Security Element Transfer Onto Extruded Card Carrier Film
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Solution Overview
Problem
Existing methods for producing card-shaped data carriers, such as smart cards, face challenges in laminating large-area or temperature-sensitive security elements without using special adhesives, which limits material choices and can damage or clog extrusion apparatuses.
Innovation Solution
A method involving an extrusion process where a transfer film with security elements is used to directly apply these elements onto an extruded melt, utilizing the melt's tack and optional contact pressure to bond them without additional adhesives, allowing for flexible material choices including unextrudable materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If lamination is used to bond films together, then films can be combined to form card bodies, but special adhesives must be introduced which are foreign material and may inadequately form the composite
Solution Approach 1:
The invention extracts and eliminates the adhesive layer from the lamination process. Instead of using special adhesives to bond films together, the patent employs direct bonding methods where the film surfaces are pressed together under heat and pressure, removing the foreign adhesive material entirely from the composite structure.
Solution Approach 2:
The invention introduces a release film as an intermediary element during the lamination process. This release film facilitates the bonding process by allowing temporary separation and controlled adhesion, then is removed to leave clean bond surfaces without requiring special adhesives, thus improving both ease of manufacture and composite formation quality.
2Adaptability or versatility
If security elements covering large area are conveyed through extrusion apparatus, then they can be integrated into the film, but they may be destroyed or clog the apparatus
Solution Approach 1:
The invention applies security elements to the film surface before the extrusion process. By pre-positioning the security elements on the film or substrate prior to extrusion, they are protected from damage and clogging during the extrusion operation, while still achieving integration into the final film structure.
Solution Approach 2:
The invention uses a release film or carrier substrate as an intermediary to hold security elements during handling and transfer. This intermediary protects the security elements from damage in the extrusion apparatus while enabling their successful integration into the film through controlled transfer processes.
3Adaptability or versatility
If temperature-sensitive materials are used for security elements, then diverse material choices are enabled, but they cannot withstand the extrusion process temperatures
Solution Approach 1:
The invention applies temperature-sensitive security elements to the film surface before extrusion, when the film is in a controlled temperature state. The security elements are positioned and secured prior to exposure to high extrusion temperatures, allowing their use despite temperature sensitivity.
Solution Approach 2:
The invention employs a release film or protective substrate as an intermediary carrier for temperature-sensitive security elements. This intermediary protects the security elements from direct exposure to extrusion temperatures during processing, enabling the use of temperature-sensitive materials while maintaining processability.
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 secure bonding of large-area and temperature-sensitive security elements directly to the film without additional materials, enhancing security and design flexibility while avoiding apparatus damage.
Implementation Method 1
heating the first material to form a melt
Implementation Method 2
cooling the extruded melt comprising the security element to form the film
Data Source
AI summary
A method for producing a film for a card-shaped data carrier, includes the following steps: providing at least one first material in an extruder of an extrusion apparatus; heating the first material to form a melt; extruding the melt through a nozzle outlet gap of the extrusion apparatus; conveying the extruded melt on a roller arrangement that is adjacent to the nozzle outlet gap and includes at least one cooling roller; providing at least one transfer film; supplying the transfer film to the extruded melt on the cooling roller is so the security element contacts a surface of the extruded melt on the surface of the transfer film; transferring the security element from the surface of the transfer film onto the surface of the extruded melt; cooling the extruded melt comprising the security element to form the film.