Security Element Embossing with Wash-Off Reflective Layer Patterning
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Solution Overview
Problem
Existing security features for data carriers and valuable documents with multiple optical elements have complex manufacturing processes, leading to precision and design tolerances, high reject rates, and economic inefficiencies.
Innovation Solution
A method involving embossing varnish application with microstructure and diffractive structure, followed by soluble wash ink printing and reflective layer deposition, with selective removal of wash ink and layers to create optically active embossed structures, utilizing thermoplastic or radiation-curable embossing lacquers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex manufacturing process with multiple work steps and materials is used to create security features with multiple optical elements, then the counterfeit protection capability is improved, but the manufacturing precision and design tolerance deteriorate due to accumulation of errors across multiple steps
Solution Approach 1:
The patent combines multiple optical elements (microstructure and diffractive structure) into a single embossing varnish layer that is applied and cured in one manufacturing step. This integration eliminates the need for separate application steps for each optical element, thereby reducing cumulative errors and maintaining high manufacturing precision while achieving complex counterfeit protection features.
Solution Approach 2:
The embossing varnish is applied with pre-formed embossed structures that define both the microstructure and diffractive structure areas before any subsequent processing. This preliminary formation of multiple optical elements in a single layer ensures precise spatial relationships and design tolerances are maintained throughout the manufacturing process.
2Reliability
If multiple separate manufacturing steps and materials are used to create security features with multiple optical elements, then the optical functionality is improved, but the device complexity and number of work steps increase
Solution Approach 1:
The patent merges the creation of multiple optical elements (microstructure and diffractive structure) into a single embossing varnish layer that contains both functional areas. This consolidation reduces the number of separate manufacturing steps and materials required, simplifying the overall device complexity while maintaining comprehensive optical functionality for security verification.
3Manufacturing precision
If multiple separate manufacturing steps are used to create security features, then the optical elements can be precisely formed, but the productivity and economic viability deteriorate due to increased reject rate and longer cycle time
Solution Approach 1:
The patent combines the formation of multiple optical elements into a single embossing varnish application and curing step, which significantly reduces the total number of manufacturing operations. This streamlined process minimizes opportunities for defects, lowers the reject rate, and improves productivity while maintaining the precision required for high-quality optical security features.
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
Produces a counterfeit-proof security element with manageable steps, maintaining high precision and economic viability, featuring micromirror and hologram effects in reflected light, and optional color-shifting effects through thin-film interference.
Implementation Method 1
both embossed structures are provided with a reflective layer spatially aligned along the embossing structures
Implementation Method 2
a diffractive structure, wherein the diffractive structure has a second optical effect
Implementation Method 3
featuring micromirror and hologram effects in reflected light
Implementation Method 4
optional color-shifting effects through thin-film interference
Data Source
Figure 1~3
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Figure 7~8
AI summary
A method for producing a security element (1) for securing data carriers or valuable documents, comprising the following steps: 1) providing a carrier substrate (2); 2) applying an embossing varnish (3), wherein the embossing varnish (3) has two areas with embossing structures (4), namely a microstructure (4a) and a diffractive structure (4b); 3) printing a soluble wash ink (5) such that the areas of the two embossing structures (4) are left unprinted. To ensure that the method is simple and economical, without negatively impacting counterfeit protection, the method according to the invention further comprises the following steps: 4) vapor deposition of a reflective layer (6) over the entire surface; 5) washing off the wash ink (5) together with the at least one layer arranged directly above the wash ink (5).