Card manufacturing method

Abstract

The present invention includes: a process of supplying a reference sheet that serves as a positioning reference; a process of supplying a first continuous sheet formed by repeatedly printing a plurality of patterns as a cycle; a process of stacking the first continuous sheet on the reference sheet to generate a stacked sheet; a process of using a detection mechanism to detect the position of each of the repeatedly printed patterns one by one; a first adjustment process of controlling the supply speed of the first continuous sheet based on the detection result of the position of the pattern, and adjusting the pattern in a prescribed position relative to the reference sheet; and a process of cutting the stacked sheet for each pattern to generate a card, wherein the pattern is formed by repeatedly printing a plurality of patterns as a cycle, and the adjustment process is performed every cycle of the plurality of patterns.

Description

Technical Field

[0001] The present invention relates to methods for manufacturing various cards. Background Art

[0002] In recent years, non-contact IC cards such as cash cards, employee ID cards with facial photos, employee ID cards, membership cards, student ID cards, foreigner registration cards, and various driver's licenses have been used as cards. Such cards are generally formed by laminating a sheet with a pattern printed on the front and back sides on an inlay. It should be noted that the inlay is a film printed with a circuit recording electronic information.

[0003] The continuous sheet to be the front and back sheets and the inlay are aligned with each other and then cut into individual card units.

[0004] Prior art literature

[0005] Patent Literature

[0006] Patent Document 1: JPH11-309969 A (Abstract)

[0007] In the alignment between the inlay and the continuous sheet, a mark called a registration mark provided on both is detected, and the pattern of the inlay and the continuous sheet are aligned. Summary of the invention

[0008] Figure 1B The printer 100 for printing a pattern on the continuous sheet 200 is shown. As shown in the figure, in one printer 100, n (plural) printing plates 101 to 106 are mounted on a roller body 110 at substantially equal angular intervals. In the current technology, it is easy to manufacture the printing plates 101 to 106 in a manner that is identical to each other. Therefore, the patterns generated by the printing plates are identical to each other.

[0009] However, in the structure of mounting each printing plate 101 to 106 on the roller body 110, it is inevitable that a slight mounting error will occur for each printing plate. Therefore, the spacing between the printed patterns is slightly uneven, and the above-mentioned alignment control is performed for each pattern, and the effect of pattern alignment control cannot be obtained. In addition, high-speed manufacturing becomes difficult.

[0010] Therefore, the present invention provides a method for manufacturing cards at a high speed while easily controlling pattern alignment.

[0011] The card manufacturing method of the present invention is characterized in that the card manufacturing method comprises:

[0012] A step of supplying a reference sheet 3 as a reference for alignment;

[0013] A step of supplying a first continuous sheet 1 in which a plurality of patterns are repeatedly printed as one cycle;

[0014] A step of laminating the first continuous sheet 1 on the reference sheet 3 to generate a laminated sheet 4;

[0015] A step of detecting the position of each pattern in the repeatedly printed pattern one by one by using a detection mechanism;

[0016] A first adjustment step of controlling the feeding speed of the first continuous sheet 1 based on the detection result of the position of the pattern and adjusting the pattern so that the pattern is at a predetermined position relative to the reference sheet 3; and

[0017] a step of cutting the laminated sheet 4 for each of the patterns to produce a card 40,

[0018] The first adjustment step is performed every one cycle of the plurality of patterns.

[0019] According to the present invention, for a first continuous sheet 1 in which a plurality of patterns are repeatedly printed as a cycle, the feeding speed of the first continuous sheet 1 is controlled based on the result obtained by detecting the position of the pattern every one of the cycles. Therefore, even if there is a deviation in the pitch of the printing plate during printing, the deviation will not interfere, and the pattern can be controlled in a manner such that it becomes a predetermined position relative to the reference sheet 3.

[0020] Furthermore, since the adjustment is performed every other cycle, the efficiency is good and it is also easy to cope with high-speed production.

[0021] In the present invention, the pattern includes not only characters, symbols, figures or drawings but also alignment marks. Generally, the alignment marks are detected as the position detection of the pattern.

[0022] In the present invention, the reference sheet 3 includes an inlay. In the case of the inlay, for example, an IC chip may be detected as a pattern. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1A is a perspective view showing an overview of a card manufacturing method according to an embodiment of the present invention. Figure 1B is a side view showing a method of printing a pattern.

[0024] Figure 2 1 is a schematic layout diagram showing an apparatus used in the manufacturing method.

[0025] Figure 3 It is a diagram showing a schematic structure of a control system.

[0026] Figure 4It is a top view showing the concept of positional deviation.

[0027] Figure 5 (a) is a top view of the card. Figure 5 (b) is a cross-sectional view of the card. Figure 5 (c) is a top view of the multi-row inlay. DETAILED DESCRIPTION

[0028] When the inlay is sandwiched between the sheets on the front and back sides to form a three-layer structure, that is, when there is a second continuous sheet serving as the back sheet, the present invention preferably includes:

[0029] A step of supplying a second continuous sheet 2 in which a plurality of other patterns are repeatedly printed as one cycle;

[0030] A step of laminating the second continuous sheet 2 on the reference sheet 3 to form the laminated sheet 4;

[0031] A step of detecting the position of each of the other repeatedly printed patterns using a detection mechanism; and

[0032] a second adjustment step of controlling the feeding speed of the second continuous sheet 2 based on the detection result of the position of the other pattern and adjusting the other pattern to a predetermined position relative to the reference sheet 3;

[0033] The second adjustment step is performed every one of the cycles of the plurality of other patterns.

[0034] In this case as well, it is easy to control the pattern alignment of the second continuous sheet 2, and the card can be manufactured at a high speed.

[0035] Preferably, the cutting position when the card is generated is adjusted according to the position of each of the plurality of patterns or each of the plurality of other patterns.

[0036] In this case, the card can be cut by aligning the pattern.

[0037] It should be noted that the alignment mark may be cut off and removed by cutting when the card is generated.

[0038] As a more specific method of the present invention, the following steps are performed:

[0039] A step of providing a mark on each of the sheets for each unit of the card and identifying the mark by the detection mechanism; and

[0040] The first adjustment step or the second adjustment step is not performed when the number of the identified marks is less than the predetermined number n corresponding to the one cycle, and the first adjustment step or the second adjustment step is performed every time the number of the identified marks reaches the predetermined number n.

[0041] In this case, since the adjustment process is performed every n times which is one cycle of printing, pattern alignment can be performed efficiently.

[0042] Preferably, the adjustment step is performed by driving the first and second dancer rollers 81 and 82 around which the first and second continuous sheets 1 and 2 stacked before the reference sheet 3 are respectively wound by the actuator 83 .

[0043] In this way, when the dancer roller is driven and controlled by the actuator, it is easy to control the feeding amount, that is, the feeding speed, of the first continuous web 1 or the second continuous web 2 .

[0044] Preferably, the result of the detection is that, when the position offset of the first or second continuous sheet 1, 2 relative to the reference sheet 3 exceeds a prescribed allowable range of ±Δ and is within a first offset range of ±Δ1, the first or second tension adjustment roller 81, 82 is moved a prescribed first constant amount T1 in a direction in which the position offset becomes smaller to perform the first or second adjustment process.

[0045] In general feedback control, control is performed with an indefinite amount corresponding to the amount of positional deviation. However, the cardboard forming the front and back sides of the card has high rigidity and a small elongation relative to the tensile force. When the supply amount of the cardboard is increased sharply, it is easy to cause a problem in the transportation at the supply clamping part (clamping roller).

[0046] Therefore, by setting the first constant amount T1 in advance, the supply speed can be controlled without causing the above-mentioned inconvenience.

[0047] Here, the first constant value T1 may be set to a range defined by, for example, the following equation (110).

[0048] Δ<(T1) / 2<Δ1……(110)

[0049] It should be noted that, when m dancer rollers are provided for each continuous sheet, the first constant value T1 may also be defined by the following equation (120).

[0050] Δ<(T1) / 2m<Δ1……(120)

[0051] Preferably, the result of the detection is that, when the position offset of the first or second continuous sheet 1, 2 relative to the reference sheet 3 is within the specified allowable range ±Δ, the actuator 83 is used to cause the first or second tension adjustment roller 81, 82 to move slightly in a direction opposite to the direction in which the first or second tension adjustment roller 81, 82 was moved last in the adjustment process.

[0052] When the tension adjustment roller is slightly moved in this way, the supply speed of the first or second continuous sheet 1, 2 remains almost unchanged by only slightly changing the tension and deflection of the first or second continuous sheet 1, 2, and the tension adjustment roller can be brought close to the home position while maintaining the position offset within the allowable range ±Δ.

[0053] Here, “slightly moving the dancer roller” means that the movement amount of the dancer roller is at least within the allowable range ±Δ and is smaller than the first constant amount T1.

[0054] Further preferably, the result of the detection is that, when the position offset of the first or second continuous sheet 1, 2 relative to the reference sheet 3 exceeds the first offset range ±Δ1, the tension adjustment roller 81 (82) is moved in the direction in which the position offset becomes smaller by a second constant amount T2 that is larger than the first constant amount T1 to perform the first or second adjustment process.

[0055] When the amount of the positional deviation increases significantly, the dancer roller is moved by the second constant amount T2 which is larger than the first constant amount T1. This allows supply control to be performed without causing a transport malfunction, as described above.

[0056] The features described and / or illustrated in association with one of the above-mentioned embodiments or the following examples may be combined with or used in place of the features of other embodiments or examples in the same or similar form in one or more other embodiments or examples.

[0057] Example

[0058] The present invention can be more clearly understood by referring to the following description of preferred embodiments with reference to the accompanying drawings. However, the embodiments and the accompanying drawings are only for illustration and description and should not be used to determine the scope of the present invention. The scope of the present invention is determined only by the technical solution. In the accompanying drawings, the same component numbers in multiple drawings represent the same or equivalent parts.

[0059] It should be noted that some of the expressions in this specification are followed by English words using parentheses to further clarify their meanings.

[0060] Hereinafter, one embodiment of the present invention will be described with reference to the accompanying drawings.

[0061] First, the card will be described before describing the embodiment.

[0062] Figure 5 (a) and (b) show an example of the card 40.

[0063] As shown in these figures, the card 40 is composed of a stack of layers of a front sheet 10, a back sheet 20, an inlay 30, and high-quality paper 31. These layers are bonded to each other by an adhesive layer 41 formed of, for example, hot melt polyurethane.

[0064] The inlay 30 is provided with an IC chip and an antenna 32. In addition, the high-quality paper 31 is formed with a through hole 33 into which the IC chip is inserted.

[0065] The card name N and the pattern G are printed on the front sheet 10, and another pattern (not shown) is printed on the back sheet 20. These patterns are printed by the printer 100 ( Figure 1B ) are repeatedly printed in a cycle of n. It should be noted that the pattern may also be only text or alignment mark.

[0066] like Figure 5 As shown in (c), each card is generated from one laminated sheet 4. The laminated sheet 4 is Figure 5 (b) The first continuous sheet to be the front sheet 10, the second continuous sheet to be the back sheet 20, the inlay 30 and the continuous sheet of high-quality paper 31 are formed. Figure 5 The laminated sheet 4 of (c) is cut vertically and horizontally to become Figure 5 (a) card 40.

[0067] Each of the sheets and the inlay 30 is provided with Figure 4 The alignment marks R0 to R2 are called alignment marks. It should be noted that in this example, for the sake of convenience, the alignment marks R0 to R2 are arranged in the center of the conveying direction, but for example Figure 5 In the case of the front sheet 10, as Figure 5 As shown in (a) of FIG. 1 , the alignment marks R0 to R2 may be arranged at corners that are removed by trimming after lamination.

[0068] Next, an outline of a method for manufacturing a card will be described.

[0069] Figure 1A For the convenience of drawing, the first and second continuous sheets 1 and 2 are shown as having a width corresponding to one card.

[0070] exist Figure 1AIn the process, a plurality of inlays 3A with a wide width formed by connecting inlays 30 vertically and horizontally and a continuous paper 3C of high-quality paper 31 are cut and divided into a plurality of single columns for conveyance. After the single-column inlays 3B formed by the cut are cut into units of individual cards, each inlay 30 is attached to the continuous paper 3C of high-quality paper, thereby generating an intermediate sheet (reference sheet) 3.

[0071] The first and second continuous sheets 1 and 2 are respectively attached to the front and back of the intermediate sheet 3. In this way, the card 40 ( Figure 5 (a)) The stacked sheets 4 are in a continuous state. Thereafter, the stacked sheets 4 are cut into units of individual cards 40.

[0072] Next, a schematic configuration of a production apparatus will be described together with an example of a production method.

[0073] exist Figure 2 In the embodiment, the first and second continuous sheets 1, 2, the multi-row inlay 3A, and the high-quality paper 31 ( Figure 5 (c) The continuous paper 3C in a continuous state is rolled out from a drum.

[0074] Figure 2 When the multi-row inlay 3A is rolled out from the drum, it is slit into a plurality of single-row inlays 3B by a slitter 60. Thereafter, the single-row inlays 3B formed by the slits are separated from each other in the width direction by a guider 61.

[0075] After that, the single-row inlay 3B is cut into units of each card by the first or second cutter 6A, 6B. For example, the first and second cutters 6A, 6B contact the first and second anvils 7A, 7B, respectively, and cut each single-row inlay 3B into units of each card. First and second suction conveyors 8A, 8B for intermittently supplying the single-row inlay 3B are arranged upstream of each cutter and anvil.

[0076] Thus, on the configuration roller 62, the substantially rectangular inlay 30 ( Figure 5 (a)) is transported in an intermittent and constant pitch configuration state.

[0077] On the other hand, high-quality paper 31 ( Figure 5 When the continuous paper 3C of (c)) is unwound from the drum, it is coated with adhesive by the coating machine 70 and then supplied to the configuration drum 62. The configuration drum 62 generates an intermediate sheet (reference sheet) 3 having inlays intermittently arranged on the continuous paper 3C between the configuration drum 62 and the clamping roller 62N. The intermediate sheet 3 is supplied between the downstream clamping rollers 63, 63.

[0078] In addition, a driving roller is generally used as one of the nip rollers 63 , 63 .

[0079] Before lamination, as described below, the first and second continuous sheets 1 and 2 are continuously supplied to the nip roller 63. The first and second continuous sheets 1 and 2 are unwound from the drum and are coated with adhesive by coaters 71 and 72 on the back side opposite to the front side on which a predetermined pattern is repeatedly printed.

[0080] After being coated with adhesive, the first and second continuous webs 1 and 2 are fed to the first and second dancer rollers 81 and 82 at the downstream, and fed to the nip roller 63 via these rollers. Each dancer roller 81 and 82 reciprocates by an actuator 83 such as a servo motor to adjust the feeding speed of each continuous web 1 and 2 to the nip roller 63.

[0081] The continuous sheets 1, 2 and the intermediate sheet 3 supplied to the clamping rollers 63, 63 are bonded to each other at the clamping rollers 63, 63, thereby generating a laminated sheet 4. The laminated sheet 4 is supplied to the trimming cutter 64 and separated into individual cards 40 and grid (frame)-shaped cut sheets 4T. It should be noted that the cards 40 are intermittently and continuously discharged onto the belt conveyor 65 and conveyed.

[0082] Next, the control system of the present production method will be described.

[0083] like Figure 2 As shown, a detection mark R0 ( Figure 4 On the other hand, a sensor S0 for detecting the alignment marks R1 and R2 ( Figure 4 ) sensors S1, S2.

[0084] The patterns of the first continuous sheet 1 and the second continuous sheet 2 are different from each other, but the structure, lamination method and control method of the two sheets stacked on the intermediate sheet 3 are essentially the same. Therefore, in the following description, the case where the first continuous sheet 1 is stacked on the intermediate sheet 3 is used as a representative description, and the description of the case where the second continuous sheet 2 is stacked on the intermediate sheet 3 is omitted.

[0085] Figure 3 An overview of the control system is shown.

[0086] As shown in the figure, the detection outputs of the sensors S0 to S2 are input to the control device 5. The control device 5 is constituted by an electronic computer.

[0087] The control device 5 includes a marker discriminating unit 50, a calculating unit such as a counter 51, and a storage unit such as a threshold value of a deviation discriminating unit 52 and a drive amount 53. The control device 5 is connected to a display 54 and an operating unit 55.

[0088] A part of the control device 5 and the sensors S0 to S2 constitute a detection mechanism that detects the position of the pattern via the position of the alignment mark as described below.

[0089] The mark determination unit 50 detects each alignment mark R0 to R2 based on the signals from each sensor S0 to S2. The counter 51 counts the number of each alignment mark R0 to R2, and when the number reaches a predetermined number, the deviation determination unit 52 determines the degree of deviation as follows.

[0090] The degree of the offset D is evaluated according to the following three stages: Figure 4 (a) of the first offset range ±Δ1, the offset D exceeds Figure 4 (b) is within the allowable range ±Δ and within the first offset range ±Δ1, and the extent of the offset D is within Figure 4 (c) is within the allowable range of ±Δ.

[0091] use Figure 4 The extent and control of this offset D will be described. Figure 4 In the example in which each alignment mark R0 to R2 is arranged at the center of the conveying direction of each sheet material for the convenience of explanation, the following description is given. Figure 4 The rectangle shown by the two-dot chain line represents the card 40 that is cut later.

[0092] like Figure 4 As in (a), when the offset D is large, that is, when the offset D exceeds the predetermined first offset range ±Δ1, Figure 3 The control device 5 reads T2 as the driving amount and moves the tension adjustment roller 81 (82) by T2 (for example, 2 mm) in the direction opposite to the direction of the deviation. As a result, the above-mentioned large deviation is greatly corrected. Such control is continued until the operation state is stabilized.

[0093] like Figure 4 As in (b), when the offset D is small, that is, when the offset D exceeds the prescribed allowable range ±Δ and is within the first offset range ±Δ1, Figure 3 The control device 5 reads T1 as the driving amount and moves the dancer roller 81 (82) by T1 (eg, 1 mm) in the direction opposite to the direction in which the dancer roller is deviating. Thus, the above-mentioned deviation is slightly corrected.

[0094] like Figure 4 As in (c), when the offset D is extremely small, that is, when the offset D is within the prescribed allowable range ±Δ, Figure 3The control device 5 reads T as the driving amount and moves the dancer roller 81 (82) by a very small amount in the direction opposite to the direction in which the dancer roller 81 (82) was moved by the previous offset control. Thus, the dancer roller 81 (82) can be brought close to the original position.

[0095] Next, we will explain in detail Figure 2 The method of producing the card 40 from each of the sheets 1 to 3.

[0096] like Figure 3 As shown, a reference sheet 3 serving as a reference for positioning and a first continuous sheet 1 on which a predetermined pattern is repeatedly printed are supplied to a nip roller 63. The nip roller 63 laminates the first continuous sheet 1 on the reference sheet 3 to form a laminated sheet 4.

[0097] In the process before lamination, the control device 5 performs the alignment mark R0 ( Figure 4 ) to detect the presence of the alignment mark. On the other hand, in the process after lamination, the control device 5 performs a pattern recorded on the first continuous sheet 1 of the stacked sheets 4, that is, the alignment mark R1 ( Figure 4 ) to detect the presence of the alignment mark.

[0098] The control device 5 determines whether the number of the alignment marks has reached a specified period. If the number of the alignment marks determined is less than the specified n corresponding to the above period, the adjustment process is not performed, and the adjustment process is performed every time the number of marks reaches the specified n. That is, the control device 5 controls the adjustment process every other period according to the above detection result. Figure 4 The feeding speed of the first continuous sheet 1 (the second continuous sheet 2) is reduced, and a first (second) adjustment step is performed to adjust the registration mark R1 of the first continuous sheet 1 (the second continuous sheet 2) to a predetermined position relative to the registration mark R0 of the reference sheet 3.

[0099] The results of the above tests are as follows: Figure 4 As in (a), the first or second continuous sheet 1, 2 is relative to the reference sheet 3 ( Figure 3 ) exceeds the first deviation range ±Δ1, Figure 3 The control device 5 moves the dancer roller 81 (82) by an amount T2 greater than the first constant amount T1 in a direction in which the positional deviation becomes smaller, thereby changing the supply amount of the first or second continuous web 1, 2 and performing the first or second adjustment step.

[0100] For example, Figure 4As in (a), when the alignment mark R1 (R2) of the first continuous sheet 1 (second continuous sheet 2) is greatly offset (larger than the first range ±Δ1) toward the downstream X1 in the conveying direction relative to the alignment mark R0 of the inlay 30, Figure 3 The control device 5 moves the dancer roller 81 (82) toward the upstream opposite to the downstream X1 by, for example, 2 mm (constant amount).

[0101] That is, before the first or second continuous sheet 1, 2 is stacked on the reference sheet 3, the dancer rollers 81, 82 around which the first or second continuous sheet 1, 2 is respectively wound are driven by the actuator 83, so as to move the dancer rollers 81, 82 to the reference sheet 3. Figure 4 The first or second continuous sheet 1, 2 is stretched in the direction in which the above-mentioned offset D of (a) becomes smaller. As a result, the offset D becomes smaller. By repeating this control, the offset D will soon become larger than the first range ±Δ1 ( Figure 3 )Small.

[0102] On the other hand, the results of the above test are as follows: Figure 4 As in (b), the first or second continuous sheet 1, 2 is relative to the reference sheet 3 ( Figure 3 ) exceeds the prescribed allowable range ±Δ and is smaller than the first deviation range ±Δ1, Figure 3 The control device 5 moves the dancer roller 81 (82) by a predetermined first constant amount T1 in a direction in which the positional deviation becomes smaller, thereby changing the supply amount of the first or second continuous web 1, 2 and executing the first or second adjustment step.

[0103] For example, Figure 4 As in (b), when the alignment mark R1 (R2) of the first continuous sheet 1 (second continuous sheet 2) is slightly offset from the alignment mark R0 of the inlay 30 toward the downstream X1 in the conveying direction, Figure 3 The control device 5 moves the dancer roller 81 (82) toward the upstream opposite to the downstream X1 by, for example, 1 mm (constant amount).

[0104] As a result, the offset amount D further decreases in the same manner as described above, and by repeating this control, the offset amount D eventually becomes smaller than the allowable range ±Δ.

[0105] In addition, the results of the above tests are as follows: Figure 4 As in (c), the first or second continuous sheet 1, 2 is relative to the reference sheet 3 ( Figure 3 ) is within the prescribed allowable range ±Δ, the actuator 83 moves the dancer rollers 81 and 82 to the position corresponding to the position they were in the previous adjustment process. Figure 3 The dancer roller moves a tiny amount T in the opposite direction of the direction it moves.

[0106] For example, Figure 4 When the alignment mark R1 (R2) of the first continuous sheet 1 (the second continuous sheet 2) is almost not offset in the conveying direction relative to the alignment mark R0 of the inlay 30, the control device 5 makes the tension adjustment rollers 81 and 82 move in the same direction as the last adjustment rollers 81 and 82. Figure 3 The dancer roller 81 (82) moves, for example, by a minute amount T (constant amount) in the (downstream) direction X1 opposite to the (upstream) direction in which it moves.

[0107] In this case, the offset amount D hardly changes due to slack of the sheet, etc. On the other hand, by repeating this control, the dancer roller 81 (82) approaches the original position, thereby preventing the dancer roller 81 (82) from being greatly displaced relative to the original position.

[0108] After the above stacking, based on Figure 2 The detection signal of the sensor S0, S1 or S2 is used to determine the position of the pattern, and the rotation of the trimming tool 64 is controlled according to the position of the pattern, thereby controlling the cutting position when the card 40 is generated.

[0109] It should be noted that in Figure 4 In the inlay 30 shown in FIG. 1 , the alignment marks R0 to R3 may also be as shown in FIG. Figure 5 As shown in (a), it is removed by cutting when cutting the card 40.

[0110] However, there is Figure 4 The position of the alignment mark R0 of the inlay 30 and the position of the alignment mark R1 (R2) of the first continuous sheet 1 (second continuous sheet 2) are different in phase in one card 40. In this case, the phase difference is input to the control device 5 in advance, and the position adjustment process as described above is performed.

[0111] In addition, if Figure 2 In this way, the sensor S0 is separated from the sensors S1 and S2 in the conveying direction X. Therefore, the timings of detecting the registration mark corresponding to a specific card 40 by the sensor S0 and the sensors S1 and S2 are greatly different. Therefore, the timing deviation needs to be considered in the control of the dancer roller.

[0112] It should be noted that the position adjustment of the sheets can also be performed by controlling the tension of each sheet.

[0113] As mentioned above, although the preferred embodiments have been described with reference to the drawings, it is easy for those skilled in the art to conceive of various changes and modifications within the obvious scope after reading this specification.

[0114] For example, two sheets may be bonded together to create a card.

[0115] In addition, the generated card can also be a contact card.

[0116] Therefore, such changes and modifications should be construed as contents within the scope of the present invention as defined by the technical claims.

[0117] Industrial Applicability

[0118] The present invention can be adopted in a method for manufacturing various cards such as cash cards.

[0119] Description of reference numerals:

[0120] 1: First continuous sheet 10: Front sheet

[0121] 2: Second continuous sheet 20: Back sheet

[0122] 3: Middle sheet (reference sheet) 3A: Multi-row inlay 3B: Single-row inlay

[0123] 3C: Continuous paper 30: Inlay 31: High-quality paper 32: Antenna 33: Through hole

[0124] 4: Laminated sheet 4T: Cut sheet 40: Card 41: Adhesive layer

[0125] 5: Control device (detection mechanism) 50: Mark determination unit 51: Counter 52: Deviation determination unit

[0126] 53: driving amount 54: display 55: operation part

[0127] 6A: First cutter 6B: Second cutter 60: Longitudinal cutting part 61: Guide

[0128] 62: Configuration roller 63: Clamping roller 64: Trimming tool 65: Belt conveyor

[0129] 7A: First anvil 7B: Second anvil 70, 71, 72: Coating machine

[0130] 8A: First suction conveyor 8B: Second suction conveyor

[0131] 81: First dancer roller 82: Second dancer roller 83: Actuator

[0132] 100: Printing press

[0133] G: Pattern N: Card name

[0134] R0, R1, R2: alignment marks

[0135] S0, S1, S2: Sensor (detection mechanism)

[0136] T: small amountT1: first constant amountT2: second constant amount

[0137] X: Conveying direction X1: Downstream X2: Upstream

[0138] ±Δ: Permissible range ±Δ1: First offset range.

Claims

1. A method for manufacturing a card, It is characterized in that The manufacturing method of the card comprises: A step of supplying a reference sheet (3) serving as a reference for alignment; A step of supplying a first continuous sheet (1) in which a plurality of patterns are repeatedly printed as a cycle; A step of supplying a second continuous sheet (2) formed by repeatedly printing a plurality of other patterns as a cycle; A step of laminating the first continuous sheet (1) and the second continuous sheet (2) on the reference sheet (3) to generate a laminated sheet (4); A step of detecting the position of each pattern in the repeatedly printed pattern one by one by using a detection mechanism; A step of detecting the position of each of the other repeatedly printed patterns by using a detection mechanism; A first adjustment step of controlling the feeding speed of the first continuous sheet (1) relative to the reference sheet (3) based on the detection result of the position of the pattern, and adjusting the pattern in a manner such that the pattern is at a predetermined position relative to the reference sheet (3); A second adjustment step of controlling the feeding speed of the second continuous sheet (2) based on the detection result of the position of the other pattern and adjusting the other pattern so that the other pattern becomes a predetermined position relative to the reference sheet (3); and a step of cutting the laminated sheet (4) for each of the patterns to produce a card (40); performing the first adjustment step every one cycle of the plurality of patterns, performing the second adjustment step every one cycle of the plurality of other patterns, The card manufacturing method further includes the steps of providing marks on the first continuous sheet and the second continuous sheet for each unit of the card and identifying the marks by the detection mechanism. When the number of the identified marks is less than the predetermined number n corresponding to the one cycle, the first adjustment process or the second adjustment process is not performed, and the first adjustment process or the second adjustment process is performed every time the number of the identified marks reaches the predetermined number n, The adjustment process is performed by driving a first tension adjustment roller (81) wound with the first continuous sheet (1) stacked in front of the reference sheet (3) and a second tension adjustment roller (82) wound with the second continuous sheet (2) stacked in front of the reference sheet (3) using an actuator (83). When the detection result shows that the positional deviation of the first continuous sheet (1) or the second continuous sheet (2) relative to the reference sheet (3) is outside a prescribed allowable range ±Δ and within a first deviation range ±Δ1, the first tension adjustment roller (81) or the second tension adjustment roller (82) is moved by a prescribed first constant amount (T1) in a direction in which the positional deviation becomes smaller, and the first adjustment process or the second adjustment process is performed, When the detection result shows that the position offset of the first continuous sheet (1) or the second continuous sheet (2) relative to the reference sheet (3) is within the specified allowable range ±Δ, the actuator (83) is used to cause the first tension adjustment roller (81) or the second tension adjustment roller (82) to move slightly in a direction opposite to the direction in which the first tension adjustment roller (81) or the second tension adjustment roller (82) was moved last in the first adjustment process or the second adjustment process.

2. The method for manufacturing a card according to claim 1, in, The cutting position when the card is generated is adjusted according to the position of each of the plurality of patterns or each of the plurality of other patterns.

3. The method for manufacturing a card according to claim 1, in, When the detection result is that the position offset of the first continuous sheet (1) or the second continuous sheet (2) relative to the reference sheet (3) is outside the first offset range ±Δ1, the first tension adjustment roller (81) or the second tension adjustment roller (82) is moved in a direction in which the position offset becomes smaller by a second constant amount (T2) that is larger than the first constant amount (T1) to perform the first adjustment process or the second adjustment process.

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