Card Data Carrier Colored Edge via Pre-Colored Foil Lamination
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Solution Overview
Problem
Existing methods for producing card-shaped data carriers with a colored edge are complex and prone to bonding issues and ink bleeding, requiring expensive printing processes and additional lacquering or adhesive-coated films.
Innovation Solution
A card-shaped data carrier with superimposed film layers, featuring a first film inside and second and third films on the outer sides, with a geometrically shaped peripheral edge that creates a visible colored impression without the need for printing, using a standard laminating process under pressure and heat, and minimizing bonding problems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a colored foil is arranged inside the card-shaped data carrier and printed on both sides in white, then a colored edge is obtained, but the printing process becomes complex and requires a lot of ink, resulting in bonding problems
Solution Approach 1:
The invention extracts the printing operation from the card manufacturing process by using pre-colored foils that already have the desired colored edges. The colored pattern is transferred to the foil before lamination, eliminating the need for subsequent printing operations on the assembled card structure.
Solution Approach 2:
The colored pattern is applied to the foil in advance before the foil is integrated into the card structure. This preliminary coloring action simplifies the overall manufacturing process by eliminating complex post-assembly printing and bonding operations.
2Shape
If card-shaped data carriers are stacked and the edges are printed in the stack, then a colored edge is obtained, but the process is complex and printing ink may run between the stacked carriers
Solution Approach 1:
The invention removes the stacking and edge-printing operation from the manufacturing process. Instead, colored foils with pre-formed colored edges are used, eliminating the risk of ink bleeding between stacked carriers entirely.
Solution Approach 2:
The invention uses disposable colored foils that already have the desired colored edges formed during foil production. These foils are integrated into the card structure without requiring subsequent printing operations, avoiding ink bleeding issues.
3Shape
If printing ink is applied to cover the colored film, then a colored edge is obtained, but bonding problems occur requiring additional lacquering and adhesive-coated films
Solution Approach 1:
The invention extracts the printing and bonding operations from the manufacturing process by using pre-colored foils with integrated colored edges. The foils are designed to be laminated directly without requiring printing, lacquering, or adhesive-coated films.
Solution Approach 2:
The invention uses composite foil structures where the colored layer and substrate are permanently bonded together during foil production. This composite structure eliminates bonding problems during card assembly since the colored foil itself provides structural integrity.
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 solution allows for a visually appealing colored edge without complex printing processes, preventing ink bleeding and reducing material costs, while maintaining a secure bond between layers, enhancing the visual appeal and durability of the data carrier.
Implementation Method 1
The films are permanently connected to one another using a standard laminating process under pressure and heat.
Data Source
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AI summary
The present invention discloses a card shaped data carrier (12) which has a structure consisting of film layers located one above the other, wherein at least one first, coloured film (14) is arranged in the interior of the structure, at least one second, white film (16) is arranged on the upper face of the first film (14), and at least a third, white film (18) is arranged on the lower face of the first film (14). A first overlay film (20) is arranged on the face of the second film (16) lying opposite the first film (14) as a first outer face of the data carrier (12), a second overlay film (22) is arranged on the face of the third film (18) lying opposite the first film as a second outer face of the data carrier (12), and a peripheral edge (24) of the data carrier (12), which is arranged between the first and second outer faces (26, 28) of the data carrier (12) and which runs along an outer periphery of the first and second outer faces (26, 28), has at least one geometric form, e.g. round or oblique.