Method for generating a data carrier and a data carrier generated therefrom

Abstract

A method for forming a data carrier for a security document comprises the steps of providing a first outer layer and a second outer layer, forming a first security feature at an interface between at least two adjacent layers, wherein the first security feature comprises a first deformation of the surface of one of the layers, and forming a stacked structure with the first outer layer and the second outer layer, wherein the stacked structure is formed by lamination, and the first deformation of the surface of one of the layers is replicated during lamination so that at least one replicated deformation is formed inside the data carrier at an interface between at least some of the layers.

Description

Technology Field

[0001] The present invention relates to a method for generating a data carrier, a data carrier generated therefrom, and a security document comprising or composed of such a data carrier.

[0002] Prior art

[0003] Data carriers for security documents, such as identification cards and passports, typically include at least one security element. This security element may be provided on the top surface of the data carrier. A well-known method for protecting data is surface embossing created by lamination plates. A disadvantage of such a method is that the security feature can be duplicated, removed, and / or replaced. It is also possible to create a similar surface embossing by desktop printing, a combination of adhesives and suitable particles, etc. Consequently, such security elements are vulnerable to forgery.

[0004] The objective of the present invention is to provide a method for forming a data carrier for a secure document that has greater security and is particularly less vulnerable to forgery.

[0005] This objective is achieved by the method according to claim 1. In particular, a method for forming a data carrier for a security document is provided, and the method comprises:

[0006] - A step of providing a first outer layer and a second outer layer,

[0007] - forming a first security feature at an interface between at least two adjacent layers - said first security feature comprises a first deformation of the surface of one of the layers -, and

[0008] - A step of forming a laminated structure with the first outer layer and the second outer layer - the laminated structure is formed by lamination - including,

[0009] A first deformation of the surface of one of the layers is replicated during lamination, and at least one replicated deformation is formed inside the data carrier at the interface between at least some of the layers.

[0010] This method allows for the complete formation of security features within the data carrier, which survive the lamination and leave a pre-made and designed deformation at the interface between some of the layers. This first security feature may also be referred to as an interface security feature because it is located at the interface between some of the layers of the data carrier. Since the security feature is located within the data carrier, data removal becomes more complex, as grinding the data carrier will simultaneously remove the designed deformation. Furthermore, because the first deformation is formed before the laminated structure of the data carrier is formed by lamination, it will be particularly difficult for a counterfeiter to modify the first deformation and the corresponding security feature after the lamination step. Therefore, the security feature is less vulnerable to copying, duplication, or modification by a counterfeiter. The data carrier obtained by this method enables subsequent personalization, such as laser engraving. In the same way, this method of marking the data carrier does not negatively interfere with embossing or diffractive surface elements. It enables various possibilities in terms of design and feature visibility, and can be overt or covert if necessary. Finally, this method can leave the outer surface of the data carrier completely smooth and intact.

[0011] This method is particularly advantageous because it is compatible with a wide range of techniques for forming the first deformation, and thus allows for strong compatibility with existing methods and equipment. In practice, the first deformation of the surface of one of the layers can be created by deformation of the material, by added material, and / or by removal of material. Different techniques for forming the first deformation of the surface of one of the layers will be discussed further later.

[0012] The method according to the present invention may include one of the following features, which are taken individually or in any possible combination:

[0013] - Before forming a laminated structure by lamination, a revealing material is applied to a first deformation on the surface of one of the layers, so that the revealing material comes into contact with the first deformation on the surface of one of the layers.

[0014] - The exposure material is a reflective material that amplifies optical effects produced by a first deformation of the surface, and said exposure material comprises or is composed of printing inks (particularly reflective inks), silk screen inks, metallic reflective materials (e.g., aluminum, silver, gold, copper and / or chromium), dielectric materials (e.g., silica (SiO₂), titania (TiO₂), and magnesium fluoride (MgF₂)), and colored reflective materials (e.g., metal flakes found particularly in printing inks or coatings, pearlescent pigments).

[0015] - The exposed material is applied to the first deformation by printing and / or coating,

[0016] - The exposed material is applied to the first deformation by silk screen printing,

[0017] - The data carrier comprises at least one exposed layer facing a first deformation on the surface of one of the layers, wherein the exposed layer contacts the first deformation on the surface of one of the layers.

[0018] - The exposed layer includes replicated variations,

[0019] - At least one exposed layer covers a surface larger than the surface covered by the first deformation of the surface of one of the layers,

[0020] - At least one exposed layer covers substantially all surface of the layer having the first deformation,

[0021] - The data carrier includes at least one inner layer,

[0022] - At least one inner layer has a first refractive index (rf1) and the exposure material has a second refractive index (rf2), and the first refractive index (rf1) is different from the second refractive index (rf2).

[0023] - The inner layer includes deformation,

[0024] - At least one inner layer includes a core layer,

[0025] - The core layer includes a first deformation,

[0026] - A first deformation of the surface of one of the layers is formed by heating the layer,

[0027] - A first deformation of the surface of one of the layers is preferably formed by a laser cutter, by laser deformation, by pre-lamination, by hot stamping, and / or by welding of said layer,

[0028] - A first deformation of the surface of one of the layers is formed without heating the layer,

[0029] - A first deformation of the surface of one of the layers is formed by a knife cutter and / or by the use of lacquer or varnish to create an embossing on the layer,

[0030] - A first deformation of the surface of one of the layers is formed by a deformation of the material of said layer,

[0031] - A first deformation of the surface of one of the layers is formed by laser deformation, by pre-lamination, by hot stamping, and / or by welding of said layer,

[0032] - A first deformation of the surface of one of the layers is formed by the addition of a material to the surface of said layer,

[0033] - A first deformation of the surface of one of the layers is formed by the use of lacquer or varnish to create an embossing on the layer,

[0034] - A first deformation of the surface of one of the layers is formed by the removal or ablation of the material of said layer,

[0035] - The first deformation of the surface of one of the layers is formed by a knife cutter and / or a laser cutter,

[0036] - The method includes the step of forming a second security feature,

[0037] - The second security feature is formed by laser engraving,

[0038] - The method includes a step of forming personalization elements,

[0039] - The personalization element overlaps at least partially with the first security feature along the extension direction,

[0040] - The method includes the step of forming a see-through portion,

[0041] - The viewing portion overlaps at least partially with the first security feature along the extension direction of the data carrier,

[0042] - The personalization element overlaps at least partially with the viewing portion and the first security feature portion along the extension direction.

[0043] The layers of the data carrier preferably comprise or are composed of one or more polymers, such as at least one plastic and / or thermoplastic polymer or a thermosetting polymer. The layers of the data carrier preferably comprise or are composed of polycarbonate (PC) and / or polyvinyl chloride (PVC) and / or polyethylene terephthalate (PET) and / or polyethylene (PE) and / or cross-linked polyethylene and / or polypropylene (PP) and / or copolymers thereof and / or mixtures thereof. The layers of the data carrier are not necessarily made of the same material. It is more preferable that the data carrier be provided by one or more layers, that is, it preferably corresponds to a layered structure. The data carrier particularly preferably corresponds to a card body as known in the field of the present invention.

[0044] Depending on the technique for forming the first deformation, different types of deformation with varying intensities and extensive depths, heights, widths, and profiles may be produced. Depending on the intensity of this deformation, the visibility of the marking may vary. The marking is overt and visible to the naked eye. On the other hand, the marking may be intangible and may require the use of magnification, such as a loupe, microscope, and / or different lighting conditions, to be visible.

[0045] The term "replicated deformation" corresponds to deformation of layers adjacent to a layer having a first deformation on its surface. The replicated deformation is induced by the first deformation through a lamination process. The first deformation on the surface of one of the layers is replicated to at least one adjacent layer. The first deformation may be replicated to multiple adjacent layers, so that the data carrier formed by the present method includes multiple replicated deformations of the first deformation on the surface of one of the layers. However, the replicated deformation is not on the outermost surface of the data carrier obtained by the present method. The replicated deformation and the first deformation are aligned along the extension direction (E). The replicated deformation has a profile that is significantly similar to the profile of the first deformation. In other words, if the deformation includes recesses, bumps, and / or dips, the replicated deformation includes similar recesses, bumps, and / or dips. However, the height and depth of the recesses, bumps and / or dips of the replicated deformation along the extension direction (E) may be lower than those of the original deformation, and thus the amplitude of the recesses, bumps and / or dips of the replicated deformation along the extension direction (E) is reduced compared to the original deformation.

[0046] The structure of the data carrier may include several internal layers. Among such internal layers, the data carrier may include a core layer. Advantageously, at least one internal layer, such as the core layer, includes a first variation.

[0047] Advantageously, before forming a laminated structure by lamination, an exposure material is applied onto a first deformation on the surface of one of the layers, so that the exposure material comes into contact with said first deformation on the surface of one of the layers. The exposure material is a reflective material that amplifies the optical effects generated by the first deformation on the surface. The materials used in this coating are designed to maximize reflectivity and visual effects such as color shifts or holographic appearances.

[0048] Preferably, the exposure material comprises or consists of printing inks, particularly reflective inks and silk screen inks. The exposure material may also comprise metallic reflective materials, particularly aluminum, silver, gold, copper, and / or chrome. In that case, the first modification of the surface may be metallized. The exposure material may also comprise dielectric materials, particularly silica (SiO₂), titania (TiO₂), and magnesium fluoride (MgF₂). The exposure material may also comprise colored reflective materials, particularly metal flakes and pearlescent pigments found in printing inks or coatings. The exposure material may comprise or consist of any of the aforementioned materials alone or in combination.

[0049] Preferably, at least one inner layer has a first refractive index (rf1) and the exposed material has a second refractive index (rf2), and the first refractive index (rf1) is different from the second refractive index (rf2).

[0050] Advantageously, the exposed material is applied to the first deformation by printing and / or coating. In a particularly advantageous embodiment, the exposed material is applied to the first deformation by silk screen printing.

[0051] Alternatively, the data carrier may include at least one exposed layer comprising an exposed material. In this case, the exposed material is included in an independent layer, i.e., the exposed layer, which is applied to a first deformation of the surface during lamination when forming a stacked structure. The exposed layer increases and / or improves the visibility of the first deformation and security features when the stacked structure of the data carrier is formed. The exposed layer is preferably selected for the inner layer having the first deformation. Advantageously, the chemical composition and physical properties of the exposed layer are not the same as those of the inner layer having the first deformation of the surface. The exposed layer is preferably adjacent to the layer having the first deformation. Advantageously, the exposed layer faces the first deformation of the surface of one of the layers, and the exposed layer contacts the first deformation of the surface of one of the layers. The exposed layer may also face the rear side of the layer having the first deformation on its front side. The exposed layer may also be separated from the first deformation of the surface of one of the layers by some inner layers in between.

[0052] The first deformation is replicated onto the exposed layer during lamination, and the exposed layer contains the replicated deformation. The first deformation of the surface is not formed directly on the exposed layer. Conversely, the first deformation is formed on a different layer, such as the first inner layer, and will be replicated onto the exposed layer only through lamination. Consequently, the exposed layer can be welded to the second inner layer as a preform. If the first deformation of the surface is formed on a layer such as the first inner layer, the preform is applied to the first inner layer together with the exposed layer.

[0053] Because the deformation is formed on a different surface rather than directly on the exposed layer or ink layer, the exposed layer is not damaged by the deformation. This also allows for strong compatibility with a number of deformation techniques, as will be discussed in more detail below. Another advantage of this approach is that the features are more attractive and have more dimensions when the deformation and the exposed layer are not at exactly the same interface.

[0054] The exposed layer does not necessarily have the same surface as the first deformation. According to one embodiment, at least one exposed layer covers a surface larger than the surface covered by the first deformation of the surface of one of the layers. Thus, the security feature is not formed only in the portion where the exposed layer exists, but rather in the portion where the first deformation of the surface exists. In this case, the exposed layer does not need to be cut or pre-formed to define the shape or area of ​​the desired security feature. The exposed layer can cover substantially all surfaces of the layer having the first deformation. According to another embodiment, at least one exposed layer covers a surface smaller than the surface covered by the first deformation of the surface of one of the layers. In this case, the entire exposed layer exhibits the desired effect, while deformation outside the exposed layer may disappear during the lamination process.

[0055] The first deformation may be formed on any of the layers because it is not on the outermost surface of the data carrier. For example, the first deformation may be formed on the inner surface of one of the outer layers. This first deformation may also be formed on the surface of one of the inner layers. At least one inner layer preferably comprises a so-called core layer, and the first deformation is formed on the surface of the core layer. The core layer is preferably substantially at the center of the stacked structure. The core layer may also comprise several sublayers. Such a multilayer core can be deformed and then laminated to an exposed layer together with the outer layers.

[0056] The core layer having a first deformation of the surface may be substantially transparent. Alternatively, the core layer having a first deformation of the surface may be colored, and advantageously, white. Depending on the appearance of the core layer, the exposed layer may have different compositions and appearances.

[0057] As mentioned above, one of the advantages of the method of the present invention is that it is compatible with a wide range of techniques for forming a first deformation of the surface of one of the layers. These different techniques may be classified into different categories. The deformation of the surface of one of the layers may be formed by heating the layer or without heating the layer. It may also be formed by deformation of the material of the layer, by addition of material to the surface of the layer, or by removal or ablation of the material of the layer. All such categories include different techniques that present specific advantages and characteristics.

[0058] As previously mentioned, a first type of technique for forming a first deformation on the surface of one of the layers is by heating the layer. Using heat to deform the surface of a polymer layer, particularly a polycarbonate layer, includes several different techniques.

[0059] Using heat to form a first deformation on the surface of one of the layers enables a faster process with less pressure and higher definition when small details are created on some layers.

[0060] Among such techniques that use heat to form a first deformation of the surface, the first technique is to use laser cutting. Laser cutting technology can be used to form a kiss-cut or a through-cut.

[0061] The kiss cut of the layer consists of cutting the material layer so that the cut does not pass through the entire thickness of the layer.

[0062] The through-cut of the layer consists of cutting the material layer so that the cut passes through the entire thickness of the layer.

[0063] The use of a laser cutter offers a high degree of design freedom. Entire sheets can be processed one at a time.

[0064] The shape of the deformation can be seen as round or smooth when observed in a cross-section along a direction perpendicular to the extension direction (E).

[0065] When forming a first deformation on the surface of one of the layers, tooling (i.e., a laser) causes melting and / or ablation of the material. Depending on the material being processed, marking by the laser may induce fluorescence.

[0066] This laser cutter technology allows for a high degree of freedom with respect to the card structure because a large number of shapes can be generated when forming the first deformation.

[0067] This laser cutter technology has the advantage of not requiring consumables to be changed along the process. In addition, the exposure layer is not essential in this method of forming the first deformation.

[0068] Another technique for forming a first deformation using heat is pre-lamination. With such a technique, the layer having the first deformation is laminated by using embossing plates. This step is separate from the lamination step for forming the stacked structure of the data carrier. This pre-lamination step can be performed with the same equipment as for the lamination step for forming the stacked structure of the data carrier, but preferably, for pre-lamination, it can be performed with a shorter lamination time and a stack of thinner sheets.

[0069] Using a pre-lamination step to form the first deformation allows for a high degree of freedom in terms of design. The entire sheet can be processed. Very small designs can be created because the deformation can have a height starting from 2 sm and a line width starting from 10 sm. The plate used to emboss the surface of the layer on which the first deformation is formed defines the level of details as well as the design.

[0070] The shape of the deformation may be round when observed in a cross-section along a direction perpendicular to the extension direction (E). The deformation depends on the shape of the embossing plate / lamination plate.

[0071] This pre-lamination technology allows for a high degree of freedom with respect to the card structure because a large number of shapes can be generated when forming the first deformation.

[0072] Pre-lamination technology allows for the formation of explicit and implicit security features within the final data carrier. Advantageously, pre-lamination technology allows for the formation of high-resolution, repeatable details on the surface of the modified layer.

[0073] Preferably, when the first deformation is formed by pre-lamination, an exposed layer is provided against the deformed layer.

[0074] This pre-lamination technology also has the advantage of a low risk of forming unwanted deformations.

[0075] Another technique for forming a first deformation using heat is hot stamping. With such a technique, a layer on which the first deformation is formed is embossed.

[0076] This type of embossing can be performed by the latest known processes. For example, this hot stamping process can be performed in a roll-to-sheet manner by a Gietz hot stamping machine, preferably with plastic 100 mm thick.

[0077] Using a hot stamping step to form the first deformation allows for good degrees of freedom in terms of design. The entire sheet can be processed, but only one sheet at a time can be processed. Very small designs can be produced because the deformation can have a height starting from 2 sm and a line width starting from 10 sm. The plate used to emboss the surface of the layer on which the first deformation is formed defines the level of detail as well as the design.

[0078] The shape of the deformation may be round when observed in a cross-section along a direction perpendicular to the extension direction (E). The deformation depends on the shape of the tooling.

[0079] This deformation technique is not the easiest to implement, as some parasitic or unwanted deformation may be generated by the tooling when forming the first deformation on the surface of the deformed layer. However, this technique benefits from the availability of tooling, as hot stamping is a widely used technique in the field of secure documents. This technique can be used particularly with DOVID foils.

[0080] This hot stamping technology allows for a high degree of freedom with respect to the card structure because a large number of shapes can be generated when forming the first deformation.

[0081] Hot stamping technology allows the formation of explicit and implicit security features within the final data carrier.

[0082] Preferably, when the first deformation is formed by hot stamping, an exposed layer is provided against the deformed layer.

[0083] Another technique for forming a first deformation using heat is ultrasonic welding. Ultrasonic welding corresponds to a process that uses mechanical vibrations within the ultrasonic range. As is generally known, these vibrations, generated by a sonotrode, are used to act on at least a portion of the deformed layer, thereby creating a first deformation. To this end, the deformed layer is preferably placed on an anvil, as is also known in the art, whereby the sonotrode is pressed onto the layer from the side opposite the anvil. Ultrasonic welding is preferably performed using an ultrasonic welding device, as is known in the art. The ultrasonic welding device is preferably commercially available.

[0084] Using an ultrasonic welding step to form the first deformation allows for a high degree of freedom in terms of design. Ultrasonic welding enables fine details such as microtext, and furthermore, allows for the creation of various features such as optically variable elements and, in particular, latent images. The marking is explicit and visible to the naked eye. On the other hand, the marking can be implicit and may require the use of magnification, such as loupes, microscopes, and / or different lighting conditions, to be visible.

[0085] Preferably, when the first deformation is formed by welding, an exposed layer is provided against the deformed layer.

[0086] In contrast to the aforementioned techniques, another type of technique for forming a first deformation on the surface of one of the layers is one that does not involve heating the layer.

[0087] Among the techniques that do not use heat to form the first deformation, the first technique is using knife cutting. The knife cutting technique can be used to form a kiss cut or a through cut.

[0088] With this technique, the entire sheet can be processed one sheet at a time. The shape of the deformation can be seen as sharp when observed in a cross-section along a direction perpendicular to the extension direction (E).

[0089] The implementation of such modification techniques is considerably easy, and since knife cutting is a widely used technique in the field of secure documents, it benefits from the availability of tooling. However, such techniques require maintenance because the blades used to cut the layers must be replaced periodically to maintain good cutting quality. Furthermore, knife cutting is not the fastest modification technique among those discussed herein.

[0090] Another type of technique that does not use heat to form the first deformation is the use of a lacquer, varnish, or any other suitable material that can be added to a surface by printing, coating, spraying, etching, etc. By adding a material to the surface of a given layer, the surface profile of the layer is deformed, and the first deformation of the surface is formed. The added material may be, for example, a lacquer or varnish, such as a printable silk screen varnish.

[0091] This technology offers a high degree of freedom in design because the shape of the deformation is free.

[0092] In addition to the aforementioned methods that do not use heat, a cold press technique may also allow for the formation of a first deformation on the surface of one of the layers.

[0093] Another type of technique for forming a first deformation of the surface of one of the layers is by deformation of the material of the layer. Deformation of the material here means that the material is neither added nor removed from the layer. Deformation of the material of the layer includes several different techniques. Among such techniques, pre-lamination of the layer, hot stamping, and welding may be mentioned.

[0094] This type of technology has the advantage of not using any consumables. These methods consume only energy.

[0095] Another type of technique for forming a first deformation on the surface of one of the layers is to add a material onto the layer. Addition of material here means that a material is added to the layer. Adding a material onto a layer includes several different techniques. Among such techniques, in particular, the use of lacquer or varnish to create an embossing on the surface of the layer may be mentioned.

[0096] This type of technology has the advantage of being compatible with a large number of materials, as there are numerous substances available for this purpose. Examples include offset inks, silkscreen inks, varnishes, adhesives, fibers, metal wires, etc. The added material can be colored or colorless. These methods can be fast and require low investment.

[0097] Another type of technique for forming a first deformation on the surface of one of the layers is by removing or ablating the material of the layer. Removal or ablation of the material here means that the material is removed from the layer. Removal of the material of the layer includes several different techniques. Among such techniques, knife cutting and laser cutting may be mentioned in particular.

[0098] This type of technology is fast and does not require consumables. Additionally, the ablation does not have the side effects of heating. However, this type of technology consumes more energy than some of the other technologies mentioned previously.

[0099] Depending on the existing facilities and configurations, some of the aforementioned technologies will require fewer modifications than others and will therefore be a better choice.

[0100] In addition, depending on the type of polymer layer used to form the data carrier, some technique for forming a first deformation on the surface of one of the layers will be more suitable.

[0101] In addition to this extensive compatibility in terms of techniques for forming a first variation of the surface of one of the layers, the method according to the present invention is also advantageously compatible with the addition of other security features and subsequent personalization. Indeed, as previously mentioned, this method of marking a data carrier does not interfere with embossing or diffractive surface elements in a negative way.

[0102] Advantageously, the method according to the present invention includes the step of forming a second security feature. The second security feature may be formed by modifying the surface of the data carrier. Since the first security feature is a so-called interface feature at the interface between at least some of the layers of the data carrier, the modification of the outermost surface of the data carrier will not interfere with the first security feature, so the second security feature may be of many types. In this case, the step of forming the second security feature follows the step of forming a laminated structure by lamination.

[0103] The second security features may be, in particular, latent images, embossing, debossing, diffractive features, and watermarks.

[0104] Advantageously, the second security feature is formed by laser engraving. The laser engraving of the data carrier formed by the method according to the present invention allows for the formation of a second security feature having a high level of complexity and reliability without interfering with the first security feature.

[0105] The second security feature may also be an interface feature formed by the method according to the present invention. In that case, the step of forming the second security feature comes before the step of forming a laminated structure by lamination.

[0106] Preferably, the second security feature overlaps at least partially with the first security feature along the extension direction (E).

[0107] Advantageously, the method includes the step of forming a personalization element. The personalization element may be formed by many different techniques well known from the latest technology. Advantageously, the personalization element is formed by laser engraving. Preferably, the personalization element overlaps at least partially with a first security feature along the extension direction (E). This overlap allows for the formation of a particularly complex design that is very difficult for a counterfeiter to replicate and / or optionally alter.

[0108] Advantageously, the method comprises the step of forming a viewing portion or window. The viewing portion may be created by forming a void within one or more layers of a data carrier, which allows visibility through the data carrier. The void may be formed by punching or cutting away some material from one or more layers of the data carrier. In the context of the present invention, the viewing portion allows viewing of at least a portion of a variation of the security feature and / or a replicated variation.

[0109] Preferably, the viewing portion overlaps at least partially with the first security feature along the extension direction (E). This overlap allows for the formation of a particularly complex design that is very difficult for a forger to replicate and / or optionally alter.

[0110] According to another aspect, the present invention relates to a data carrier obtained by a previously disclosed method. In particular, the data carrier according to the present invention is extended along an extension direction (E), and

[0111] - A first outer layer forming the first outer surface of a data carrier,

[0112] - A second outer layer forming a second outer surface of a data carrier, and

[0113] - Includes at least one inner layer between the first outer layer and the second outer layer,

[0114] The first outer layer, the second outer layer, and the at least one inner layer form a laminated structure, and

[0115] A data carrier includes a first security feature at an interface between at least two adjacent layers, and the first security feature includes a first deformation of the surface of one of the layers and at least one replicated deformation induced by the first deformation.

[0116] All the technical advantages presented above in relation to the method of forming a data carrier apply equally to the data carrier according to the present invention.

[0117] The data carrier structure may include several inner layers. Preferably, at least one inner layer includes at least one exposed layer. The exposed layer increases and / or improves the visibility of the first deformation and security feature when the stacked structure of the data carrier is formed. The exposed layer is preferably selected for the inner layer having the first deformation. Advantageously, the chemical composition and physical properties of the exposed layer are not the same as those of the inner layer having the first deformation on its surface. Advantageously, the exposed layer faces the first deformation on the surface of one of the layers, and the exposed layer contacts the first deformation on the surface of one of the layers. The exposed layer may also be separated from the first deformation on the surface of one of the layers by some inner layers in between. The exposed layer may also face the rear side of the layer having the first deformation on its front side.

[0118] The first deformation is replicated on the exposed layer during lamination, and the exposed layer includes the replicated deformation.

[0119] Preferably, at least one exposed layer comprises offset inks and varnishes, silk screen printing inks and varnishes, DOVID (Diffractive Optically Variable Image Device), OVI (Optically Variable Ink), pearlescent inks, metallic inks, metallic foils, and / or colored plastic films.

[0120] Advantageously, the exposed layer covers substantially the entire surface of the layer having the first deformation. Therefore, the security feature is not formed only in the portion where the exposed layer exists, but rather is formed in the portion where the first deformation of the surface exists. This allows the manufacturing process to be simplified as the exposed layer does not need to be cut or pre-formed to define the shape or area of ​​the desired security feature.

[0121] Advantageously, the data carrier comprises a so-called core layer comprising a first deformation on its surface. The core layer is an inner layer of the data carrier. The core layer is preferably substantially at the center of the stacked structure. The core layer may also comprise several sublayers.

[0122] As previously mentioned, the first deformation of one of the layers and consequently the first security feature can be formed by many different techniques. As already mentioned above, the term deformation of the surface of a given layer includes different types of deformation of the surface, such as deformation of the material of the given layer, addition of material onto the given layer, and removal of material from the given layer.

[0123] The technologies presented above can be classified into one of these three categories. Depending on the type of technology, the type of the first security feature may vary. The first security feature of the data carrier is external and visible to the naked eye. On the other hand, the marking may be internal and may require the use of magnification, such as a loupe, microscope, and / or different lighting conditions, to be visible.

[0124] Advantageously, the first security feature of the data page may include at least one of a latent image, embossing, debossing, microtext, optically variable elements, and a watermark-like feature. Some of these security features, such as latent images, may become visible when the viewing and / or lighting angle is appropriately changed. Some other security features, such as watermark-likes, may become visible or more prominent under backlight conditions compared to any other lighting configuration.

[0125] The security element preferably has the shape of a pattern. The pattern may be an ordered pattern or an unordered pattern. An ordered pattern preferably includes pattern elements arranged in a repetitive manner. An unordered pattern preferably includes pattern elements distributed randomly. In both cases, the pattern elements may correspond to geometric shapes such as lines or circles, barcodes, or any set of randomly appearing elements. A security element inspectable by the human eye is understood to be verifiable without the need for any dedicated equipment. A machine-readable security element is understood to be verifiable by dedicated equipment, for example, by a mobile phone configured to take a picture of the security element and perform software-based verification of the pattern. The phone operates with visible light in relation to the light source as well as the capture. However, verification may likewise require specific lighting conditions, such as ultraviolet or infrared illumination, and the same applies to the capture device. Furthermore, if the security element is provided at very high resolution, verification may require a certain level of magnification.

[0126] The first outer layer and / or the second outer layer may be formed by different materials adapted for their use in security documents and data carriers, such as PVC, PETG, ABS, etc. Advantageously, the first outer layer and / or the second outer layer comprises a thermoplastic material. Preferably, the first outer layer and / or the second outer layer comprises polycarbonate.

[0127] In the same way, at least one core layer may be formed by different materials adapted for their use in security documents and data carriers, such as PVC, PETG, ABS, etc. Advantageously, at least one core layer comprises a thermoplastic material. Preferably, at least one core layer comprises polycarbonate, and more preferably transparent polycarbonate.

[0128] The outer layers and the core layer do not need to be of the same type. For example, a data carrier having a PET core and PVC surface layers can be manufactured according to the method of the present invention.

[0129] Advantageously, the data carrier according to the present invention comprises a second security feature. The second security feature may be formed by modifying the surface of the data carrier. In that case, since the first security feature is a so-called interface feature at the interface between at least some of the layers of the data carrier, the modification of the outermost surface of the data carrier will not interfere with the first security feature, so the second security feature may be of many types. The second security features may be, in particular, a latent image, an embossing, a debossing, a diffractive feature, a watermark, etc. Advantageously, the second security feature is obtained by laser engraving. Laser engraving of the data carrier according to the present invention allows for the formation of a second security feature having a high level of complexity and reliability without interfering with the first security feature.

[0130] The second security feature may also be an interface feature obtained according to the same process as for the first security feature.

[0131] Preferably, the second security feature overlaps at least partially with the first security feature along the extension direction (E).

[0132] Advantageously, the data carrier includes a viewing portion or a window. In this case, the different layers of the data carrier are preferably at least partially translucent in the region of the viewing portion.

[0133] Preferably, the viewing portion overlaps at least partially with the first security feature along the extension direction (E). This overlap allows for the formation of a particularly complex design that is very difficult for a forger to replicate and / or optionally alter.

[0134] The interaction between the viewing portion and the first security feature involves the strategic placement of the first variant and / or replicated variant aligned with the viewing portion. This configuration allows for the enhancement of document security by combining different security feature elements in a manner that is difficult to replicate or forge. By integrating the interfacial security feature with the formation of the viewing portion, the data carrier achieves a multi-layered security approach. This makes it significantly more difficult for forgers to accurately replicate all security elements.

[0135] A viewing portion may be created by forming a void within one or more layers of a data carrier, which allows visibility through the data carrier. The void may be formed by punching or cutting away some material from one or more layers of the data carrier. In the context of the present invention, the viewing portion allows viewing of at least a portion of a variation and / or a duplicated variation of a security feature.

[0136] In the described embodiment, the see-through portion is part of a multilayer structure comprising transparent and white polycarbonate layers, and the transparent layer has potentially embossed security features. This combination of the see-through portion and the embossed elements contributes to the security of the document and makes it more resistant to forgery.

[0137] The first security feature of the data carrier is explicit and visible to the naked eye. On the other hand, the marking may be implicit and may require the use of magnification, such as a loupe, microscope, and / or different lighting conditions, to be visible. In the same way, the second security feature of the data carrier may be explicit or implicit.

[0138] Advantageously, the data carrier includes a personalization element. The personalization element can be formed by many different techniques well known from modern technology, such as laser engraving. The personalization element may include, in particular, a photograph of the holder of the security document containing the data carrier. Advantageously, the personalization element overlaps at least partially with the first security feature along the extension direction (E). This overlap allows for the formation of a particularly complex design that is very difficult for a forger to duplicate and / or optionally alter.

[0139] Preferably, the view portion and the personalization element overlap at least partially with the first security feature along the extension direction (E). This overlap allows for the formation of a much more complex design that is particularly difficult for a forger to replicate and / or optionally alter.

[0140] According to another aspect, the present invention relates to a security document comprising or composed of at least one data carrier as previously disclosed. The security document is preferably a smart card, identification card, passport, credit card, banknote, etc. Brief explanation of the drawing

[0141] Preferred embodiments of the present invention are described below with reference to the drawings. This is intended to explain preferred embodiments of the present invention and is not intended to limit them. In the drawings, FIG. 1 illustrates a cross-sectional view of the first step of a method for forming a data carrier according to the present invention. FIG. 2a illustrates a cross-sectional view of a second step of a method for forming a data carrier according to the present invention, in which an exposed material is directly applied to a first deformation. FIG. 2b illustrates a cross-sectional view of a second step of a method for forming a data carrier according to the present invention, wherein an exposed material is provided as an exposed layer. FIG. 3 illustrates a cross-sectional view of the third step of a method for forming a data carrier according to the present invention. FIG. 4 illustrates another embodiment of a laminated structure formed according to the present invention in a cross-sectional view. FIG. 5 illustrates a plan view of a first data carrier according to the present invention including a first security feature. FIG. 6 illustrates a plan view of a second data carrier according to the present invention, including a first security feature and a personalization element. Figure 7 shows an enlarged plan view of the data carrier of Figure 6. Figure 8 shows another enlarged plan view of the data carrier of Figure 6. FIG. 9 illustrates a plan view of a third data carrier according to the present invention including a first security feature. FIG. 10 illustrates a plan view of a fourth data carrier according to the present invention, including a first security feature and a personalization element. Specific details for implementing the invention

[0142] Embodiments of the present invention will be further illustrated with reference to the drawings.

[0143] FIG. 1 illustrates a cross-sectional view of a first step of a method for forming a data carrier according to the present invention. In this first step, a first outer layer (11), a second outer layer (12), and several inner layers (20) are provided. The number of inner layers (20) may vary depending on the desired characteristics of the data carrier. One of these inner layers (20) is a so-called core layer (22). This core layer is substantially located at the center of the data carrier along the extension direction (E). Additionally, an exposed layer (30) is provided. Depending on the technique used to form the first deformation of the surface, an exposed layer may not be required to form the first security feature. The layers depicted in these drawings are not drawn to a constant scale. In most cases, the exposed layer is much thinner than the other layers.

[0144] In the second step as illustrated in FIG. 2, a first deformation (40) of the surface of the core layer (22) is formed. In FIG. 2a, the exposure material (32) is applied directly onto the first deformation (40) of the surface, particularly by silk screen printing technology. In FIG. 2b, the exposure material (32) is provided as an exposure layer (30). In the first case, the first deformation (40) of the surface of the core layer (22) will form a first security feature at the interface between the core layer and the upper inner layer facing the exposure material. In the second case, the first deformation (40) of the surface of the core layer (22) will form a first security feature at the interface between the core layer, the exposure layer, and the upper inner layer facing the exposure layer.

[0145] In the third step as illustrated in FIG. 3, a stacked structure is formed with a first outer layer (11), a first inner layer (20), an exposed layer (30), a core layer (22), a second inner layer (20), and a second outer layer (12). This stacked structure is formed by lamination. The parameters of the lamination process will depend on the properties of the layers of the data carrier, their thickness, etc. During lamination, heat and pressure are applied to the stack of layers, and some material of the layers adjacent to the core layer having a first deformation of the surface flows and follows the shape of the first deformation. Thus, during lamination, the first deformation (40) of the surface of the core layer (22) is replicated, and at least one replicated deformation (42) is formed inside the data carrier at the interface between at least some of the layers. In the embodiment illustrated in FIG. 3, a replicated deformation (42) is located at the interface between the core layer (22) and the exposed layer (30), and another replicated deformation (42) is located at the interface between the exposed layer (30) and the upper inner layer (20) facing the exposed layer (30). Depending on the strength of the deformation (40), the height and depth of the resulting recesses, and the thickness of the layers, bumps and / or dips, the replicated deformation (42) may be replicated into more adjacent layers. For example, for a stronger deformation having higher strength, some replicated deformation may also be located at the interface between the upper inner layer (20) and the first outer layer (11).

[0146] FIG. 4 is another embodiment of a laminated structure formed according to the method described above. This structure further includes a viewing portion (70). The first outer layer (11) and the second outer layer (12) are opaque layers. This opacity is represented by a hatching pattern in FIG. 4. Conversely, the core layer (22) and the inner layers (20) are translucent or significantly transparent. This example is for illustrative purposes only, and it is not explicitly excluded that layers depicted without a hatching pattern in other drawings may also be opaque layers. The opaque layers of the laminated structure include openings, advantageously formed prior to the lamination step. The opaque layers of the laminated structure include a translucent or significantly transparent material, such as transparent polycarbonate, in the area corresponding to the viewing portion. This transparent portion of the opaque layers may be formed by removing a portion of the opaque material prior to the lamination step. During lamination, the transparent material of adjacent layers flows and fills the voids within the opaque layers. In the embodiment illustrated in FIG. 4, the transparent polycarbonate of the inner layers (20) flows during lamination and fills the voids within the first outer layer (11) and the second outer layer (12). The view portion is represented by the region (70). At least a portion of the first security feature (50) overlaps with the view portion (70). In other words, the first security feature (50) is at least partially aligned with the view portion (70).

[0147] FIG. 5 illustrates a top view of a first data carrier (1) according to the present invention including a first security feature (50). In this data carrier, the first variation (40) is formed by the pre-lamination of a core layer made of polycarbonate. This first variation is a microtext forming the characters "SETEC". The exposed layer (30) used in this data carrier (1) is a DOVID element. The obtained security feature (50) is an apparent security feature or a Level 1 security feature because it is visible to the naked eye without the need for magnification under specific lighting conditions. The outermost surface of this data carrier (1) is kept smooth and may undergo further personalization with the subsequent addition of a second security feature.

[0148] FIG. 6 illustrates a plan view of a second data carrier (1) according to the present invention, comprising a first security feature (50) and a personalization element (60). The first variation (40) is formed by the pre-lamination of a core layer made of polycarbonate. This first variation (40) forms guilloche lines. The exposed layer (30) used in this data carrier (1) is a DOVID element. The obtained security feature (50) is an apparent security feature or a Level 1 security feature because it is visible to the naked eye without the need for magnification under specific lighting conditions. This data carrier (1) also includes a personalization element (60) in the form of a photograph of the end user's face. This personalization element (60) is formed by laser engraving. Personalization follows the formation of a stack of layers forming the first security feature (50) and the data carrier (1).

[0149] FIG. 7 is an enlarged plan view of the data carrier (1) of FIG. 6. In this view, the data carrier (1) is shown with a transparent light. This allows the controller to see the guilloche (50) under the personalization (60). The first deformation (40) of the surface and the corresponding first security feature (50) remain intact and visible after the lamination process and the personalization process. The combination of the personalization (60) and the superimposed guilloche (50) forms a complex data carrier (1) with a high level of security.

[0150] FIG. 8 is an additional enlarged plan view of the data carrier of FIG. 6, illustrated in see-through light. The first security feature (50) is illustrated outside the area having the personalized element (60). This data carrier also includes a second security feature in the form of microtext forming the characters “SETEC”. This second security feature (52) is obtained by the same process as for the first security feature (50). The second security feature (52) is particularly small and entails the need for enlargement to be readable. This second security feature (52) is an implicit security feature or a Level 2 security feature.

[0151] FIG. 9 illustrates a top view of a third data carrier (1) according to the present invention comprising a first security feature (50). In this data carrier, the first variation (40) is formed by the pre-lamination of a core layer made of polycarbonate. This first variation includes microtext forming the characters “SETEC” and several pattern lines forming ellipses. The exposed layer (30) used in this data carrier (1) is a silkscreen ink containing metallic pigments. The obtained security feature (50) is an explicit security feature in the case of a pattern, as well as an implicit security feature in the case of microtext.

[0152] FIG. 10 illustrates a plan view of a fourth data carrier (1) according to the present invention, comprising a first security feature (50) and a second security feature (52). In this data carrier, the first variation (40) is formed by the pre-lamination of a core layer made of translucent polycarbonate. The exposed layer (30) used in this data carrier (1) is a pearlescent ink layer that forms a leaf pattern, said leaf pattern survives the lamination process and is observable in the obtained data carrier (1). The first variation (40) forms a guilloche pattern (50). This data carrier (1) also includes a second security feature (52) in the form of microtext forming the characters "SETEC". This second security feature (52) is obtained by the same process as for the first security feature (50). The second security feature (52) is particularly small and requires magnification to be readable. This second security feature (52) is an implicit security feature or a level 2 security feature.

Claims

Claim 1 A method for forming a data carrier (1) for a security document (100), comprising: providing a first outer layer (11) and a second outer layer (12); forming a first security feature (50) at an interface between at least two adjacent layers, wherein the first security feature (50) comprises a first deformation (40) on the surface of one of the layers; forming a stacked structure with the first outer layer (11) and the second outer layer (12), wherein the stacked structure is formed by lamination; wherein the first deformation (40) on the surface of one of the layers is replicated during lamination, so that at least one replicated deformation (42) is formed inside the data carrier (1) at an interface between at least some of the layers. Claim 2 A method according to claim 1, wherein a revealing material (32) is applied to the first deformation (40) on the surface of one of the layers before forming the laminated structure by lamination, such that the revealing material (32) comes into contact with the first deformation (40) on the surface of one of the layers. Claim 3 In paragraph 2, the method wherein the exposed material (32) is applied to the first deformation (40) by printing and / or coating. Claim 4 In paragraph 2, the data carrier (1) comprises the exposure material (32) and at least one exposure layer (30) facing the first deformation (40) on the surface of one of the layers, wherein the exposure layer (30) contacts the first deformation (40) on the surface of one of the layers, and the exposure layer (30) comprises a replicated deformation (42). Claim 5 A method according to any one of claims 1 to 4, wherein the data carrier comprises at least one inner layer (20), and the at least one inner layer (20) comprises the first deformation (40). Claim 6 In paragraph 5, the method wherein at least one inner layer (20) has a first refractive index (rf1) and the exposed material (32) has a second refractive index (rf2), and the first refractive index (rf1) is different from the second refractive index (rf2). Claim 7 A method according to any one of claims 1 to 6, wherein the method comprises the step of forming a see-through portion (70), wherein the see-through portion (70) overlaps at least partially with the first security feature (50) along the extension direction (E). Claim 8 A method according to any one of claims 1 to 7, wherein the first deformation (40) of the surface of one of the layers is formed by embossing and / or hot stamping the layer. Claim 9 A method according to any one of claims 1 to 8, wherein the method comprises the step of forming a personalization element (60), wherein the personalization element (60) preferably overlaps at least partially with the first security feature (50) along the extension direction. Claim 10 A data carrier (1) for a security document (100), wherein the data carrier (1) is extended along an extension direction (E) and comprises a first outer layer (11) forming a first outer surface of the data carrier (1), and a second outer layer (12) forming a second outer surface of the data carrier (1), wherein the first outer layer (11) and the second outer layer (12) form a stacked structure, and the data carrier (1) comprises a first security feature (50) at an interface between at least two adjacent layers, wherein the first security feature (50) comprises a first deformation (40) of the surface of one of the layers and at least one replicated deformation (42) induced by the first deformation (40). Claim 11 In claim 10, the data carrier comprises an exposed material (32) facing the first deformation (40) on the surface of one of the layers, wherein the exposed material (32) contacts the first deformation (40) on the surface of one of the layers, the data carrier (1). Claim 12 In claim 11, the data carrier comprises at least one exposed layer (30) including the exposed material (32), and the exposed layer (30) includes a replicated variant (42) and / or the data carrier comprises at least one inner layer (20), and the at least one inner layer (20) includes the first variant (40), the data carrier (1). Claim 13 In any one of claims 10 to 12, the data carrier (1) comprises a viewing portion (70), wherein the viewing portion (70) overlaps at least partially with the first security feature portion (50) along the extension direction (E). Claim 14 In any one of claims 10 to 13, the first security feature (50) comprises at least one of an optically variable image, embossing, debossing, and watermark-like feature, and / or the at least one exposure layer (30) comprises offset inks and varnishes, silk screen printing inks and varnishes, DOVID, OVI, pearlescent inks, metallic inks, metallic foils, and / or colored plastic film, data carrier (1). Claim 15 A security document (100) comprising at least one data carrier (1) according to any one of claims 10 to 14 or composed of said at least one data carrier (1), wherein the security document (100) is preferably a smart card, identification card, passport, credit card, banknote, etc.

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