Plastic card and its manufacturing method

Abstract

To provide a plastic card of which design is prevented from being impaired by wear of the side surfaces of the card even when the side surfaces of the plastic card are rubbed against a magnetic card reader when magnetic information on the plastic card is read using the card reader.SOLUTION: A plastic card 20 comprising a laminate with an inner polyvinyl chloride layer 1 comprising at least one layer and an outer polyethylene terephthalate layer 2 provided on the front and back surfaces of the polyvinyl chloride layer, has a decorative layer 4 on the side surface, and in the cross-section of the side surface of the plastic card, the surface of the polyvinyl chloride layer is provided inside a straight line connecting two points where the polyvinyl chloride layer and the polyethylene terephthalate layer contact.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] This relates to a plastic card whose design is enhanced by forming a decorative layer on the side surface. [Background technology]

[0002] As an example of a plastic card with a highly designed side surface, Patent Document 1 discloses a plastic card in which printing is performed over the entire periphery of a sheet-like spacer exposed on the side surface of the plastic card, which is formed by laminating exterior sheets on both sides of a sheet-like spacer having an opening for accommodating an IC module. Patent Document 2 also discloses a plastic card having an image printed by pad printing on the side surface of the plastic card.

[0003] To read the information recorded on the magnetic recording section of these plastic cards, the card is inserted into a slot in a card reader and the side of the card is pressed against the bottom of the slot while sliding to read the information. This process causes wear on the side of the card, which can impair the card's design. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2015-130100 [Patent Document 2] Japanese Patent Application Publication No. 2018-122563 Summary of the Invention [Problem to be solved by the invention]

[0005] To solve the above problems, the present invention aims to provide a plastic card whose design is not impaired by wear on the side of the card even when the side of the plastic card is rubbed against a card reader when magnetic information on the plastic card is read using a magnetic card reader. [Means for solving the problem]

[0006] One embodiment of the present invention is a plastic card comprising a laminate having at least one inner vinyl chloride layer and outer polyethylene terephthalate layers provided on the front and back surfaces of the vinyl chloride layer. A decorative layer is provided on the side of the plastic card, and in a cross section of the side of the plastic card, the surface of the vinyl chloride layer is provided inside a straight line connecting two points where the vinyl chloride layer and the polyethylene terephthalate layer meet. [Effects of the Invention]

[0007] According to the plastic card of the present invention, in a cross section of a plastic card having an inner layer and outer layers provided on the front and back sides of the inner layer, the surface of the inner layer is provided inside the line connecting the two points where the inner layer meets the outer layer. Therefore, when reading the magnetic information on the plastic card using a magnetic card reader, even if the side of the plastic card is rubbed against the card reader, only the outer layer is rubbed, so the decorative layer provided on the side of the card is not worn away, and the design is not impaired.

[0008] Furthermore, according to the method for producing a plastic card of the present invention, the plastic card of the present invention It is possible to manufacture the following. [Brief explanation of the drawings]

[0009] [Figure 1] 1A and 1B are cross-sectional explanatory views illustrating the process of forming a plastic card of the present invention, in which (a) shows a schematic diagram of the change in the cross-sectional shape of the card side before transferring the decorative layer, and (b) shows a schematic diagram of the change in the cross-sectional shape of the card side after transferring the decorative layer. [Figure 2] 1 is a cross-sectional view illustrating the cross-sectional shape of a side surface of a plastic card of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0010] <Plastic card> The plastic card of the present invention will be described with reference to FIGS. The plastic card 20 of the present invention is a plastic card made up of a laminate having an inner layer 1 made up of at least one layer and outer layers 2, 2' provided on the front and back surfaces of the inner layer 1.

[0011] The side surface 3 of the plastic card 20 of the present invention is provided with a decorative layer 4, which serves to enhance the card's design. FIG. 1 is a cross-sectional view illustrating the state before the decorative layer 4 is formed, with the side surface 3 being a flat surface. On the other hand, FIG. 2 is a cross-sectional view illustrating the state after the decorative layer 4 has been formed on the side surface. Initially, the side surface 3 was flat, but after the decorative layer is formed, it becomes a side surface 7 that is recessed inward, with the decorative layer 4 provided on top of it (see FIG. 1(b)).

[0012] That is, in the cross section of the side of the plastic card 20 of the present invention, the side surface of the inner layer 1 is characterized by being located inside the straight line 6 connecting the two points 5, 5' where the inner layer 1 contacts the outer layers 2, 2'.

[0013] (inner layer) The inner layer 1 is the core layer of the plastic card 20 of the present invention. The layer structure of the inner layer 1 may be a single layer or a laminate of two or more layers. The material constituting the inner layer 1 is preferably a resin with low heat resistance, such as PVC (polyvinyl chloride) or PETG (glycol-modified polyethylene terephthalate).

[0014] Here, heat resistance refers to, for example, the molding shrinkage rate and heat distortion temperature of a resin. The volume of a resin (plastic) expands at higher temperatures and contracts at lower temperatures. The ratio of these is the molding shrinkage rate. When molding resin in a mold, if the mold dimension is 1c and the corresponding dimension of the molded product is 1, the molding shrinkage rate is expressed as {(1c - 1) / 1c} x 100 (%). Therefore, the higher the molding shrinkage rate, the greater the shrinkage that occurs when the resin softens and solidifies. The heat distortion temperature is the temperature at which a specified deformation occurs when the resin is heated at a constant rate under load. For example, it can be the temperature measured according to ASTM D648 Method A or B. It can also be the temperature measured according to JIS K7191-2:2015 Method A or B.

[0015] As explained above, by using a resin with a high molding shrinkage rate for the inner layer 1, the volume of the inner layer 1 is reduced in the cross section of the side of the plastic card 20, making it easier to form a concave cross section of the side. Similarly, by using a resin with a low heat distortion temperature for the inner layer 1, the inner layer 1 softens even at a temperature at which the outer layer 2 does not soften, and the shrinking stress generated in the inner layer 1 when forming the laminate (outer layer 2 / inner layer 1 / outer layer 2) is released. As a result, the volume of the inner layer 1 is reduced, and a concave cross section of the side of the plastic card 20 is formed.

[0016] In addition to molding shrinkage, the reason why resin tends to shrink in a solid state is due to internal stress generated when the resin is molded into a sheet. For example, when a force is applied to a resin to process it into a sheet or film, stress remains within the sheet. For example, in the case of a uniaxially stretched film, a compressive stress that tends to shrink remains within the sheet or film as a reaction to being pulled in the flow direction. This stress is released when the sheet or film softens and shrinks. It is preferable to use a resin sheet or resin film that has such residual compressive stress as the resin sheet or resin film used as the inner layer 1.

[0017] In this way, the inner layer 1 of the cross section of the side of the plastic card 20 has a recessed structure, so that even if the side of the plastic card 20 is rubbed against the bottom of the slit of a card reader or against another object, the decorative layer 4 will not be rubbed. Therefore, damage to the decorative layer 4 can be avoided. Although the decorative layer 4 formed on the outer layer 2 will be damaged, the decorative layer 4 formed on the inner layer 1 will not be damaged, so the decorative layer 4 itself will hardly be damaged.

[0018] The inner layer 1 is configured as one layer, but it does not necessarily have to be a single layer, and may be configured as two or more layers. A let may be included.

[0019] When an IC inlet is included, any known IC inlet can be used, for example, an IC inlet support made of polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polyimide (PI), paper, synthetic paper, etc., on which an IC chip and antenna electrically connected to each other are provided.

[0020] Examples of antennas include those made by etching or punching a metal foil, typically aluminum or copper, into a pattern, those made by applying conductive ink to a pattern using known methods such as screen printing, flexographic printing, gravure printing, or inkjet printing, and those made by winding and welding.

[0021] The resin constituting the inner layer 1 may contain various additives such as conventionally known pigments and extender pigments, such as titanium oxide, calcium carbonate, barium sulfate, and white lead, as well as heat stabilizers and ultraviolet absorbers.

[0022] (outer layer) The outer layer 2 is a layer disposed on the front and back surfaces of the inner layer 1 which is the core of the plastic card 20 of the present invention. The layer structure of the outer layer 2 may be a single layer or a laminate of two or more layers. The material constituting the outer layer 2 is preferably a highly heat-resistant resin such as PET (polyethylene terephthalate) or PC (polycarbonate).

[0023] The thickness of the outer layer 2 is preferably 0.040 mm to 0.120 mm. If the thickness of the outer layer 2 is thin, the inner layer 1 will be thicker, which will increase the width of the recess on the card side after thermal transfer of the decorative layer 4. However, the area of ​​the hard layer will be smaller, which will reduce the resistance to rubbing on the side. Therefore, a thickness of 0.040 mm or more is required. On the other hand, if the outer layer 2 is thick, the width scraped off by rubbing will be wider, which will reduce the effect of protecting the decorative layer 4, so a thickness of 0.120 mm or less is preferred.

[0024] Moreover, it is desirable that the color of the outer layer 2 be transparent or similar to that of the decorative layer 4.

[0025] The outer layer 2 may contain various known additives such as heat stabilizers, ultraviolet absorbers, plasticizers, and antistatic agents, or may be subjected to special treatments such as matte finish.

[0026] Furthermore, there is no problem if a functional layer such as a layer having laser printability or an adhesive layer is separately provided between the inner layer 1 and the outer layer 2.

[0027] Such a functional layer may be provided in the form of a sheet, or may be provided as a coating layer or a printed layer.

[0028] (decorative layer) The decorative layer 4 is a layer that enhances the design of the side surface of the plastic card 20 of the present invention. The decorative layer 4 may be a single layer or may be composed of two or more layers, with at least a layer having a pattern or optical effect that enhances the design disposed on the outermost surface.

[0029] The decorative layer 4 is made up of layers including at least an adhesive layer and a protective layer, and an intermediate layer may be provided between them.

[0030] The decorative layer 4 is formed as a decorative transfer film and is formed by thermally transferring it onto the side surface 3 of the plastic card 10 (see FIG. 1(a)).

[0031] The layer structure of the decorative transfer film will be described below.

[0032] Supports used for decorative transfer films include papers such as capacitor paper, as well as resin films such as polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polypropylene (PP), polyvinyl chloride (PVC), polycarbonate (PC), triacetyl cellulose (TAC), and polyimide (PI), of which polyethylene terephthalate (PET) is preferred for its ease of handling and cost.

[0033] The support may be subjected to various treatments such as antistatic treatment, easy adhesion treatment, and release treatment.

[0034] The thickness of such a support can be set to 1 μm to 100 μm, and in consideration of ease of handling, it can be set to about 3 μm to 50 μm.

[0035] The method for forming the decorative layer 4 described above involves thermally transferring a decorative transfer film to the side of a plastic card. However, this method is not limited to this method, and any method may be used as long as a pattern or a layer with an optical effect is formed on the side. The pattern can also be formed using a printing method. Optically functional layers can be formed using various coating techniques or transfer methods. The thermal transfer method is preferred because it involves heating a transfer film pressed against the side of the plastic card to transfer the pattern layer or optically functional layer, thereby thermally affecting the inner layer 1 of the side. However, if the decorative layer 4 is formed using a method that does not require heat, such as printing, the same effect can be achieved by separately heating at least the side of the plastic card to the same temperature as in the thermal transfer method. [Example]

[0036] Next, an embodiment of the present invention will be described.

[0037] Example 1 First, an inner layer of the core material and an outer layer of the exterior sheet (or oversheet) were laminated together to create a laminate that would become a plastic card.The laminate was then punched to create plastic cards.

[0038] Specifically, the plastic card was prepared according to the following procedure. First, a vinyl chloride sheet having a thickness of 0.70 mm was prepared as the inner layer (core material) and a polyethylene terephthalate sheet having a thickness of 0.05 mm was prepared as the outer layer (exterior sheet).

[0039] Using these sheets, the outer layer was laminated on the front and back of the inner layer, and then thermally laminated using a thermal laminating device to produce a laminate with a layer structure of polyethylene terephthalate sheet (0.05 mm) / vinyl chloride sheet (0.70 mm) / polyethylene terephthalate sheet (0.05 mm).

[0040] The reason for setting the thickness of the inner and outer layers to 0.70 mm and 0.05 mm, respectively, is that preliminary tests yielded the results shown in Table 1. That is, when the combinations of outer layer thicknesses: 0.038 mm, 0.050 mm, 0.100 mm, 0.125 μm, and 0.188 mm and inner layer thicknesses: 0.424 mm, 0.550 mm, 0.600 mm, 0.700 mm, and 0.724 mm were used as shown in Table 1, only levels 2 and 3 produced good results, as shown in Table 1. Therefore, the combination of level 2, which is close to the card thickness standard of 0.76 mm, was adopted. The criteria for the evaluation in Table 1 are as follows: ○: The peeled width is less than 30% of the width of the side of the plastic card △: The peeled width is between 30% and 50% of the width of the side of the plastic card ×: The peeled width is 50% or more of the width of the side of the plastic card However, in level 1, although the peeling was not noticeable, the width of the peeled area was wider than the width of the outer layer and it had even peeled into the inner layer, so the strength of the card was also reduced and it was rated as fair. The percentage of peeled width was calculated as (peel width at both ends x 2) ÷ thickness of plastic card x 100 (%). For example, at level 2, (0.05 mm x 2) ÷ (0.050 x 2 + 0.700) x 100 ≒ 12.5 (%). At level 4, (0.125 x 2) ÷ (0.125 x 2 + 0.550) x 100 ≒ 31.3 (%).

[0041] [Table 1]

[0042] Next, this laminate was cut into a card shape using a cutting die conforming to ID-I defined in the JIS standard (X6301:2005), to obtain individual cards.

[0043] A decorative transfer film described below was transferred to the side of the resulting individualized card using a roll-type thermal transfer machine RH-150 (manufactured by Navitas Co., Ltd.) to form a decorative layer consisting of a protective layer, a relief structure forming layer, a reflective layer, and an adhesive layer, thereby obtaining a plastic card of the present invention.

[0044] The transfer conditions using the roll-type thermal transfer machine were set temperature (transfer temperature): 180°C, set pressure (transfer pressure): 4000N, and decorative transfer film feed speed: 20mm / sec.

[0045] The amount of depression 7 (see FIG. 2) after transfer on the side surface of the plastic card produced in this manner was measured and found to be 20 μm to 30 μm.

[0046] (decorative transfer film) Next, the manufacturing method of the decorative transfer film used will be described. First, as the support for the decorative transfer film, a PET film (Lumirror 25T60; A protective layer was formed on this PET film using a gravure coater with the following protective layer coating solution so that the film thickness after drying would be 5.0 μm. A relief structure forming layer was then formed on top of this using a gravure coater with the following relief structure forming layer coating solution so that the film thickness after drying would be 2.0 μm.

[0047] Next, a nickel plate having a concave-convex structure as a hologram pattern was used to emboss the surface of the relief structure forming layer, and then a thin aluminum film was formed to a thickness of 40 nm by vacuum deposition.

[0048] Thereafter, the following adhesive layer coating liquid was applied using a gravure coater to form an adhesive layer so that the film thickness after drying would be 1.0 μm, thereby obtaining a decorative transfer film.

[0049] (Coating solution for protective layer) Acrylic resin 30 parts by mass Silica filler 3 parts by mass Toluene 40 parts by mass Methyl ethyl ketone 40 parts by mass Methyl isobutyl ketone 20 parts by mass

[0050] (Coating liquid for relief structure forming layer) 25 parts by mass of a mixture of vinyl chloride-vinyl acetate copolymer and urethane resin Methyl ethyl ketone 70 parts by mass Toluene 30 parts by mass

[0051] (Coating liquid for adhesive layer) Polyester resin 5 parts by mass Vinyl chloride-vinyl acetate copolymer resin 20 parts by mass Methyl ethyl ketone 40 parts by mass Toluene 40 parts by mass

[0052] <Example 2> The same procedure as in Example 1 was carried out except that the temperature set during transfer using the roll-type thermal transfer machine was 240°C.

[0053] Example 3 The same procedures as in Example 1 were carried out except that the temperature setting during transfer using the roll-type thermal transfer machine was 180° C. and the feed speed was 40 mm / sec.

[0054] Example 4 The procedure was the same as in Example 1, except that the decorative transfer film was fed at a speed of 50 mm / sec during transfer using a roll-type thermal transfer machine.

[0055] <Comparative Example 1> The same procedure as in Example 1 was carried out except that the temperature set during transfer by the roll-type thermal transfer machine was 170°C.

[0056] <Comparative Example 2> The same procedure as in Example 1 was carried out except that the temperature set during transfer using the roll-type thermal transfer machine was 250°C.

[0057] <Comparative Example 3> The procedure was the same as in Example 1, except that the decorative transfer film was fed at a speed of 60 mm / sec during transfer using the roll-type thermal transfer machine.

[0058] <Evaluation> (Swipe test) The plastic card samples produced in Examples 1 to 4 were manually read 1,000 times using a magnetic card reader, and then a swipe test was conducted in which the side of the plastic card was observed under a microscope or visually to check for peeling of the decorative layer. The results were the same as those for level 2 in Table 1, and all peeling of the decorative layer from both ends of the card side was about 0.05 mm, which was good.

[0059] (Quality of decorative layer) The quality of the decorative layer was evaluated visually for shrinkage of the outer layer and adhesion of the decorative layer, and the results are shown in Table 2.

[0060] [Table 2]

[0061] In Examples 1 to 4, the transfer temperature of the decorative layer was 180°C to 240°C, and the feed speed of the decorative transfer film was 20mm / sec to 50mm / sec. In all cases, no shrinkage of the outer layer (exterior sheet) was observed, and the width of the decorative layer peeled off from the side edge was 0.05mm or less, so the adhesion was also good. Therefore, the overall results were judged to be good (◯).

[0062] Comparative Example 1 was produced at a feed speed of 20 mm / sec and a transfer temperature of 170°C. Because the temperature was low, no shrinkage of the outer layer was observed, but the adhesion of the decorative layer was insufficient. Therefore, it was judged to be overall poor (×).

[0063] Comparative Example 2 was produced at a feed speed of 20 mm / sec and a transfer temperature of 250°C. Because the temperature was too high, shrinkage of the outer layer was observed. The adhesion of the decorative layer was sufficient. Therefore, it was judged to be poor (×) overall.

[0064] Comparative Example 3 was produced at a feed rate of 60 mm / sec and a transfer temperature of 180°C. Because the feed rate was too fast, heating was insufficient, and although no shrinkage of the outer layer was observed, the adhesion of the decorative layer was insufficient. Therefore, it was judged to be overall poor (×). [Explanation of symbols]

[0065] 1. Inner layer 2. Outer layer 3. Side of the plastic card 4. Decorative layer 5. The point where the inner and outer layers meet 6. A line connecting the two points where the inner and outer layers meet. 7. Dent amount 10. Plastic card (before the decorative layer is transferred) 20. Plastic card (after the decorative layer has been transferred)

Claims

1. A plastic card comprising a laminate including at least one inner vinyl chloride layer and outer polyethylene terephthalate layers provided on the front and back surfaces of the vinyl chloride layer, The side of the plastic card is provided with a decorative layer, In a cross section of a side surface of the plastic card, the surface of the vinyl chloride layer is provided inside a straight line connecting two points where the vinyl chloride layer and the polyethylene terephthalate layer are in contact with each other. Plastic card.

2. A laminate in which a sheet-like or film-like resin B that forms an outer layer is laminated on the front and back surfaces of a sheet-like or film-like resin A that forms an inner layer is cut into individual pieces in the form of a card, A method for manufacturing a plastic card, comprising: bringing a transfer foil having a decorative layer on a substrate into contact with a side surface of the laminate using a roll-type thermal transfer machine under conditions of a transfer temperature of 180°C or higher and 240°C or lower and a feed speed of 20 mm / sec or higher and 50 mm / sec or lower, thereby transferring the decorative layer to the side surface; The molding shrinkage rate of the resin A is greater than the molding shrinkage rate of the resin B. A method for manufacturing plastic cards.

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