Card Body Side Surface Sealing During Separation
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Solution Overview
Problem
Conventional methods for manufacturing multilayer card bodies result in cards with weak mechanical properties due to pre-damage during the punching process, leading to delamination issues and the need for costly rework, such as delamination tests and adhesive sealing.
Innovation Solution
A method that enhances mechanical properties by sealing the side surface of the card body during or after separation, using techniques like heat generation, ultrasonic waves, or laser radiation to bond delaminated layers, eliminating the need for pre-separation delamination tests and improving durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If cards are cut, milled or punched out from laminated sheet, then card shape is formed, but side surface of cards is pre-damaged and layers delaminate
Solution Approach 1:
The patent applies preliminary action by sealing the side surface of the card body before final separation from the laminated sheet. The method involves applying a sealing agent to the side surface and curing it to form a protective seal that prevents delamination during subsequent punching or cutting operations. This preliminary sealing protects the vulnerable side surface before the cards are cut out from the laminated sheet.
Solution Approach 2:
The patent introduces a sealing agent as an intermediary substance between the layers and the external environment. This sealing agent penetrates into the side surface and cures to form a protective barrier that bonds the layers together, preventing delamination during the punching process. The sealing agent acts as a mediator that strengthens the interlayer bonding at the side surface.
2Measurement precision
If delamination test is carried out after punching, then pre-damaged layers are detected, but cards must return to beginning of manufacturing process
Solution Approach 1:
The patent converts the harmful effect of punching-induced damage into a beneficial outcome by using the same punching process to apply the sealing agent simultaneously. The punching tool is designed to apply sealing agent to the side surface during the separation process, so that the potentially damaging punching operation also performs the beneficial sealing function, eliminating the need for separate testing and rework.
Solution Approach 2:
The patent merges the separation process with the sealing process into a single integrated operation. The punching tool that separates individual cards from the laminated sheet simultaneously applies and cures the sealing agent on the side surface. This combination of operations eliminates the need for separate delamination testing and adhesive sealing steps, significantly reducing manufacturing time.
3Strength
If adhesive is used for sealing card, then layers are bonded, but additional manufacturing steps are required
Solution Approach 1:
The patent changes the physical-chemical parameters of the sealing process by using a sealing agent that can be applied in liquid form and then cured through UV irradiation or heat treatment. This transformation from liquid application to solid bonding state allows for simplified process integration, where the same tool performs both separation and sealing functions without requiring separate adhesive application and curing equipment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method produces cards with improved mechanical properties and extended lifespan, meeting ISO 7810 standards without requiring rework, thus increasing efficiency and reducing manufacturing costs.
Implementation Method 1
The separating tool (20) is adapted to generate heat for sealing the side surface (10)
Implementation Method 2
the side surface is sealed by using mechanical or laser engrailed edges or micro-structuring
Implementation Method 3
using techniques like heat generation, ultrasonic waves, or laser radiation to bond delaminated layers
Implementation Method 4
using techniques like heat generation, ultrasonic waves, or laser radiation to bond delaminated layers
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a method for manufacturing a multilayer card body (1), in particular for a portable data carrier, with improved properties in that the side surface of the card body is sealed during separation or after it has been separated from a laminated sheet. Further, the invention relates to a card body (1), manufactured according to the method. Besides, the invention relates to a corresponding separating tool (20). Moreover, the invention relates to an apparatus for manufacturing a multilayer card body (1). The invention has the essential step of the side surface (10) being sealed by using mechanical or laser engrailed edges or micro-structuring; this step is not shown in the figures.