3D Security Element via Structural Layer Lamination
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Solution Overview
Problem
Existing methods for producing three-dimensional security features on plastic cards are costly and require special materials and steps, limiting the depth and integration of these features with other card elements.
Innovation Solution
A method involving a structural layer with a pattern that is pressed into the core layer during lamination, deforming a design layer connected to the core, allowing for a three-dimensional effect without damaging existing structural components, using common production methods and materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a coating with metallic or organic pigments is printed onto a substrate and a thicker lacquer layer forming a pattern is applied, then a three-dimensional effect is achieved, but the process becomes complex and requires special materials
Solution Approach 1:
The patent combines the pattern-forming lacquer layer with the top protective layer into a single integrated layer. This layer serves dual functions: creating the three-dimensional pattern effect and providing surface protection, thereby eliminating the need for separate application steps and reducing overall process complexity
Solution Approach 2:
The top layer is designed to perform multiple functions simultaneously: it creates the visual three-dimensional pattern, provides mechanical protection to the underlying coating, and serves as the final surface of the security element. This multi-functionality reduces the number of required layers and process steps
2Shape
If a thicker lacquer layer is used to create the three-dimensional effect, then the visual impact is enhanced, but the potential penetration depth is limited by the thin coating thickness
Solution Approach 1:
The patent resolves the thickness limitation by shifting from vertical penetration into the thin coating to horizontal layering above it. The pattern-forming lacquer is applied as a thicker layer on top of the coating, creating three-dimensional relief patterns that achieve visual depth without requiring penetration through the entire coating thickness
3Adaptability or versatility
If a full-surface layer of metallic ink is applied to a core and a thicker lacquer layer is applied over this, then a unique card feature is created, but it cannot be easily combined with other card features and requires a sufficiently soft and thick top layer
Solution Approach 1:
The integrated top layer is designed as a universal component that can accommodate various underlying designs and patterns. It can be applied over different types of coatings (metallic, organic, inorganic pigments) and can work with various card features, making the solution highly adaptable and combinable with other card elements without requiring additional specialized layers
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
Enables the creation of three-dimensional patterns suitable for payment, credit, and ID cards with enhanced visual effects, easily combinable with other features, without increasing material or process complexity.
Implementation Method 1
The structural layer is pressed into the core layer of the security element by lamination
Implementation Method 2
deforming a design layer connected to the core
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a method for producing a physical security element comprising a pattern (10) with a three-dimensional effect. A support (1) and at least one translucent cover layer (8, 9) are provided. A design layer (3) is applied onto the support (1). Either the support (1) has a lower degree of thermal dimensional stability than the cover layer (8) or the cover layer (9) has a lower degree of thermal dimensional stability than the support (1). The design layer (3) is deformable under the effect of pressure. A translucent structural layer is arranged between the support (1) and the cover layer (8), said structural layer forming the pattern (10). The structural layer (5) has a higher degree of thermal dimensional stability than either the support (1) or the cover layer (9). The support (1) and the layers (3, 5, 8, 9) are laminated under the effect of pressure and heat. During the lamination process, the structural layer (5) is pressed into the support (1) or into the cover layer (9), whereby the design layer (3) is deformed in a manner corresponding to the pattern (10) formed by the structural layer (5), and the structural layer (5) is deformed in the edge regions (15) of the structural layer such that the surfaces (17, 18) of the structural layer run together tangentially in the cross-section.