Portable Data Carrier Recesses for Flat Surface Integration
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Solution Overview
Problem
Conventional methods for producing card-shaped data carriers with large mounted elements, such as batteries or wire-embedded coils, fail to achieve a flat surface due to the integration of these elements, requiring precision tools and complex handling processes.
Innovation Solution
A method involving the creation of recesses with positioning aids in a core layer, where a first part of filling material is incorporated before the mounted element is inserted, and a second part is applied directly to the element, followed by the use of a cover foil and doctor knife to spread the filling material pressurelessly, ensuring a flat surface without excessive tool contact or precision demands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If large mounted elements are integrated into card body using conventional methods, then the mounted elements can be incorporated, but the card surface becomes uneven and non-flat
Solution Approach 1:
The patent applies preliminary action by creating recesses in the card body before inserting the mounted elements. These recesses are specifically designed to accommodate the volume of large mounted elements, ensuring that when the elements are inserted and the recesses are filled with adhesive, the card surface remains flat. This preliminary preparation of the card body structure prevents surface unevenness before the mounting process occurs.
Solution Approach 2:
The patent applies local quality by creating localized recesses only in the specific areas where large mounted elements will be positioned, rather than modifying the entire card body. The recesses are precisely positioned and sized to match the footprint and volume requirements of individual mounted elements, allowing the rest of the card body to maintain its original flat structure while accommodating the irregular volumes of the mounted elements.
2Manufacturing precision
If precision tools and complex handling processes are used to achieve flat surface, then surface flatness can be improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent eliminates the need for complex precision tools by performing preliminary action - creating recesses in the card body before mounting. This approach allows the use of conventional, simpler manufacturing tools to create the recesses, which then naturally accommodate the mounted elements and maintain surface flatness without requiring sophisticated pressure control or specialized equipment during the mounting process.
Solution Approach 2:
The patent employs a disposable stencil that is placed on the card body to define the recess areas. This stencil is a simple, low-cost tool that requires no precision calibration or complex handling. After the adhesive is applied through the stencil and the recesses are formed, the stencil is removed and discarded, having served its purpose without requiring sophisticated tooling or complex process control.
3Manufacturing precision
If adhesive is applied pressurelessly with stencil and doctor knife, then surface flatness is improved, but handling complexity and tool contact increase
Solution Approach 1:
The patent applies preliminary action by pre-forming recesses in the card body before adhesive application. This preliminary structure guides the adhesive flow and containment, allowing the adhesive to be applied more simply without requiring complex pressure control mechanisms. The recesses naturally contain the adhesive and prevent it from spreading beyond the intended areas, simplifying the overall adhesive application process.
Data Source
AI summary
A method for producing a data carrier which has a built-in element. A recess for receiving the built-in element and a collecting groove for receiving displaced filling material are formed in a core layer. An excess of filling material is specifically provided in the free spaces remaining between the wall of the recess and the built-in element and on the surface. With a covering film interposed, the filling material is then rolled or spread out over the surface by means of a doctor blade.