Data Card Tab Attachment via Ultrasonic Welding
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Solution Overview
Problem
Existing methods for producing book-like identity, valuable, or security documents with integrated data cards are complex and inflexible, leading to difficulties in stacking, transportation, and processing due to the attachment of flexible tabs during manufacturing, which complicates the production of these documents.
Innovation Solution
A device and method where the flexible tab is attached to the data card after production, using ultrasonic welding for a secure and efficient connection, allowing for easier handling and processing, and incorporating a system for quality control and individualized production of the documents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the tab is integrated into the data card during manufacture, then the data card structure is complete, but the handling, stacking, and transportation become complex
Solution Approach 1:
The patent divides the data card production into separate stages: first producing the data card without the tab, then attaching the tab separately. This segmentation allows the data card to be manufactured, handled, and stacked independently before the tab attachment step, resolving the contradiction between complete structure and ease of handling.
Solution Approach 2:
The patent performs preliminary production of the data card without the tab, completing all data card-specific operations first. The tab is then attached in a subsequent step. This preliminary action enables simplified handling and stacking during the main production phase while still achieving the complete final structure.
2Productivity
If the tab is attached to the data card during manufacture, then the data card is ready for use, but the transportation and packaging become complex
Solution Approach 1:
The patent segments the production process into two distinct phases: data card production without tab, then tab attachment. This allows standardized packaging of data cards without tabs, simplifying the transportation and packaging system while maintaining high productivity through automated tab attachment in the second phase.
Solution Approach 2:
The patent introduces an intermediate step where data cards are produced and packaged without tabs, then tabs are attached as a separate operation. This intermediary approach decouples the complex tab attachment from the data card production, allowing simplified packaging systems while maintaining overall productivity.
3Reliability
If the tab protrudes over the data card surface, then the tab is securely attached, but the data cards cannot be stacked or can only be stacked to a limited extent
Solution Approach 1:
The patent performs the tab attachment as a preliminary action before final packaging, allowing tabs to be securely attached to individual data cards. The data cards are then packaged in a way that accommodates the protruding tabs, enabling stable stacking while maintaining secure tab attachment.
Solution Approach 2:
The patent addresses the stacking limitation by changing the packaging dimensionality - packaging data cards in orientations or configurations that accommodate the protruding tabs, such as edge-oriented packaging or using packaging structures that provide space for the tab protrusion while maintaining stacking stability.
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
This approach simplifies the production and handling of data cards by enabling easy stacking and transportation, reduces complexity in processing, and ensures efficient production of book-like identity, valuable, or security documents with enhanced security features.
Implementation Method 1
The tab is integrated into the data card, that is to say it is already attached to the data card during its manufacture
Data Source
Figure 1~2b
Figure 2c~2f
Figure 3
AI summary
A device (200) for producing a data card (106) for a book-like identification, value, or security document (100) is provided, the device (200) comprising: - a processing unit (206), the processing unit (206) having a receptacle for the data card (106) and means (216) for positively and/or materially joining the flap (120) and the data card (106) in an overlap area (121), and - a dispensing unit (204) for the flap (120), the dispensing unit (204) having a feed device (218) for an endless belt (220) for the flap (120), a cutting device (222) for the endless belt (220), and a holding and transport device (224) for the flap (120), the holding and transport device (224) being used to hold a longitudinal edge of the tab (120) and designed for transporting the tab (120) to receive the data card (106).