Multi-layer polymer composite device with enclosed components and method for manufacturing multi-layer polymer composite devices with enclosed components

Description

background

[0001] This paper describes a multilayer polymer composite device with enclosed components and a method for manufacturing multilayer polymer composite devices with enclosed components. Furthermore, a device for manufacturing multilayer polymer composite devices is described.

[0002] The polymer composite devices described here can, for example, have a credit card format, such as according to ISO / IEC 7810.

[0003] Multilayer polymer composite devices with embedded components, such as display cards, are known to be state of the art. The embedded components (batteries, indicator elements, sensors, etc.) have a spatial extent. However, in most applications, a flat surface of the polymer composite devices, such as the display cards, is desired on both the front and back sides. Therefore, it is necessary to compensate for the spatial extent of the embedded components. Voids or gas inclusions in the polymer composite devices, which could negatively affect their durability and mechanical strength, are undesirable.

[0004] At the same time, conventional hot lamination processes are not or hardly suitable for the production of multilayer polymer composite devices with enclosed components, as the high temperatures and pressures required for this can damage the enclosed or to-be-enclosed components.

[0005] A well-known method for implementing multilayer polymer composite devices with flat surfaces is to adapt the individual layers of the polymer composite device to the geometry of the enclosed or to-be-enclosed components. For example, recesses corresponding to the geometry of the components to be enclosed can be introduced into the individual layers by a stamping process, thus compensating for the spatial extent of the components and resulting in flat surfaces for the polymer composite device.

[0006] However, precisely punching the recesses, which each correspond to the geometry of the components to be enclosed, is very complex, especially when dealing with a large number of components, and requires a high precision in the punching process.

[0007] A well-known further development of this manufacturing process involves providing the individual layers of the polymer composite device with recesses. These recesses are suitable for compensating for the spatial expansion of the components, but are only approximately adapted to the geometry of the individual components. To prevent the formation of cavities, which would particularly affect the mechanical strength of the polymer composite devices, a filler or adhesive is introduced into the recesses. This filler or adhesive is designed to liquefy during the manufacturing process of the polymer composite devices, thereby encapsulating and fixing the components. The softening point of the filler or adhesive is below a temperature threshold at which damage to the components is to be expected.

[0008] EP 2 596 950 B1 discloses a method for producing film composite materials with embedded components. In this method, the expansion of the embedded components is compensated for by recesses in the film composite material. To prevent voids, a leveling material is introduced into the film composite material, the leveling material having a lower softening point than the surrounding film composite material. The leveling material can, for example, be a thermally activated adhesive. If the film composite material is heated above the softening point of the leveling material during production, the leveling material flows around the embedded components and fixes them in place.

[0009] EP 2 085 914 B1 discloses a polymer card and a method for producing it. The polymer card has a module or display element surrounded by an adhesive layer. The adhesive layer flows around the module or display element and is thermally curable.

[0010] A disadvantage of known polymer composite devices and their associated manufacturing processes is that voids cannot be completely avoided, for example, due to a lack of filler material in the recesses. Furthermore, it is still necessary to create recesses, even if only approximately corresponding to the geometries of the electronic components to be housed. This significantly increases the manufacturing effort of the polymer composite device.

[0011] Another disadvantage of known polymer composite devices and their associated manufacturing processes is the complex and difficult temperature control required during production. Particularly when heating a filler or adhesive that is unevenly distributed across different layers of the polymer composite device, uniform thermal activation of the filler or adhesive is challenging. This is because, firstly, parts of the filler or adhesive are located in different layers, and secondly, the surrounding polymer material, which has a higher softening point than the filler or adhesive, acts as a thermal insulator.

[0012] One well-known application of polymer composite devices, especially polymer cards, is the authentication of an operator of a data processing device, for example a home computer in the context of internet banking (online banking).

[0013] From DE 10 2015 205 081 A1, a corrugated tube is known which has an outer layer of polyamide, an additional outer layer of polyamide, a middle layer of polyethylene, and an inner layer of polyamide. The material of the middle layer is selected such that it does not bond with the materials of the adjacent layers. The layers are colored differently. This gives the corrugated tube improved wear indication.

[0014] From WO 2013 / 085723 A1, an article with a composite structure is known. To manufacture the article, a strip is first wound in multiple layers, the strip having fibers impregnated with polymer resin. Subsequently, it is heated so that the polymer resin softens, and then subjected to pressure treatment in a press, which causes solidification and eliminates air inclusions.

[0015] Further technological background information is revealed in the subsequently published document "Vicat Softening Temperature" by Polymer Service GmbH Merseburg. This document presents the VICAT softening temperatures for various selected plastics in tabular form.

[0016] Document WO 2014 / 149926 A1 further discloses a polymer card and a method for manufacturing it. The polymer card has at least one thermoplastic layer with a recess. Document DE 195 33 983 A1 also discloses an example of a chip card. The disclosed chip card has electronic components arranged between two layers of polymer material. Problem to be solved

[0017] Despite existing solutions, there is still a need for an improved polymer composite device with enclosed components.

[0018] The task is therefore to provide an improved multilayer polymer composite device with enclosed components.

[0019] Furthermore, an associated manufacturing process and a corresponding manufacturing device for the improved multilayer polymer composite device are to be provided.

[0020] The manufacturing of the polymer composite device should be facilitated, the number of necessary work steps reduced and / or simplified, and the number of components required reduced. Solution presented here

[0021] This problem is solved by a multilayer polymer composite device according to claim 1 and a manufacturing method according to claim 8.

[0022] Advantageous configurations are defined by the dependent requirements.

[0023] A card-shaped polymer composite device comprises a first thermoplastic cover layer made of a polymer material with a first softening temperature and a second thermoplastic cover layer made of a polymer material with a second softening temperature. The polymer composite device further comprises a support layer arranged between the first and second cover layers. An inner layer, formed from at least one first thermoplastic inner layer made of a polymer material with a third softening temperature, is arranged between the first and second cover layers. The inner layer is bonded to at least part of the support layer. The third softening temperature is lower than both the first and second softening temperatures. The first and second cover layers are arranged in relation to the inner layer.

[0024] One advantage of the polymer composite device is that at least one inner layer softens / liquefies upon heating of the polymer composite device starting at the third softening temperature, while the two outer layers remain dimensionally stable at least up to a first and / or second softening temperature. The inner layer of polymer material forms / encloses the support layer located between the outer layers, which can contain electronic components. Therefore, the inner layer does not need to be adapted to the geometry of the support layer and / or the components located on the support layer, or only to a significant extent. Furthermore, it is not necessary to introduce an additional filler or adhesive into the polymer composite device.This simplifies temperature control in a manufacturing process, as only the softening temperatures of at least one inner layer and the cover layers need to be considered, and the softening temperatures of the two cover layers can be identical. Uniform heating of at least one inner layer is desirable, but not strictly necessary, as the softening / liquefaction of at least one inner layer compensates for manufacturing and / or process inaccuracies. After the temperature of the polymer composite device drops, the at least one softened and / or liquefied inner layer can solidify again and form a fixed and / or material-bonded and / or adhesive bond with the substrate and / or with at least one of the cover layers.

[0025] The manufacturing process can therefore be simplified and / or accelerated.

[0026] The polymer composite device can include at least one display device arranged between the first cover layer and the second cover layer. In particular, the display device can be arranged on the carrier layer.

[0027] The display device can be, for example, a PLCD or LCD display. In particular, the display device can be electronic paper ("ePaper display"). The display brightness of the display device can be variably adjustable.

[0028] Advantages of electronic paper include its ability to be manufactured in a particularly space-saving manner, with a thin display, and its flexibility, which prevents damage even with limited deformation of the polymer composite device. Furthermore, electronic paper requires comparatively little energy to display optically recognizable characters, thus reducing the power supply and the space required for a power source, such as a battery.

[0029] The first cover layer and / or the second cover layer may, particularly in the area of ​​the display device, have at least a partially transparent and / or scratch-resistant section, so that at least part of the at least one display device is optically recognizable / readable for a viewer and / or an electronic reading device.

[0030] The first and / or the second cover layer and / or a partially transparent area of ​​the first and / or the second cover layer may have a matte or a glossy surface.

[0031] Possible embodiments of the polymer composite device include a first and / or second cover layer, each comprising several (partial) polymer materials with different softening temperatures. In these embodiments, the first and second softening temperatures are, respectively, the softening temperatures of the (partial) material with the lowest softening temperature.

[0032] Furthermore, at least one thermoplastic inner layer can be at least partially transparent, at least in the area of ​​the display device.

[0033] Possible embodiments of the polymer composite device include an inner layer, which has at least one inner layer consisting of several polymer materials with different softening temperatures. In these embodiments, the third softening temperature is that of the material with the lowest softening temperature.

[0034] The multilayer polymer composite device further comprises at least one first battery, in particular a rechargeable one.

[0035] Furthermore, the multilayer polymer composite device features a first overheating protection layer and, optionally, a second overheating protection layer. The first and, optionally, the second overheating protection layer comprise polymer materials whose softening temperatures are higher than the third softening temperature. The first and / or the second overheating protection layer can each consist partially or entirely of polymer materials, in particular polycarbonate. In other embodiments, the first and / or the second overheating protection layer can consist partially or entirely of other materials, for example, silicon dioxide.

[0036] The first overheating protection is arranged between the first battery and the first cover layer, in particular adjacent to a surface of the first battery facing the first cover layer.

[0037] Additionally, the first overheating protection can also be arranged between the at least one display device and the first cover layer, in particular adjacent to a surface of the display device facing the first cover layer.

[0038] The second overheating protection can be arranged between the first battery and the second cover layer, in particular adjacent to a surface of the first battery facing the second cover layer.

[0039] Alternatively or additionally, the second overheating protection can also be arranged between the at least one display device and the second cover layer, in particular adjacent to a surface of the display device facing the second cover layer.

[0040] The first and / or the second overheating protection can be designed and arranged in such a way that they simultaneously cover / protect from overheating both the first battery and at least one display device and / or other components.

[0041] The first and / or second overheating protection can cover / protect a multiple electronic components from overheating.

[0042] One advantage of using one or more overheating protection devices is the protection of particularly heat-sensitive components, such as the display device or the first battery. Overheating protection devices specifically safeguard those components located closest to one of the cover layers from overheating. Heat applied to the polymer composite device from the outside thus does not reach the heat-sensitive components, or only reaches them to a lesser extent and / or with a time delay, while at least one inner layer softens / liquefies. Furthermore, the first and / or second overheating protection device provides additional protection for sensitive components against high pressures or pressure spikes, such as those that can occur during lamination.

[0043] A further advantage of the first and / or second overheating protection is that it can prevent or at least reduce deformation of heat- and / or pressure-sensitive components. For example, electronic paper displays can develop warps or wavy surface structures at high temperatures, such as those that can occur during lamination processes. Such deformation can be at least partially prevented by the first and / or second overheating protection.

[0044] The first and / or second overheating protection can be transparent.

[0045] The inner layer of the multilayer polymer composite device can have a second thermoplastic, in particular transparent, inner layer, wherein the softening temperature of the second thermoplastic inner layer is equal to or lower than the third softening temperature.

[0046] Furthermore, the inner layer of the multilayer polymer composite device can comprise a third, fourth, fifth, and / or sixth thermoplastic, in particular transparent, inner layer, wherein the softening temperature of the third, fourth, fifth, and / or sixth thermoplastic inner layer is equal to or lower than the softening temperature of the third. The inner layer of the multilayer polymer composite device can comprise a plurality of, in particular transparent, inner layers, wherein the softening temperatures of the inner layers are each less than or equal to the softening temperature of the third. The softening temperatures of the inner layers can be identical or different from one another. The optical properties of the inner layers can differ from one another.

[0047] One advantage of implementing multiple inner layer layers that together form the inner layer is that it allows for complete encapsulation of the substrate and / or other elements with the inner layer. This improves the fixation and / or the material-bonded encapsulation of the substrate with polymer material.

[0048] The multilayer polymer composite device can include a second battery / accumulator, particularly a rechargeable one. The second battery / accumulator can be protected by the first and / or second overheating protection device. Furthermore, it is possible to protect a first electronic component, for example, the first battery, by the first and / or second overheating protection device, and a second electronic component, for example, the second battery, by a third and / or fourth overheating protection device. The number of overheating protection devices or measures can correspond to the number of electronic components to be protected.

[0049] Furthermore, the multilayer polymer composite device can incorporate electronic components, particularly semiconductor components. These components can form an electronic circuit. The components can be arranged on the substrate layer. Additionally, the components can be manufactured using a printing process. The substrate layer can be a printed circuit board (PCB).

[0050] Furthermore, the polymer composite device may also include magnetic strips, antennas, chips, activation or operating status indicators, and / or charge status indicators for the first and / or second battery. The activation or operating status indicator(s) and / or charge status indicator(s) may, for example, be designed as LED indicators, particularly multi-colored ones.

[0051] In one embodiment, the multilayer polymer composite device may include a fingerprint sensor which is designed and arranged to detect and / or store a fingerprint.

[0052] One advantage of a fingerprint sensor is that it enables person authentication. For example, the electronic circuitry can store information about a fingerprint and compare it to a fingerprint detected by the sensor. Depending on the result of the comparison, further processes can be executed or prevented by the electronic circuitry.

[0053] In one variant, the multilayer polymer composite device can include an induction coil suitable for receiving wirelessly transmitted energy. The ends of the induction coil can each be connected to charging contacts of the first and / or the second rechargeable battery / accumulator, enabling recharging of the first and / or second battery / accumulator via wireless inductive energy transfer.

[0054] Alternatively or additionally, recharging of the first and / or second battery / accumulator can be enabled by two charging contacts, each connected to the battery / accumulator, wherein the charging contacts are arranged to allow charging of the battery / accumulator by an external power supply. The charging contacts are not completely enclosed by the polymer composite device.

[0055] Optionally, an additional contact protector or stopper made of polycarbonate can insulate an exposed outer part of the charging contacts from the thermoplastic inner layer(s). The contact protector or stopper can be arranged between the cover layers, preferably in a manner inconspicuous to an observer of the polymer composite device.

[0056] One advantage of the contact protection or stopper is that the exposed outer contacts are thermally insulated from the thermoplastic inner layer(s). This prevents the thermoplastic inner layer(s) from melting due to heat emitted by the charging contacts during battery / accumulator charging.

[0057] Furthermore, the contact protector or stopper can also protect the exposed part of the charging contacts during lamination, as it forms a temperature-resistant barrier for the inner layers, which are melted, especially during the lamination process. This prevents or at least reduces contamination and / or obstruction of the charging contacts by the melted inner layers during lamination.

[0058] In one embodiment, the multilayer polymer composite device has at least one switch ("on / off button"), which is preferably surrounded by a spacer element, particularly annular in shape. In other embodiments, the spacer element can also have the outline of a polygonal frame or be partially annular. The terms "annular," "partially annular," and "outline of a polygonal frame" refer here to a cross-section of the spacer element or to a top view from the perspective of an observer of the polymer composite device. In the case of an annular spacer element, the body of the spacer element can, for example, also be described as a hollow cylinder. The spacer element can be made of materials from the group of metals and / or plastics, particularly silicones.

[0059] The spacer element can extend beyond the switch in the direction from the second cover layer to the first cover layer or in the direction from the first cover layer to the second cover layer. In particular, the spacer element can be suitable for preventing compressive forces on the switch during lamination.

[0060] The at least one switch and / or the spacer element can be arranged between the first and second cover layers, particularly on the substrate layer. Both the switch and the spacer element can either penetrate the first or second cover layer or be concealed by it. If the switch is concealed by the first or second cover layer, the first or second cover layer elastically spans the switch.

[0061] The switch can be designed for haptic activation by an operator. In particular, the switch can be a push button elastically covered by a protective layer and / or optically concealed, which can be actuated / activated by an operator of the polymer composite device by applying physical pressure to the polymer composite device in the area of ​​the switch. Alternatively, the switch can also be a push button penetrating a protective layer and / or optically detectable, which can be actuated / activated by an operator of the polymer composite device by applying physical pressure.

[0062] The switch can be configured to start and / or stop the operation of the electronic circuit and / or the display device. Alternatively or additionally, in other embodiments, the switch can serve to control further elements of the polymer composite device.

[0063] In a further development, the multilayer polymer composite device can have a plurality of switches for controlling device elements of the polymer composite device.

[0064] In one embodiment, the multilayer polymer composite device can include an optical sensor arranged and configured to detect an optically recognizable symbol. The optical sensor and / or the electronic circuitry can be arranged and configured to compare the detected optically recognizable symbols with stored information and / or to process them electronically.

[0065] The optical sensor and / or the electronic circuit can be arranged and configured to forward the detected optically recognizable characters and / or information determined on the basis of the detected optically recognizable characters to the display device.

[0066] Optionally, the polymer composite device can also include a light sensor. The display brightness can be adjusted depending on the ambient light level detected by the light sensor.

[0067] In one variant, the optical sensor is positioned on the side of the substrate facing away from the display device. Similarly, the light sensor and / or the exposed outer parts of the charging contacts can be positioned on the side of the substrate facing away from the display device.

[0068] A method for manufacturing a card-shaped polymer composite device comprises the following steps: Providing a first thermoplastic cover layer made of a polymer material with a first softening temperature, providing a second thermoplastic cover layer made of a polymer material with a second softening temperature, providing a support layer, providing an inner layer formed of at least one first thermoplastic inner layer made of a polymer material with a third softening temperature, wherein the third softening temperature is lower than the first softening temperature and lower than the second softening temperature, arranging the support layer and the inner layer between the first cover layer and the second cover layer, wherein the inner layer at least partially forms / surrounds / encloses the support layer, arranging a first battery between the first cover layer and the second cover layer, arranging a first overheating protection comprising a polymer material.whose softening temperature is greater than the third softening temperature, between the first battery and the first cover layer, applying a pressing force to at least one of the cover layers, such that the first cover layer and the second cover layer are at least partially pressed into contact with the inner layer, heating the pressed-in layers to a manufacturing temperature, wherein the manufacturing temperature is at least equal to the third softening temperature and the manufacturing temperature is less than the first softening temperature and the manufacturing temperature is less than the second softening temperature.

[0069] The execution order of the steps is not fixed. In particular, the deployment of the layers can occur in any order.

[0070] Furthermore, the process for manufacturing a polymer composite device may include at least one of the following steps: Arranging a display device and / or a first battery between the first cover layer and the second cover layer, in particular on the carrier layer; arranging a second overheating protection device between the display device and / or the first battery and the second cover layer, in particular adjacent to a surface of the display device and / or the first battery facing the second cover layer; cooling the layers to a temperature which is lower than the third softening temperature; releasing the pressing force.

[0071] The order in which the steps are executed is not specified.

[0072] Furthermore, prior to the described process steps for the production of a polymer composite device, electronic components, in particular semiconductor components, can be arranged on the substrate layer, in particular by a printing process.

[0073] One advantage of this process, besides its simple process control, particularly its simple temperature control, is that the overall heating time can be reduced. Specifically, an inner layer already in direct contact with the cover layer can be softened / liquefied by heating. Thus, externally supplied heat reaches the material to be softened / liquefied as soon as the first and / or second cover layer is heated.

[0074] In the process described here, the heating of the layers pressed in the system can be stopped after a predetermined period of time, preferably 60 seconds, particularly preferably 30 seconds.

[0075] One advantage is that the shorter heating time protects temperature-sensitive elements, such as electronic components.

[0076] A lamination device described herein, but not belonging to the invention, which is suitable for manufacturing a polymer composite device, comprises at least a first thermopress having a first heatable press plate and a second heatable press plate. The press plates are aligned parallel to each other and together define an interior space. A first laminating plate rests against the surface of the first press plate facing the second press plate, at least during the manufacturing of the polymer composite device. A second laminating plate rests against the surface of the second press plate facing the first press plate, at least during the manufacturing of the polymer composite device.Furthermore, a first insulation layer is located on the surface of the first laminating plate facing the second press plate, and a second insulation layer is located on the surface of the second laminating plate facing the first press plate.

[0077] At least the first press plate can be effectively displaced in one direction towards the second press plate, so that the first and second insulating inserts can be brought into contact with a workpiece located inside, in particular with a polymer composite device. In a further development of the lamination device, the first and / or the second press plate can be effectively displaced. The first laminating plate can be heated by heating the first press plate, and the second laminating plate can be heated by heating the second press plate. The first insulating insert can be heated with a time delay by heating the first laminating plate, and the second insulating insert can be heated with a time delay by heating the second laminating plate.

[0078] The first and / or second insulating layer is designed to transfer heat with a time delay. After this delay, the heat is transferred to the workpiece, particularly the polymer composite device, with a uniformly increasing temperature.

[0079] One advantage of such a lamination device is the improved temperature control achieved through the time-delayed heating of the insulating inserts. Due to the direct contact of the insulating inserts with the workpiece, the workpiece is heated directly in line with the heating of the insulating insert.

[0080] The insulating inserts can be designed to be particularly elastic or flexible in a predetermined area in order to avoid scratching and / or damaging the polymer composite device to be manufactured when in direct contact with it.

[0081] In one embodiment of the lamination device, the first thermopress may further comprise a first heating device for heating the first press plate and / or a second heating device for heating the second press plate. In a further embodiment, the first thermopress or a second thermopress may comprise a first cooling device for cooling the first press plate of the first thermopress or for cooling a first press plate of the second thermopress and / or a second cooling device for cooling the second press plate of the first thermopress or for cooling a second press plate of the second thermopress.

[0082] In variants where the lamination device includes a second thermopress, the second thermopress can be constructed analogously to the first. In particular, the second thermopress, which especially includes a first and / or a second cooling device, can also include an arrangement of press plates, laminating plates, and insulating inserts corresponding to that of the first thermopress. The insulating inserts of the second thermopress, which are in direct contact with the polymer composite device being manufactured, can improve the temperature control during cooling of the polymer composite device, analogous to the heating of the polymer composite device by the first thermopress.

[0083] Furthermore, the lamination device may include a transport device which is designed and arranged to transport a workpiece to be manufactured, or an arrangement consisting of the workpiece to be manufactured and the laminating plates and / or the insulating inserts, into the interior of the thermopress and / or to transport a workpiece, or an arrangement consisting of the workpiece to be manufactured and the laminating plates and / or the insulating inserts, out of the interior of the thermopress.

[0084] The transport device can be designed and arranged to move a workpiece or arrangement to be manufactured in a conveying direction and / or to be movable in a lowering direction which is essentially orthogonal to the conveying direction.

[0085] The transport device can in particular be a conveyor belt which is movable / lowerable in one direction orthogonal to a conveying direction.

[0086] In one variant, the transport device can comprise two parallel conveyor belts which can be lowered into suitable recesses in the first and / or second thermopress. These recesses are located on a press plate of the first and / or second thermopress.

[0087] The lamination device can include at least one sensor arrangement that detects the position of the workpiece, in particular the polymer composite device. The workpiece position can be detected both inside and outside the interior of the thermopress. In the event of incorrect workpiece positioning, a manufacturing process can be interrupted and / or the workpiece position can be corrected using a control system. Brief description of the characters

[0088] Further features, properties, advantages, and possible modifications will become clear to a person skilled in the art from the following description, which refers to the accompanying drawings. The dimensions and proportions of the components shown in the figures are not to scale. The invention is defined solely by the claims; the following description and the drawings serve to enhance understanding thereof. Fig. 1 schematically shows a polymer composite device with enclosed components. Fig. 2 schematically shows a polymer composite device with enclosed components in a lamination device. Figs. 3 and 4 schematically show a lamination device with a transport device. Detailed description of the figures

[0089] Comparable or identical components and features with the same effect are identified by the same reference symbols in the figures. For clarity, reference symbols for individual features and components have sometimes been omitted in the figures, although these features and components are already identified by reference symbols in other figures. Components and features not described again in relation to the other figures are similar in form and function to the corresponding components and features shown in the other figures.

[0090] Figure 1Figure 1 shows a polymer composite device 100 with a first cover layer 110 and a second cover layer 120. The first cover layer 110 and the second cover layer 120 are made of a thermoplastic polymer material, in particular polycarbonate. In the illustrated embodiment, the first cover layer 110 and the second cover layer 120 are made of the same thermoplastic polymer material; however, this is not the case in all embodiments according to the invention.

[0091] The first cover layer 110 and the second cover layer 120 form the outermost layers of the polymer composite device 100. A support layer 130 and an inner layer 140 are arranged between the first cover layer 110 and the second cover layer 120.

[0092] A plurality of electronic components 133 are arranged on the substrate layer 130. Furthermore, a fingerprint sensor 134, a first rechargeable battery 131, and a display device are arranged on or attached to the substrate layer 130. The display device is designed and configured to display optically recognizable characters. The substrate layer, in conjunction with the components arranged on or attached to it, has an uneven cross-sectional profile with raised elements. In other variants (not shown), the substrate layer 130 can, for example, include a second battery, an optical sensor, a switch, an induction coil, and / or connection contacts for the first and / or second battery.

[0093] The inner layer 140 comprises in the Fig. 1The illustrated embodiment comprises six inner layer layers 141, 142, 143, 144, 145, and 146. In the illustrated embodiment, the six inner layer layers are made of the same thermoplastic transparent polymer material; however, this is not the case in all embodiments according to the invention. The inner layer layers 141, 142, 143, 144, 145, and 146 can, for example, consist of a single material, particularly a uniform PET, PETG, ABS, or PVC.

[0094] The inner layer 140 partially surrounds the carrier layer 130 and the components arranged on or attached to it. For this purpose, recesses are provided in the first, second, third, fourth, and fifth inner layer layers, which are suitable for receiving the carrier layer and the components arranged on or attached to the carrier layer. In other embodiments (not shown) with only slightly raised components, the implementation of recesses in one or more inner layer layers can be completely omitted.

[0095] The first cover layer 110 has a transparent and scratch-resistant section 111, which, from the perspective of an observer of the polymer composite device 100, is positioned above the display device. The transparent section 111 is also made of a thermoplastic polymer material / polycarbonate. In the embodiment shown here, the section 111 is a separate piece of polymer film inserted into the first cover layer 110. However, this is not the case in all embodiments. Furthermore, the first cover layer 110 has a recess in the area of ​​the fingerprint sensor 134, so that the fingerprint sensor 134 is not covered by the first cover layer 110.

[0096] The fingerprint sensor 134 shown is suitable for capturing and storing an operator's fingerprint. The fingerprint sensor 134, as well as the electronic components 133, is powered by the first battery 131.

[0097] The first thermoplastic cover layer 110 with the transparent section 111 has a softening temperature T1. The second cover layer 120 has a softening temperature T2. In the illustrated embodiment, the softening temperatures T1 and T2 are identical, but this is not the case in all embodiments according to the invention.

[0098] The inner layer 140, which comprises the six inner layer layers 141, 142, 143, 144, 145, 146, has a uniform softening temperature T3. In other embodiments, the inner layer can comprise a plurality of inner layer layers, wherein the individual inner layer layers can have different softening temperatures.

[0099] The softening temperature T3 is lower than the softening temperature T1 or T2.

[0100] For example, the softening temperature T3 can have a value of 140 degrees Celsius. The softening temperatures T1 and T2 can each have a value between 160 and 220 degrees Celsius, for example.

[0101] If the polymer composite device 100 is heated above its softening temperature T3, the inner layer 140 softens or liquefies, while the first and second cover layers 110, 120 remain dimensionally stable at least until the polymer composite device 100 is heated to temperatures T1 and T2, respectively. This ensures that the polymer composite device 100 maintains a flat surface, even when heated above its softening temperature T3.

[0102] If, in addition to heating the polymer composite device 100, a pressing force is exerted on the first and / or the second cover layer 110, 120, the inner layer 140 forms / flows around / encloses the carrier layer 130 and the elements arranged on or on it in a materially bonded manner, so that no cavities remain inside the polymer composite device 100.

[0103] The in Figure 1The illustrated embodiment of the polymer composite device 100 also features a first overheating protection device 137 and a second overheating protection device 138, which are made of a transparent polymer material. The softening temperatures of the first and second overheating protection devices 137, 138 are higher than the temperature T3. During heating of the polymer composite device 100 above the softening temperature T3, both the first and the second overheating protection devices 137, 138 remain dimensionally stable. The first overheating protection device 137 is arranged on the surface of the first battery 131 and the display device facing the first cover layer 110. The second overheating protection device 138 is arranged on the surface of the first battery 131 and the display device facing the second cover layer 120.

[0104] During the heating of the polymer composite device 100, the first overheating protection 137 and the second overheating protection 138 protect temperature-sensitive electronic components of the polymer composite device 100 by absorbing some of the supplied heat and delaying heating of the components.

[0105] One advantage of the polymer composite device 100 is that no additional filler or adhesive material is required to fix the cross-sectionally uneven substrate layer. This significantly simplifies temperature control during manufacturing, thereby reducing the overall production time. This is particularly beneficial for temperature- and / or pressure-sensitive electronic components. The temperature-sensitive components closest to the two cover layers are further protected by the use of overheating protection.

[0106] Figure 2 Figure 1 schematically shows a thermopress 210, which is suitable for heating a polymer composite device 100 and exerting a pressing force on it. The thermopress 210 comprises a first press plate 211 and a second press plate 212.

[0107] The first press plate 211 and the second press plate 212 are aligned parallel to each other and together define an interior space. A first laminating plate 221 rests against the surface of the first press plate 211 facing the second press plate 212. A second laminating plate 222 rests against the surface of the second press plate 212 facing the first press plate 211.

[0108] In the Figure 2In the illustrated embodiment, an insulating insert in the form of a first Teflon film 231 is located on the surface of the first laminating plate 221 facing the second press plate 212. An insulating insert in the form of a second Teflon film 232 is located on the surface of the second laminating plate 222 facing the first press plate 211.

[0109] The insulating inserts promote uniform heat transfer to the polymer composite device being heated, thus contributing to maintaining the flat surfaces of the polymer composite device during the application of pressing force.

[0110] The polymer composite device 100 to be manufactured is arranged between the first and the second Teflon film 231, 232.

[0111] In the Figure 2In the illustrated embodiment, the first press plate 211 is arranged and designed to exert a pressing force on the polymer composite device 100 by means of a pressing-effective displacement in the direction of the second press plate 212.

[0112] Both the first and second press plates 211, 212 are designed and arranged to be heated by a heating device (not shown). The heat supplied to the press plates 211, 212 is initially transferred to the laminating plates 221, 222. The laminating plates 221, 222 each heat the first and second Teflon films 222, 232, respectively, with the Teflon films delaying the transfer of heat to the polymer composite device 100 arranged in the thermopress. After the delay has elapsed, the heat is transferred to the polymer composite device 100 at a uniformly increasing temperature.

[0113] The thermopress 210 is designed and arranged to heat the polymer composite device 100 to a production temperature TF, wherein the production temperature TF is higher than the softening temperature T3 and lower than the softening temperature T1 or T2. The thermopress 210 is designed and arranged to simultaneously exert a pressing force on the polymer composite device 100 while heating it.

[0114] Furthermore, the thermopress 210 is designed and arranged to stop the heating of the layers pressed in the system after a predetermined period of time, preferably 60 seconds, particularly preferably 30 seconds.

[0115] Figure 3 and Figure 4 Figure 1 shows a lamination device 200, which comprises a first thermopress 210 and a second thermopress 240, as well as a transport device 400. The second thermopress 240 corresponds in its construction to the one shown in Figure 2. Figure 2 The thermopress 210 shown. Furthermore, the second thermopress 240 is arranged and designed to cool a polymer composite device 100 by means of a cooling device (not shown) and simultaneously exert a pressing force on the polymer composite device 100.

[0116] Optionally, a vacuum can be generated in the area of ​​the first and / or second thermopress, in particular in the interior of the first and / or second thermopress, during the heating and / or cooling of the polymer composite device.

[0117] A transport device 400 successively conveys a plurality of polymer composite devices into the interiors of the thermopresses 210, 240 and out of the interiors of the thermopresses. The polymer composite devices are each arranged in an assembly of two laminating plates and two Teflon films. The arrangements correspond to the one described in Figure 1 arrangement shown.

[0118] The transport device 400 comprises two, in particular independently movable, circulating belts 410, 420, which are suitable for moving the polymer composite device or the arrangements along a conveying direction X. The circulating belts 410, 420 are guided over the drive rollers 430. The circulating belts 410, 420 are designed and arranged to lower into recesses 213, 214 provided for this purpose before or during the pressing action of the respective first press plates of the thermopresses 210, 240.

[0119] In other words, the conveyor belts 410 and 420 are movable in a direction Y that is essentially orthogonal to the conveying direction X. The conveyor belts 410 and 420 can be positioned in the recesses 213 and 214 of the thermopresses 210 and 240.

[0120] When the conveyor belts 410, 420 are lowered, the conveyed assemblies, in which the polymer composite devices to be manufactured are held, lose direct contact with the conveyor belts and rest against a surface of the respective thermopress. Furthermore, the conveyor belts 410, 420 are designed and arranged to be moved out of the recesses 213, 214 after the release of the press force, so that contact between the conveyor belts and the polymer composite devices is re-established and the successive conveying in the conveying direction X can continue.

[0121] The lowering of the conveyor belts 410, 420 can be achieved, for example, by lowering the drive rollers 430.

[0122] In a further development (not shown), the first and / or second thermopress can each have its own transport device, each with its own drive. The transport devices can interlock in a transfer area. In particular, the parallel conveyor belts of the transport devices can have different distances from each other, thus enabling the transport devices to interlock. Independent operation of the transport devices is possible.

Claims

1. A polymer composite device in card form (100) comprising a first thermoplastic covering layer (110) of a polymer material with a first softening temperature (T1), a second thermoplastic covering layer (120) of a polymer material with a second softening temperature (T2), a carrier layer (130) which is arranged between the first covering layer (110) and the second covering layer (120), an inner layer (140) which is formed of at least a first thermoplastic inner layer (141) made of a polymer material with a third softening temperature (T3) and arranged between the first covering layer (110) and the second covering layer (120), a first battery (131) arranged between the first covering layer (110) and the second covering layer (120), a first overheat protection (137) containing a polymer material whose softening temperature is higher than the third softening temperature (T3), wherein the inner layer (140) at least partially surrounds the carrier layer (130) in a material-bonding manner, the third softening temperature (T3) is lower than the first softening temperature (T1) and lower than the second softening temperature (T2), wherein the first covering layer (110) and the second covering layer (120) are arranged in contact with the inner layer (140), and the first overheat protection (137) is arranged between the first battery (131) and the first covering layer (110).

2. The polymer composite device (100) according to claim 1, further comprising at least one display device, wherein the at least one display device is arranged between the first covering layer (110) and the second covering layer (120), in particular on the carrier layer (130), the first covering layer (110) and / or the second covering layer (120) include, in particular in the region of the display device, at least one partially transparent section, so that at least part of the at least one display device is optically recognizable / readable for an observer and / or an electronic reader, and / or at least one thermoplastic inner layer (141) is at least partially transparent at least in the area of the display device.

3. The polymer composite device (100) according to one of the preceding claims, further comprising a second overheat protection device (138), which in particular comprises a polymer material whose softening temperature is higher than the third softening temperature (T3), wherein the second overheat protection device (138) is arranged between the display device and / or the first battery (131) and the second covering layer (120), in particular lying against a surface of the display device and / or the first battery (131) facing the second covering layer (120).

4. The polymer composite device (100) according to one of the preceding claims, wherein the inner layer (140) further comprising a second thermoplastic, in particular transparent, inner layer (142), wherein the softening temperature of the second thermoplastic inner layer (142) is the same as or lower than the third softening temperature (T3), and / or a third thermoplastic, in particular transparent, inner layer (143), wherein the softening temperature of the third thermoplastic inner layer (143) is the same as or lower than the third softening temperature (T3), and / or a fourth thermoplastic, in particular transparent, inner layer (144), wherein the softening temperature of the fourth thermoplastic inner layer (144) is the same as or lower than the third softening temperature (T3), and / or a fifth thermoplastic, in particular transparent, inner layer (145), wherein the softening temperature of the fifth thermoplastic inner layer (145) is the same as or lower than the third softening temperature (T3), and / or a sixth thermoplastic, in particular transparent, inner layer (146), wherein the softening temperature of the sixth thermoplastic inner layer (146) is the same as or lower than the third softening temperature (T3).

5. The polymer composite device (100) according to one of claims 3 or 4, further comprising a second, in particular rechargeable, battery (132), and / or electronic components (133), in particular semiconductor components, arranged in particular on the carrier layer (130), which form an electronic circuit, and / or at least one fingerprint sensor (134) which is arranged and configured to detect and / or store a fingerprint, and / or at least one induction coil, which is electrically conductively connected to the first and / or the second battery, and / or at least two connection contacts which are electrically conductively connected to the first and / or second battery, wherein the first and / or second battery can be charged by an electric current which is brought about by applying a voltage to the connection contacts and / or by inductive energy transfer to the induction coil.

6. The polymer composite device (100) according to one of the preceding claims, further comprising at least one switch, which is preferably surrounded by an in particular annular spacer element, wherein the at least one switch and / or the spacer element are arranged between the first covering layer (110) and the second covering layer (120), in particular on the carrier layer (130), and / or the switch is configured for starting and / or ending operation of the electronic circuit and / or of the display device, and / or the spacer element protrudes beyond the switch in the direction from the second covering layer (120) to the first covering layer (110) or in the direction from the first covering layer (110) to the second covering layer (120).

7. The polymer composite device (100) according to one of the preceding claims, further comprising an optical sensor which is arranged and configured to detect an optically recognizable symbol, in particular a QR code, wherein the optical sensor and / or the electronic circuit are arranged and designed to compare the detected optically recognizable symbols with stored information and / or to process them electronically, and / or the optical sensor and / or the electronic circuit are arranged and configured to transmit the detected optically recognizable symbols and / or information determined on the basis of the detected optically recognizable symbols to the display device, and / or the optical sensor is positioned on the side of the carrier layer (130) that faces away from the display device.

8. A method for producing a polymer composite device in card form (100), comprising the steps of: - providing a first thermoplastic covering layer (110) made of a polymer material with a first softening temperature (T1), - providing a second thermoplastic covering layer (120) of a polymer material with a second softening temperature (T2), - providing a carrier layer (130) - providing an inner layer (140) formed of at least a first thermoplastic inner layer (141) of a polymer material with a third softening temperature (T3), wherein the third softening temperature (T3) is lower than the first softening temperature (T1) and lower than the second softening temperature (T2), - arranging the carrier layer (130) and the inner layer (140) between the first covering layer (110) and the second covering layer (120), wherein the inner layer (140) at least partially surrounds the carrier layer (130), - arranging a first battery (131) between the first covering layer (110) and the second covering layer (120), - arranging a first overheat protection (137), which contains a polymer material whose softening temperature is greater than the third softening temperature (T3), between the first battery (131) and the first covering layer (110), - exerting a pressing force on at least one of the covering layers (120, 130) so that the first covering layer (110) and the second covering layer (120) are pressed at least partially into contact with the inner layer (140), - heating the layers pressed into contact (110, 120, 130) to a manufacturing temperature (TF), wherein the manufacturing temperature (TF) is at least equal to the third softening temperature (T3), the manufacturing temperature (TF) is lower than the first softening temperature (T1), and the manufacturing temperature (TF) is lower than the second softening temperature (T2).

9. The method for producing a polymer composite device (100) according to claim 8, further comprising at least one of the steps: - arranging a display device between the first covering layer (110) and the second covering layer (120), in particular on the carrier layer (130), - placing a second overheat protection (138) between the display device and / or the first battery (131) and the second covering layer (120), in particular lying against a surface of the display device and / or the first battery (131) facing the second covering layer (120), - cooling the layers (110, 120, 130) to a temperature which is lower than the third softening temperature (T3), - releasing the pressing force.

10. The method for producing a polymer composite device (100) according to claim 8 or 9, wherein prior to the method steps, electronic components, in particular semiconductor components, are arranged on the carrier layer, in particular by a printing process.

11. Method for producing a polymer composite device (100) according to one of claims 8 to 10, wherein heating of the layers pressed into contact is ended after a predetermined period of time, preferably 60 seconds, particularly preferably 30 seconds.