Method and device for producing a sheet and / or a film, in particular for manufacturing card bodies and / or security elements, and same for portable data carriers using bio-based plastics

Abstract

The present invention relates to a method and a production device (20) for producing a sheet (21) and / or a film (22), in particular for manufacturing card bodies (2) and / or security elements (6) for portable data carriers (1), and to corresponding card bodies (2) and / or security elements (6) for a portable data carrier (1) and same, wherein the method comprises the following steps: providing at least one polylactide plastic as a first mixture portion (A) of a base mixture (G); providing at least one bio-based plastic as a second mixture portion (B) of the base mixture (G); mixing the base mixture (G) consisting of at least the first mixture portion (A) and at least the second mixture portion (B); and extruding the sheet (21) and / or the film (22) from at least the base mixture (G).

Description

[0001] 648.0281DE / 514630

[0002] Method and apparatus for producing a sheet and / or a film, in particular for manufacturing card bodies and / or security elements as well as the same for portable data carriers using bio-based plastics

[0003] The invention relates to the provision of portable data carriers that are made as far as possible from bio-based materials. In particular, the invention relates to a method for producing a sheet and / or a film, especially for manufacturing card bodies and / or security elements for portable data carriers, a card body and / or security element for a portable data carrier, a portable data carrier, a manufacturing device for producing a card body and / or a security element for a portable data carrier, and the use of a base mixture of at least a first mixture component and at least a second mixture component for extruding a sheet and / or a film, especially for manufacturing card bodies and / or security elements for portable data carriers.

[0004] Background of the invention

[0005] Portable data carriers are known from the prior art and can be used, for example, for cashless payment of goods or services, for personal identity verification, and / or for accessing internet-based applications. Accordingly, there are, for example, card-shaped data carriers in the form of chip cards in general, payment cards such as credit or debit cards, as well as identity cards or national identity cards. Such data carriers typically comprise an electronic circuit with an electronic component, such as a chip, which can be accessed to read data and, based on this, to authorize a legitimate owner of the data carrier to perform a specific action. Additionally, portable data carriers can include optical elements that can serve both decorative and security purposes.

[0006] Security features are also known from the prior art and can be affixed, for example, to portable data carriers, banknotes, or other cards. These security features can also be incorporated into official documents and documents used for personal identification. Such security features can include decorative and / or anti-forgery images, as well as corresponding patterns, emblems, seals, or similar elements.

[0007] According to current technology, the card bodies and security elements of portable data carriers are generally made of plastic. While the use of plastic provides relatively high stability and resistance to environmental influences, it is problematic for two reasons. First, the chemical substances required for its production are derived from limited resources, such as fossil petroleum. Second, recycling the plastic after the portable data carrier's lifespan can be difficult, costly, or even impossible.

[0008] DE 102021 004810, for example, relates to a card-shaped data carrier, in particular a smart card, comprising an electronic chip module with at least one chip and a contact structure, and a card body with an arrangement area for receiving the chip module, wherein the chip module is arranged in the arrangement area of ​​the card body and is connected to the card body by means of at least one adhesive, wherein the adhesive is designed to be thermolytically and / or chemically soluble for separating the connection between the chip module and the card body within a predetermined temperature range. The invention further relates to a method for releasing an adhesive bond for a card-shaped data carrier.

[0009] US 11,842,237 B2 deals with exemplary designs of biodegradable cards as well as systems and methods for their manufacture. A biodegradable card can comprise a biodegradable substrate, a magnetic particle slot within the biodegradable substrate configured to receive magnetic particles, a high-coercivity magnetic stripe comprising magnetic particles printed onto the biodegradable substrate and encoded with payment account data, and a biodegradable waterproof coating, the coating covering at least the magnetic stripe. Polyurethane is proposed as the biodegradable material for the waterproof coating. DE 10219306 B4 relates to an electronic data carrier, in particular a smart card, with numerous electronic components, manufactured from two components that are assembled in a final process step to form the finished data carrier.The first component contains all the electronic components, and the second component has a recess for installing the first component. For example, a graphics component can be manufactured according to ecological principles, such as from biodegradable material like paper or biodegradable plastic.

[0010] Furthermore, Terzopoulou, Z.; Zamboulis, A.; Papadopoulos, L.; Grigora, M.-E.; Tsongas, K.; Tzetzis, D.; Bikiaris, DN; Papageorgiou, GZ, in “Blending PLA with Polyesters Based on 2,5-Furan Dicarboxylic Acid: Evaluation of Physicochemical and Nanomechanical Properties”; Polymers 2022, 14, 4725 (https: / / doi.org / 10.3390 / polyml4214725), discuss the use of polylactic acid (PLA) as a readily available, compostable, bio-based polyester with high strength and toughness, making it ideal for 3D printing applications. Polymer blending allows its properties, such as slow decomposition and crystallization rate and low elongation, to be improved economically and easily, thus increasing its versatility. They are investigating the effects of various 2,5-furan dicarboxylic acid (FDCA)-based polyesters on the physicochemical and mechanical properties of PLA.Poly(butylene furan-2,5-dicarboxylate) (PBF) and its copolymers with poly(butylene adipate) (PB Ad) were synthesized in various comonomer ratios and mixed with 70 wt% PLA using melt compounding. The thermal, morphological, and mechanical properties of the mixtures were investigated. All mixtures were immiscible, and the presence of the dispersed phases improved the crystallizability of PLA. Mechanical tests revealed plasticization of PLA after mixing and a small but measurable weight loss after seven months of burial in soil. Reactive mixing was evaluated as a compatibility-mediator-free method for improving miscibility, and it was found that, if the thermal stability of the mixture components allowed, some transesterification reactions occurred between the PLA matrix and the FDCA-based dispersed phase after 20 minutes at 250 °C.

[0011] Morreale, Marco; Baiamonte, Marilena; Correnti, Antonio; Messina, Sergio; La Mantia, Francesco Paolo; “Biodegradable polymer films: processability, technological properties and their viability for flexible packaging applications”, Polymer International, 73-8; 0959-8103 (https: / / doi.org / 10.1002 / pi.6630), pages 603 to 611, 2024 Society of Industrial Chemistry; address the replacement of conventional, fossil-resource-based polymers typically used for such applications. This is no easy task, as the more environmentally friendly solutions must exhibit suitable properties in terms of processability and final characteristics. They subject three commercially available biodegradable (and at least partially bio-based) polymers to preliminary rheological and mechanical analysis in order to conduct film-making experiments in laboratory equipment.Furthermore, the oxygen and water vapor barrier properties were investigated through permeability measurements. The investigation was then carried out on films produced in industrial plants, and the results were compared with those of a typical standard polypropylene (PP) film used in flexible packaging applications. It was found that the mechanical properties (in some cases even up to 25-30% higher than the PP variant) as well as the oxygen permeability were adequate. On the other hand, the water permeability was significantly higher than that of PP films, which should be taken into account in cases where high water vapor barrier properties are required.

[0012] A disadvantage of existing portable data storage media is that the materials used in their manufacture are not derived from renewable resources to a satisfactory degree. Furthermore, the disposal of such media can be complex and ecologically problematic. For example, while materials classified as biodegradable, such as polyurethane, may indeed decompose over a certain period, this decomposition time can be very long depending on the circumstances, and the resulting decomposition products may be undesirable.

[0013] Description

[0014] It is therefore an object of the present invention to provide portable data storage media and security elements that are as biodegradable as possible and that can be manufactured as simply and cost-effectively as possible. In particular, it can be considered an object of the present invention to improve the environmental compatibility of portable data storage media and security elements, both with regard to the materials used and their degradation products.

[0015] This problem is solved by the subject matter of the independent claims. Exemplary embodiments are described in the dependent claims and the following description.

[0016] The preferred embodiments and their advantages presented with reference to the respective sheets and / or films for card bodies, security elements, portable data carriers, and / or manufacturing devices according to the invention apply accordingly to methods for their manufacture according to the invention. The components of the sheets, films, card bodies, security elements, portable data carriers, and / or manufacturing devices according to the invention can each be formed or configured by corresponding process steps. Further features of the invention will become apparent from the claims, the figures, and the description of the figures.

[0017] A method for producing a sheet and / or a film, in particular for manufacturing card bodies and / or security elements for portable data carriers, is provided, comprising the following steps: providing at least one polylactide plastic as a first component of a base mixture; providing at least one bio-based plastic as a second component of the base mixture; mixing the base mixture from at least the first component and at least the second component; and extruding the sheet and / or film from the base mixture.

[0018] A card body and / or security element for a portable data carrier is provided, characterized in that the card body or the security element is manufactured at least section by section using a corresponding method.

[0019] A portable data carrier is provided, which includes a corresponding card body or security element.

[0020] A manufacturing device for producing a card body and / or a security element for a portable data carrier is provided, wherein the manufacturing device is configured to carry out a corresponding process. A basic mixture of at least one first mixture component and at least one second mixture component for extruding a sheet and / or a film, in particular for manufacturing card bodies and / or security elements for portable data carriers, is provided, wherein at least one polylactic acid plastic constitutes the at least one first mixture component and at least one bio-based plastic constitutes the at least one second mixture component.

[0021] The solution according to the invention enables the provision of card bodies and / or security elements for portable data carriers that comprise both bio-based and biodegradable materials. Thus, card bodies and / or security elements can be produced from renewable raw materials or at least natural sources. In this way, at least the card bodies or security elements of the portable data carriers can be designed to be completely or at least largely biodegradable, with their degradation times and products being unproblematic and thus helping to ensure a high level of environmental compatibility.

[0022] According to one embodiment of the method, the sheet and / or film can form at least one core layer and / or at least one surface layer of the card body. The core layer can thus provide the card body with its essential mechanical properties, in particular the necessary stability, for example, to accommodate a data storage module of the portable data carrier. The surface layer can protect the core layer from harmful environmental influences. Both the core layer and the surface layer can support or form the security element. In this way, the environmental compatibility of portable data carriers can be further improved.

[0023] According to one embodiment of the method, the sheet and / or film may comprise several co-extruded sublayers based on different base mixtures. The sublayers may be co-extruded and / or laminated together. For example, between 1 and 5, preferably between 2 and 4, preferably 3 sublayers may form the sheet and / or film. The sublayers may be provided from bio-based material, as required. Constructing the sheet and / or film from sublayers can help to achieve the necessary stiffness and stability of the data body, as required. According to one embodiment of the method, the first mixture may comprise approximately 50%, approximately or more than 60%, and / or approximately or more than 70% of the base mixture.The proportion of the first mixing component in the base mixture can yield at least one second mixing component. The respective mixing components can be selected such that the structure of the sheet and / or film, composed of sublayers with different mixing components, exhibits stiffness, stability, and other properties, such as transparency levels, that meet the respective requirements.

[0024] According to one embodiment of the method, the sheet and / or film can be formed at least partially amorphous, semi-crystalline, and / or crystalline. For example, PLA can be produced in amorphous and semi-crystalline form with varying degrees of crystallinity. The respective degrees of crystallinity can be selected such that the sheet and / or film, composed of sublayers with different mixture proportions, exhibits stiffness, stability, and other properties, such as transparency levels, that meet the specific requirements.

[0025] According to one embodiment of the process, the bio-based plastic may contain polybutylene adipate furanate (PBAF) and / or polybutylene sebacinate furanate (PBSF). The PBAF or polybutylene adipate co-furanate is a two-block copolymer. The first block can be provided from the bio-producible monomers 1,4-butanediol and 2,5-furandicarboxylic acid as basic components. For the second block, the bio-producible monomers adipic acid and sebacic acid can be used as alternatives. While adipic acid is available from biological sources, it is currently still largely produced from petroleum. Sebacic acid is readily available from biological sources. By using sebacic acid for the second block, the PBSF or PBSF is produced using a bio-based formulation.Polybutylene sebacinate-co-furanoate is provided, which, compared to PBAF, exhibits minimal chain length elongation and thus tends to impart increased flexibility to sheets and / or films produced from it. The respective proportions of PBAF and PBSF can be selected so that a sheet and / or film structure with different mixture proportions exhibits stiffness, stability, and other properties, such as flexibility, that meet the specific requirements. Brief description of the figures.

[0026] Exemplary embodiments of the invention are explained in more detail below with reference to schematic drawings.

[0027] This shows:

[0028] Fig. 1 shows a schematic top view of an embodiment of a portable data carrier comprising a card body with a data carrier module embedded therein.

[0029] Fig. 2 shows a schematic cross-sectional view of the map body along a section line AA drawn in Fig. 1.

[0030] Fig. 3 shows a schematic top view of a manufacturing device and a plurality of card bodies for portable data carriers before singulation.

[0031] Fig. 4 shows a schematic of a method for producing the card body.

[0032] In the figures, identical or functionally equivalent elements are provided with the same reference symbols.

[0033] Detailed description of exemplary embodiments

[0034] The representations in the figures are schematic and not to scale. If the same reference symbols are used in different figures in the following figure description, these denote identical or similar elements. However, identical or similar elements can also be designated by different reference symbols.

[0035] Fig. 1 shows a schematic top view of a portable data carrier 1 with a card body 2 in which a data carrier module 3 can be accommodated. The portable data carrier 1 extends in a longitudinal direction X, a transverse direction Y, and a vertical direction Z, which together define a Cartesian coordinate system. The card body 2 comprises a core layer 4, the surface of which is provided at least partially with a surface layer 5 (see Fig. 2), wherein the core layer 4 and / or surface layer 5 can carry, have, and / or form a security element 6.

[0036] Fig. 2 shows a schematic cross-sectional view of the map body 2 of the portable data carrier 1 along a section line AA drawn in Fig. 1. The map body 2 comprises a core layer 4, which is covered above and below by a surface layer 5. The core layer can be provided as a layered assembly 10 of sublayers, such as a first sublayer 11, a second sublayer 12, a third sublayer 13, a fourth sublayer 14 and / or a fifth sublayer 15.

[0037] Furthermore, Fig. 2 illustrates that the core layer thickness d4 of the core layer 5, measured essentially parallel to the height direction Z, can be greater than the surface layer thickness ds of the surface layer 5, which in turn can be smaller, larger, and / or approximately the same as the thickness dio of the sublayers 11, 12, 13, 14, 15 of the layer assembly 10. For example, the core layer 4 or the layer assembly 10 can be (co-)extruded. The surface layer 5 can also have a corresponding layer structure.

[0038] Fig. 3 shows a schematic top view of a manufacturing device 20 and a plurality of card bodies 2 for portable data carriers 1 before singulation. The core layer 4 can be provided as a sheet 21, for example, a core layer sheet, for a plurality of card bodies 2. The surface layer 5 can be provided as a film 22 or cover layer for a plurality of card bodies 2 and cover the sheet 21. The sheet 21 can be clamped or held in and / or on a receiving device 23, for example, a clamping frame and / or laminating sheet, of the manufacturing device 20, at least as long as the core layer 4 and the surface layer 5 are bonded together, for example, by laminating, gluing, spraying, applying, sticking, or the like. Afterwards, the plurality of card bodies 2 or...These comprehensive portable data carriers 1, for example, are removed together as production sheets from the manufacturing device 20 for singulation or are singulated within it, for example by punching, laser cutting, or similar processes. Fig. 4 shows a schematic of a process with steps S for producing the sheet 21 and / or the film 22, for example, for manufacturing the card body 2. In a first step S1, a first mixture component A can be provided. The first mixture component is, for example, a polylactide plastic, i.e., polylactides or polylactic acid (PLA). In a second step S2, a second mixture component B can be provided. The second mixture component B is polybutylene adipate furanate (PBAF) and / or polybutylene sebacinate furanate (PBSF). PBAF can be represented in its structural formula as follows:

[0039] Poly(butylene adipate-co-furanoate)(PBAF)

[0040] PBAF can be synthesized from 1,4-butanediol and 2,5-furandicarboxylic acid or 1,4-butanediol and adipic acid, which can be represented by their respective structural formulas as follows:

[0041] 2,5-Furandicarboxylic acid

[0042] Adipic acid. As an alternative to adipic acid, sebacic acid can be used, which can be represented in its structural formula as follows and through whose use PBSF is synthesized:

[0043] Sebacic acid

[0044] In a third step, S3, a base mixture G is blended from the first shot composition A and the second mixture composition B. In a fourth step, S4, further mixture components C, such as additives, can be added to the base mixture. Additives can include color pigments, color-changing elements, fillers, processing aids, lubricants, impact modifiers, and similar substances.

[0045] In a fifth step S5, a corresponding extrusion mixture E can then be extruded, which may contain the base mixture G on its own or the base mixture G with further mixture components C. The sheet 21 or its sub-layers and / or the film 22 can be produced by extrusion. These can in turn be co-extruded to form a layer composite 10 and thus comprise sub-layers 11, 12, 13, 14, 15. Alternatively or additionally, corresponding layer composites 10 and / or sub-layers 11, 12, 13, 14, 15 can be added at a later time, for example by laminating, gluing, applying, spraying, or similar processes.

[0046] In a sixth step, S6, sheet 21 and / or film 22 can be further processed and / or finished. For example, they can be printed as core layer 4 and / or surface layer 5. Accordingly, core layer 4 and / or surface layer 5 can be customized or adapted, for example, by adding elements to the surface layer, such as "wow effects" (glitter pigments, luminescent pigments) or security pigments, such as fluorescence. The security element 6 can thus be created, for example, by printing, laser engraving, or similar processes on sheet 21 and / or film 22, or core layer 4 and / or surface layer 5.

[0047] It should also be noted that "comprehensive" or "comprising" does not exclude other elements or steps, and "a" or "an" does not exclude a plurality. Furthermore, it should be noted that features or steps described with reference to one of the above embodiments may also be used in combination with other features or steps of other embodiments described above. Reference numerals in the claims are not to be considered as limitations.

[0048] Reference symbol list

[0049] 1 portable storage device 25

[0050] 2 Carrier body A first mixture component

[0051] 3 Data carrier module B second mixture component

[0052] 4 Core layer C further mixture component / additive

[0053] 5 surface layer materials

[0054] 6 Safety element 30 E Extrusion between

[0055] 10 Layer composite / partial layers G Base mix

[0056] 11 first sub-layer S step

[0057] 12 second sub-shift

[0058] 13 third sublayer X longitudinal direction

[0059] 14 fourth sublayer 35 Y transverse direction

[0060] 15 fifth sublayer Z vertical direction

[0061] 20 Manufacturing device 51 Providing the first mixture component

[0062] 21 sheets / core layer sheets 52 Providing second mixing facility

[0063] 22 film / topcoat application 40 parts

[0064] 23 Receiving device / Clamping frame 53 Mixing the base mixture 54 Addition of further mixture components d4 Core layer thickness 55 Extrusion ds Surface layer thickness 45 S6 Further processing and / or partial layer thickness

Claims

Patent claims 1. Method for producing a sheet (21) and / or a film (22), in particular for producing card bodies (2) and / or security elements (6) for portable data carriers (1), comprising the following steps: Providing at least one polylactide plastic as a first mixture component (A) of a base mixture (G); Providing at least one bio-based plastic as a second component (B) of the base mixture (G); Mixing the basic mixture (G) from at least the first mixture component (A) and at least the second mixture component (B); and Extruding the sheet (21) and / or the film (22) from at least the base mixture (G).

2. Method according to claim 1, characterized in that at least one core layer (4) and / or at least one surface layer (5) of the card body (2) is formed with the sheet (21) and / or the film (22).

3. Method according to claim 1 or 2, characterized in that the sheet (21) and / or the film (22) comprises several co-extruded sub-layers (10, 11, 12, 13, 14, 15) based on different base mixtures (G).

4. Method according to at least one of the above claims, characterized in that the first mixture component (A) forms the base mixture (G) to approximately 50%, approximately or more than 60% and / or approximately or more than 70%.

5. Method according to at least one of the above claims, characterized in that the sheet (21) and / or the foil (22) is formed at least sectionally amorphous, semi-crystalline and / or crystalline.

6. Method according to at least one of the above claims, characterized in that the bio-based plastic comprises polybutylene adipate furanate (PBAF) and / or polybutylene ebacinate furanate (PBSF).

7. Card body (2) and / or security element (6) for a portable data carrier (1), characterized in that the card body (2) or the security element (6) is manufactured at least section by section using a method according to at least one of claims 1 to 6.

8. Portable data carrier (1), characterized by a card body (2) and / or a security element (6) according to claim 7.

9. Manufacturing device (20) for manufacturing a card body (2) and / or a security element (6) for a portable data carrier (1), characterized in that the manufacturing device (20) is configured to carry out a method according to at least one of claims 1 to 6.

10. Use of a base mixture (G) of at least one first mixture component (A) and at least one second mixture component (B) for extruding a sheet (21) and / or a film (22), in particular for manufacturing card bodies (2) and / or security elements (6) for portable data carriers (1), characterized in that at least one polylactide plastic forms the at least one first mixture component (A) and at least one bio-based plastic forms the at least one second mixture component (B).

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