Galvanic Light-Diffracting Structures on Laminating Tools
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Solution Overview
Problem
Current methods for producing light-diffracting structures on laminating tools are complex and costly, requiring additional manufacturing steps and materials, which compromises the security and precision of holograms on documents like identity cards and passports.
Innovation Solution
The method involves exclusively galvanic application of at least two metal layers on the laminating tool's surface to directly create light-diffracting structures, eliminating the need for a separate hologram and integrating hologram attachment into the manufacturing process, allowing for precise placement and reduced material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a separate hologram is produced and then attached to a card, then the hologram can be manufactured with specialized equipment, but the manufacturing process becomes complex and costly with multiple steps
Solution Approach 1:
The invention merges the hologram manufacturing process with the card manufacturing process by directly forming light-diffracting structures on the laminating tool surface. This integration eliminates the need for separate hologram production and attachment steps, reducing overall process complexity while maintaining hologram quality
Solution Approach 2:
The laminating tool is given multiple functions: it performs both the laminating function and the hologram formation function simultaneously. The tool surface is modified to include light-diffracting structures that create holograms during the normal lamination process, making the tool universal for both purposes
2Manufacturing precision
If a separate hologram is attached to a card in an additional manufacturing step, then the hologram can be applied after lamination, but the precise placement is subject to tolerances reducing security
Solution Approach 1:
The light-diffracting structures are pre-formed on the laminating tool surface before the card lamination process. This preliminary action ensures that when the card is laminated, the hologram is simultaneously formed with precise placement, eliminating placement tolerance issues that would reduce security
3Ease of manufacture
If photoresist and electroplating are used to create light-diffracting structures, then metal layers can be deposited, but large-area electroplating must be produced and then largely removed, increasing time and material expenditure
Solution Approach 1:
Instead of producing large-area electroplating that must then be removed, the invention uses local quality by applying photoresist only in specific patterns where metal deposition is desired. This localized approach allows direct formation of the required metal structures without subsequent removal steps, improving productivity
4Ease of manufacture
If multiple manufacturing steps are used to produce holograms and laminate cards, then each step can be optimized independently, but the overall manufacturing cost increases
Solution Approach 1:
The invention combines multiple manufacturing steps into a single integrated process. The lamination process and hologram formation process are merged into one operation, where the laminating tool with pre-formed light-diffracting structures creates the hologram during normal lamination, eliminating separate hologram production and attachment steps
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 manufacturing process, reduces costs, and enhances security by enabling precise and integrated hologram production directly on documents, improving counterfeiting resistance through precise light-diffracting structures.
Implementation Method 1
the structures are produced exclusively by galvanic application of at least two metal layers on the upper side
Implementation Method 2
directly producing light-diffracting structures on a laminating tool
Data Source
Figure 1~2
Figure 3a~3b
Figure 3c~3d
AI summary
The invention relates to a method for producing light-diffusing structures (1, 2, 3) on a laminating tool (10) with a top surface (11) whose surface (12) is defined as a reference plane (R), characterized in that the structures (1, 2, 3) are produced exclusively by electroplating at least one first metal layer onto the top surface (11).