Multilayer Security Element Inner Window Lamination
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Solution Overview
Problem
Existing multilayer security elements with transparent or translucent regions are challenging to manufacture, particularly when creating inner windows in opaque areas, as they require complex processes and are not cost-effective for card-shaped security elements.
Innovation Solution
A multilayer security element is created with transparent or translucent regions by using transparent or transmissive materials during lamination, where cutouts in the functional layers are filled with material from adjoining build-up layers, allowing for the formation of inner windows with various edge contours and security features that can be viewed from different depths, using polycarbonate materials and a feature carrier layer to enhance perception.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a window element is inserted in exact register in the central layer, then the security element achieves effective security features, but the manufacturing process becomes elaborate and challenging
Solution Approach 1:
The patent extracts the window formation process from the central layer and relocates it to the build-up layers. Cutouts are formed in the functional layers, and the window is created by filling these cutouts with transmissive material from the build-up layers during lamination. This extraction eliminates the need for precise window element insertion into the central layer, thereby reducing manufacturing complexity while maintaining security feature effectiveness.
Solution Approach 2:
The patent applies preliminary action by forming cutouts in the functional layers before lamination. The build-up layers are prepared with transmissive material that will automatically fill the cutouts during the lamination process. This preliminary preparation ensures that the window is formed correctly without requiring complex post-processing or precise insertion operations, thus simplifying manufacturing while maintaining reliability.
2Ease of manufacture
If transparent or transmissive material is specifically provided for creating transparent regions, then the transparent regions can be formed, but the manufacturing process becomes complex and costly
Solution Approach 1:
The patent applies universality by making the build-up layers serve dual functions: they provide structural support and encasement for the security element, and they simultaneously serve as the source of transmissive material for forming the window. The build-up layers are made of transmissive material throughout, eliminating the need for separate transparent material preparation. This multi-functionality reduces both material preparation complexity and manufacturing costs.
Solution Approach 2:
The patent merges the window formation process with the lamination process. Instead of separately preparing transparent material and then forming the window, the cutouts in the functional layers are filled with material from the build-up layers during the same lamination step that bonds all layers together. This merging of operations simplifies the manufacturing process and reduces costs by eliminating separate material preparation and window formation steps.
3Ease of operation
If inner windows are created in opaque areas, then security features can be viewed from different depths, but the manufacturing process requires complex steps
Solution Approach 1:
The patent introduces a transparent functional layer as an intermediary between the opaque feature carrier layer and the build-up layers. This functional layer contains cutouts that allow the transmissive material from the build-up layers to fill and create the window. The intermediary functional layer enables the window to be formed in the opaque area without requiring complex direct modification of the feature carrier layer, thus improving security feature visibility while keeping the process relatively simple.
4Shape
If the material of the functional layers has a thickness of less than 100 μm, then excellent planarity is achieved, but the manufacturing precision requirements increase
Solution Approach 1:
The patent specifies a thickness parameter for the functional layers (less than 100 μm) that optimizes planarity. By controlling the thickness parameter within this range, the patent achieves excellent planarity of the security element surfaces. The lamination process is designed to accommodate this thickness specification, and the build-up layers are configured to provide sufficient material for filling cutouts while maintaining the required planarity when the functional layers are within the specified thickness range.
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 enables the easy manufacture of security elements with excellent planarity and clear security feature visibility in different depth positions, supporting the impression of depth through the interposition of a transparent functional layer, while maintaining cost-effectiveness and flexibility in design.
Implementation Method 1
The layers are interconnected by application of heat and pressure
Data Source
AI summary
An easily manufacturable multilayer security element has an opaque functional layer that is arranged between two build-up layers of transmissive material. The opaque functional layer has at least one cutout. The layers are connected by lamination to form an areal body with planar surfaces. The cutout is filled up with transmissive material of the build-up layers. One build-up layer supports a feature carrier layer. A security feature, which is arranged at least partially below the cutout, is formed in the feature carrier layer and/or between the functional layer and the feature carrier layer. The cutout forms an inner window through which the security feature is recognizable.