Portable Data Carrier Cavity Lamination With a Stiffening Layer
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Solution Overview
Problem
Existing methods for producing cavities in data carriers, such as chip cards, face issues with precision and dimensional accuracy due to material deformation and leakage during thermal processes, leading to inadequate cavity formation.
Innovation Solution
A method involving a core layer with a recess covered by stiffening and cover layers, where the stiffening layer prevents material intrusion into the cavity, ensuring precise and stable cavity formation through lamination at elevated temperature and pressure without adhesives, and allowing for symmetrical construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermal joining processes are used to create cavities in data carriers, then the cavities can be formed and sealed, but the dimensional accuracy of the cavities deteriorates due to material deformation and liquefied material forcing into cavities
Solution Approach 1:
The patent applies preliminary action by creating the cavity shape in the core layer before the thermal joining process. The cavity is formed by a recess in the core layer that is filled with a core material, and this pre-formed cavity structure is then covered by the stiffening layer and seal layer. This ensures the cavity geometry is established before thermal effects can cause deformation or material intrusion, maintaining dimensional accuracy while still allowing thermal sealing to occur.
Solution Approach 2:
The stiffening layer serves as an intermediary element between the core layer (with cavity) and the seal layer. This intermediate layer provides mechanical support and prevents the seal layer from deforming into the cavity during thermal joining, while also preventing liquefied material from the core layer from forcing into the cavity. The stiffening layer acts as a protective mediator that maintains cavity dimensional accuracy during the thermal process.
2Ease of manufacture
If adhesives or similar materials are used during cavity production, then the cavities can be sealed, but the material may leak into the cavities causing contamination
Solution Approach 1:
The stiffening layer acts as an intermediary barrier between the adhesive application area and the cavity. The adhesive is applied to the core layer or seal layer, but the stiffening layer prevents this adhesive from penetrating into the cavity recess. This intermediary structure allows cavity sealing to occur while maintaining cavity cleanliness by blocking adhesive intrusion.
Solution Approach 2:
The stiffening layer functions as a thin film or shell that provides a barrier between the adhesive and the cavity. This thin film structure is sufficient to prevent adhesive penetration while still allowing the thermal joining and sealing processes to proceed. The stiffening layer's thin-film nature allows it to be integrated into the multi-layer structure without adding excessive complexity.
3Object-affected harmful factors
If the cavity is formed after the metallic core layer is separated from the metallic multi-panel sheet, then no short-circuit-causing metal chips remain in the slot, but the cavity formation precision is insufficient
Solution Approach 1:
The patent applies preliminary action by forming the cavity shape in the core layer before the final assembly and sealing steps. The cavity is created by a recess in the core layer that is filled with core material, and this pre-formed structure is then covered by the stiffening layer and seal layer. This ensures the cavity geometry is established before thermal effects can cause deformation or material intrusion, maintaining dimensional accuracy while still allowing thermal sealing to occur.
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
Enhances the dimensional stability of the carrier body and cavities, preventing material intrusion and maintaining precision during thermal joining processes, thereby improving cavity manufacturing accuracy.
Implementation Method 1
The stiffening layer can prevent any material, such as adhesive or displaced portions of the core layer and/or cover layer, from penetrating the recess from which the cavity is formed
Implementation Method 2
connecting the core layer, the stiffening layer, and the cover layer to one another
Implementation Method 3
particularly when using thermal joining processes
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a method for producing a carrier body (2), in particular for a portable data carrier (1), with a cavity (3), a corresponding carrier body (2), a portable data carrier (1) and a production device (20) for producing portable data carriers (1), wherein the method comprises the following steps: providing a core layer (10) with at least one recess (13) which predetermines a contour of the cavity (13), covering the core layer (10) with a stiffening layer (11), covering the stiffening layer (11) with a cover layer (12) and connecting the core layer (10), the stiffening layer (11) and the cover layer (13) to one another.