, and wherein a second portion of the optical security device is visible in the window region.

[0080] Examples of security documents according to certain embodiments of this disclosure include security documents in which the optical markings of authenticity are damaged in the area of ​​the optical security device near the ultrasonic weld.

[0081] Examples of security documents according to certain embodiments of this disclosure include security documents in which the optical security device is a micro-optical security device comprising a focusing element and an image icon element.

[0082] Examples of security documents according to certain embodiments of this disclosure include security documents in which an optical security device is surface-mounted to a first surface of a substrate.

[0083] Examples of security documents according to certain embodiments of this disclosure include security documents in which the optical security device is a micro-optical security device including an effect region comprising a layer of focusing elements and a layer of image icon elements, wherein the optical security device includes a transition region, and wherein an ultrasonic weld is disposed in the transition region.

[0084] Examples of security documents according to certain embodiments of this disclosure include security documents that also include raised portions comprising ultrasonic welds.

[0085] Examples of security documents according to certain embodiments of this disclosure include security documents in which raised portions include tactile markings indicating the authenticity of the security document.

[0086] Examples of security documents according to certain embodiments of this disclosure include security documents in which tactile markings of authenticity include at least one of bars, dots, solid circles, solid patterns, alphanumeric characters, or Braille characters.

[0087] Examples of security documents according to certain embodiments of this disclosure include security documents in which optical security devices include machine-readable security features.

[0088] Examples of security documents according to certain embodiments of this disclosure include security documents in which a third surface is coated with one or more of acrylate, thermoplastic or thermosetting adhesive.

[0089] Examples of methods for producing security documents according to certain embodiments of this disclosure include methods comprising: positioning an optical security device on a first surface of a substrate, wherein the substrate includes a first surface and a second surface opposite to the first surface, the first surface comprising a cellulose material, and the optical security device including an optical mark of authenticity for the security document and a third surface comprising a thermoplastic polymer; clamping the optical security device and the substrate together under a predetermined clamping pressure applied by an ultrasonic probe and a mold; and while the optical security device and the substrate are clamped together, applying vibrational energy through the ultrasonic probe for a predetermined welding time to produce an ultrasonic weld that bonds a segment of the first surface to a segment of the third surface.

[0090] Examples of methods for producing security documents according to certain embodiments of this disclosure include methods in which an optical security device is positioned on a first surface of a substrate at the wet end of a paper machine.

[0091] Examples of methods for producing security documents according to certain embodiments of this disclosure include methods in which an optical security device is positioned on a first surface of a substrate at the dry end of a paper machine.

[0092] Examples of methods for producing security documents according to certain embodiments of this disclosure include methods in which vibrational energy is applied to the dry end of a paper machine.

[0093] Examples of methods for producing security documents according to certain embodiments of this disclosure include methods in which vibrational energy is applied to a printing press.

[0094] Examples of methods for producing security documents according to certain embodiments of this disclosure include methods in which positioning an optical security device on a first surface of a substrate is performed as part of a roll-to-roll manufacturing process.

[0095] Examples of methods for producing security documents according to certain embodiments of this disclosure include methods in which clamping the optical security device and the substrate together at a predetermined clamping pressure is performed as part of a roll-to-roll manufacturing process.

[0096] Examples of methods for producing security documentation according to certain embodiments of this disclosure include methods in which applying vibrational energy via an ultrasonic probe to generate an ultrasonic weld that bonds a portion of a first surface to a portion of a third surface is performed as part of a roll-to-roll manufacturing process.

[0097] Examples of methods for producing safety documentation according to certain embodiments of this disclosure include methods in which the predetermined clamping pressure is less than 30 psi.

[0098] Examples of methods for producing safety documentation according to certain embodiments of this disclosure include methods in which the predetermined clamping pressure is less than 20 psi.

[0099] Examples of methods for producing safety documents according to certain embodiments of this disclosure include methods in which the predetermined clamping pressure is less than 10 psi.

[0100] Examples of methods for producing security documentation according to certain embodiments of this disclosure include methods in which the predetermined welding time is greater than 0.25 seconds.

[0101] Examples of methods for producing security documents according to certain embodiments of this disclosure include methods in which the predetermined welding time is 0.25 seconds or less.

[0102] Examples of methods for producing security documents according to certain embodiments of this disclosure include methods in which the predetermined welding time is 0.15 seconds or less.

[0103] Examples of methods for producing security documents according to certain embodiments of this disclosure include methods in which the predetermined welding time is 0.1 seconds or less.

[0104] Examples of methods for producing security documents according to certain embodiments of this disclosure include methods in which the cellulose material includes at least one of the following: wood pulp, cotton fiber, flax fiber, linen fiber, sisal fiber, hemp fiber, Abaca fiber, Kozo fiber, Mitsumata fiber, bamboo fiber, or Kenaf fiber.

[0105] Examples of methods for producing security documentation according to certain embodiments of this disclosure include methods in which the thermoplastic polymer includes at least one of polyester, polyethylene terephthalate (PET), polypropylene, polyethylene, or nylon.

[0106] Examples of methods for producing security documentation according to certain embodiments of this disclosure include methods in which an ultrasonic weld contacts a second surface of a substrate.

[0107] Examples of methods for producing security documents according to certain embodiments of this disclosure include methods in which an optical security device is positioned on a first surface of a substrate in a manner that defines a window region and a bridge region, wherein a first portion of the optical security device is embedded within the bridge region, wherein an ultrasonic weld is disposed within the bridge region, and wherein a second portion of the optical security device is visible in the window region.

[0108] Examples of methods for producing security documents according to certain embodiments of this disclosure include methods in which clamping the optical security device and the substrate together with a predetermined clamping pressure damages the authenticity of the optical markings in the region near the ultrasonic weld of the optical security device.

[0109] Examples of methods for creating security documents according to certain embodiments of this disclosure include methods in which the optical security device is a micro-optical security device comprising a focusing element and an image icon element.

[0110] Examples of methods for creating security documents according to certain embodiments of this disclosure include methods in which positioning an optical security device on a first surface of a substrate includes mounting the optical security device surface to the first surface of the substrate.

[0111] Examples of methods for producing security documents according to certain embodiments of this disclosure include methods in which the optical security device is a micro-optical security device including an effect region comprising a layer of focusing elements and a layer of image icon elements, wherein the optical security device includes a transition region, and wherein an ultrasonic weld is disposed in the transition region.

[0112] Examples of methods for producing security documents according to certain embodiments of this disclosure include methods in which an optical security device and a substrate are clamped together and vibrational energy is applied to generate an ultrasonic weld to form a raised portion including the ultrasonic weld.

[0113] Examples of methods for creating security documents according to certain embodiments of this disclosure include methods in which raised portions include tactile markings of the authenticity of the security document.

[0114] Examples of methods for creating security documents according to certain embodiments of this disclosure include methods in which tactile markings of authenticity include at least one of bars, dots, alphanumeric characters, solid patterns, or Braille characters.

[0115] Examples of methods for creating security documents according to certain embodiments of this disclosure include methods in which the optical security device includes machine-readable security features.

[0116] Examples of methods for producing security documents according to certain embodiments of this disclosure include methods in which an optical security device and a substrate are clamped together under a predetermined clamping pressure applied by an ultrasonic probe and a mold, and an ultrasonic weld is performed as part of a printing process, in which vibrational energy is applied by the ultrasonic probe for a predetermined welding time to produce an ultrasonic weld that bonds a segment of a first surface to a segment of a third surface.

[0117] This disclosure should not be construed as implying that any particular element, step, or function is a fundamental element, step, or function that must be included within the scope of the claims. Furthermore, unless a participle follows the exact phrase “for a means of…”, the claims are not intended to invoke 35 USC §112(f).

Claims

1. A security document (200) comprising: Substrate (205), the substrate comprising a first surface and a second surface opposite to the first surface, the first surface comprising a cellulose material; An optical security device (220) includes an optical mark for the authenticity of the security document and a third surface, the third surface comprising a thermoplastic polymer; An ultrasonic weld (225) forms an adhesive portion between a segment of the first surface and a segment of the third surface; Window area (221); and Bridge area (223), The first part of the optical safety device is embedded in the bridge area. The ultrasonic weld is located in the bridge region, and The second part of the optical safety device is visible in the window area.

2. The security document of claim 1, wherein the cellulose material comprises at least one of the following: wood pulp, cotton fiber, flax fiber, sisal fiber, hemp fiber, Abaca fiber, Kozo fiber, Mitsumata fiber, bamboo fiber, or Kenaf fiber.

3. The security document as claimed in claim 2, wherein the flax fiber is linen fiber.

4. The security document of claim 1, wherein the thermoplastic polymer comprises at least one of polyester, polyethylene terephthalate (PET), polypropylene, polyethylene, or nylon.

5. The security document of claim 1, wherein the ultrasonic weld contacts the second surface of the substrate.

6. The security document as claimed in claim 1, wherein the optical mark of authenticity is damaged in the region of the optical security device near the ultrasonic weld.

7. The security document as claimed in claim 1, wherein the optical security device is a micro optical security device (300) comprising a focusing element (305) and an image icon element (321).

8. The security document of claim 1, wherein the optical security device is surface-mounted to the first surface of the substrate.

9. The security document of claim 1, further comprising a raised portion including the ultrasonic weld.

10. The security document of claim 9, wherein the raised portion includes a tactile marker (601a) indicating the authenticity of the security document.

11. The security document of claim 10, wherein the tactile markings of authenticity include at least one of bars, dots, solid patterns, alphanumeric characters, or Braille characters.

12. The security document of claim 11, wherein the solid pattern is a solid circle.

13. The security document of claim 1, wherein the optical security device includes machine-readable security features.

14. The security document of claim 1, wherein the third surface is coated with one or more of a thermoplastic or thermosetting adhesive.

15. The security document of claim 14, wherein the thermosetting adhesive is an acrylate.

16. A security document (200) comprising: Substrate (205), the substrate comprising a first surface and a second surface opposite to the first surface, the first surface comprising a cellulose material; An optical security device (220) includes an optical mark for the authenticity of the security document and a third surface, the third surface comprising a thermoplastic polymer; as well as An ultrasonic weld (225) forms an adhesive portion between a segment of the first surface and a segment of the third surface. The optical safety device described therein is a micro optical safety device including an effect area (615), the effect area comprising a focusing element and an image icon element. The optical safety device includes a transition region (620), and The ultrasonic weld is located in the transition region.

17. A method for creating a security document, the method comprising: An optical security device is positioned on a first surface of a substrate, wherein the substrate includes the first surface and a second surface opposite to the first surface, the first surface comprising a cellulose material, and the optical security device includes an optical mark for the authenticity of the security document and a third surface comprising a thermoplastic polymer; The optical safety device and the substrate are clamped together under a predetermined clamping pressure applied by the ultrasonic probe and the mold; as well as While the optical safety device and the substrate are clamped together, vibrational energy is applied through the ultrasonic probe within a predetermined welding time to generate an ultrasonic weld that bonds a segment of the first surface to a segment of the third surface. The optical safety device is positioned on the first surface of the substrate by defining a window area and a bridge area. The first part of the optical safety device is embedded in the bridge area. The ultrasonic weld is located in the bridge region, and The second part of the optical safety device is visible in the window area.

18. The method of claim 17, wherein the optical safety device is positioned on the first surface of the substrate at the wet end of the paper machine.

19. The method of claim 17, wherein the optical safety device is positioned on the first surface of the substrate at the dry end of the paper machine.

20. The method of claim 17, wherein the vibrational energy is applied at the dry end of the paper machine.

21. The method of claim 17, wherein the vibrational energy is applied to the printing press.

22. The method of claim 17, wherein positioning the optical safety device on the first surface of the substrate is performed as part of a roll-to-roll manufacturing process.

23. The method of claim 17, wherein clamping the optical safety device and the substrate together with a predetermined clamping pressure is performed as part of a roll-to-roll manufacturing process.

24. The method of claim 17, wherein performing the application of vibrational energy through the ultrasonic probe to generate an ultrasonic weld that bonds a portion of the first surface to a portion of the third surface is part of a roll-to-roll manufacturing process.

25. The method of claim 17, wherein the predetermined clamping pressure is less than 30 pounds per square inch (psi).

26. The method of claim 17, wherein the predetermined clamping pressure is less than 20 psi.

27. The method of claim 17, wherein the predetermined clamping pressure is less than 10 psi.

28. The method of claim 17, wherein the predetermined welding time is greater than 0.25 seconds.

29. The method of claim 17, wherein the predetermined welding time is 0.25 seconds or less.

30. The method of claim 17, wherein the predetermined welding time is 0.15 seconds or less.

31. The method of claim 17, wherein the predetermined welding time is 0.1 seconds or less.

32. The method of claim 17, wherein the cellulose material comprises at least one of the following: wood pulp, cotton fiber, flax fiber, sisal fiber, hemp fiber, Abaca fiber, Kozo fiber, Mitsumata fiber, bamboo fiber, or Kenaf fiber.

33. The method of claim 32, wherein the flax fiber is flax cloth fiber.

34. The method of claim 17, wherein the thermoplastic polymer comprises at least one of polyester, polyethylene terephthalate (PET), polypropylene, polyethylene, or nylon.

35. The method of claim 17, wherein the ultrasonic weld contacts the second surface of the substrate.

36. The method of claim 17, wherein clamping the optical safety device and the substrate together with a predetermined clamping pressure damages the authenticity of the optical mark in the region of the optical safety device near the ultrasonic weld.

37. The method of claim 17, wherein the optical security device is a micro optical security device comprising a focusing element and an image icon element.

38. The method of claim 17, wherein positioning the optical safety device on the first surface of the substrate comprises mounting the surface of the optical safety device to the first surface of the substrate.

39. The method of claim 17, wherein clamping the optical safety device and the substrate together and applying vibrational energy to generate an ultrasonic weld forms a raised portion including the ultrasonic weld.

40. The method of claim 39, wherein the raised portion includes a tactile marker indicating the authenticity of the security document.

41. The method of claim 40, wherein the tactile markers of authenticity include at least one of bars, dots, alphanumeric characters, solid patterns, or Braille characters.

42. The method of claim 17, wherein the optical security device includes a machine-readable security feature.

43. The method of claim 17, wherein the optical safety device and the substrate are clamped together under a predetermined clamping pressure applied by the ultrasonic probe and the mold, and an ultrasonic weld is performed as part of the printing process, in which vibrational energy is applied by the ultrasonic probe for a predetermined welding time to generate an ultrasonic weld that bonds a segment of the first surface to a segment of the third surface.

44. A method for creating a security document, the method comprising: An optical security device is positioned on a first surface of a substrate, wherein the substrate includes the first surface and a second surface opposite to the first surface, the first surface comprising a cellulose material, and the optical security device includes an optical mark for the authenticity of the security document and a third surface comprising a thermoplastic polymer; The optical safety device and the substrate are clamped together under a predetermined clamping pressure applied by the ultrasonic probe and the mold; as well as While the optical safety device and the substrate are clamped together, vibrational energy is applied through the ultrasonic probe within a predetermined welding time to generate an ultrasonic weld that bonds a segment of the first surface to a segment of the third surface. The optical safety device described therein is a micro-optical safety device that includes an effect area, the effect area comprising a focusing element layer and an image icon layer. The optical safety device includes a transition region, and The ultrasonic weld is located in the transition region.

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