Flexible Smart Card Circuits with Laser-Revealed Color Layers
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Solution Overview
Problem
Existing methods for manufacturing smart card modules with flexible printed circuits lack the ability to create complex, multicolored patterns visible through the spaces between electrical contacts, limiting design complexity and potential security features.
Innovation Solution
Incorporating a method of laser etching different-colored strata of dielectric material to reveal underlying colors, utilizing photochromic or thermochromic agents that change color with light or temperature, and optionally using reinforcing layers to prevent adhesive creep.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional manufacturing methods are used to produce flexible printed circuits, then the production process is simple and reliable, but the ability to create complex multicolored patterns is limited
Solution Approach 1:
The dielectric substrate is divided into multiple colored layers (first dielectric layer, second dielectric layer, third dielectric layer) with different colors (e.g., white, blue, yellow). Each layer is deposited separately and can be selectively removed or modified independently, enabling complex multicolored patterns to be created through systematic segmentation of the coloring process
Solution Approach 2:
The colored dielectric layers are deposited and patterned before the conductive traces are formed. This preliminary coloring allows the complex multicolored design to be established in advance, and subsequent manufacturing steps (such as laser etching to remove material) can reveal the predetermined color patterns without requiring complex operations during the final assembly
2Adaptability or versatility
If multiple colored layers are added to create multicolored patterns, then design complexity and security features are enhanced, but the manufacturing process becomes more complex
Solution Approach 1:
The patent utilizes multiple dielectric layers with different intrinsic colors (white, blue, yellow) to create security features. The colored layers are selectively positioned and revealed through controlled removal of other layers, enabling complex color patterns and security features without requiring additional complex manufacturing steps beyond standard multilayer deposition processes
Solution Approach 2:
Instead of using complex mechanical patterning systems to create color patterns, the patent employs selective chemical or physical removal (such as laser etching) of dielectric layers to reveal underlying colored layers. This substitution simplifies the manufacturing process by replacing complex mechanical coloring operations with a more straightforward selective removal approach
3Device complexity
If laser etching is used to reveal underlying colors, then multicolored patterns can be created, but the manufacturing precision requirements increase
Solution Approach 1:
The laser etching process removes dielectric material selectively to reveal underlying colored layers. By controlling the depth and area of etching, the patent achieves precise color pattern revelation without requiring extremely high precision - partial removal of layers is sufficient to expose the desired colors, and excessive removal can be compensated by the layered structure itself
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 multicolored patterns and security features in smart card modules, enhancing design complexity and security through visible color changes, while maintaining reliable electrical connections.
Implementation Method 1
a method comprising: providing a complex material having a shape of a thin board or strip, the complex material comprising an assembly comprising at least two different-colored strata of dielectric material and at least one layer of electrically conductive material resting on the assembly comprising at least two different-colored strata of dielectric material
Implementation Method 2
utilizing photochromic or thermochromic agents that change color with light or temperature
Implementation Method 3
utilizing photochromic or thermochromic agents that change color with light or temperature
Data Source
AI summary
A method for manufacturing flexible printed circuits for smart card modules, wherein a complex material is provided. This complex material includes an assembly including at least two different-colored strata. Zones of this assembly are visible through the layer of electrically conductive material. This manufacturing method includes an operation that consists in laser etching at least one of the two different-colored strata over a portion of that zone of the assembly of strata that is left visible, so as to reveal the color of the other of the two different-colored strata. Printed circuit manufactured by this method. Module and smart card including this printed circuit.


