Ultrasonic-Welded Secure Covers With High-Resolution Optical Security Elements

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Solution Overview

Problem

Existing security elements in secure article covers, such as passports, suffer from low resolution, high costs, and complex equipment, making it difficult to produce durable and recognizable security features.

Innovation Solution

Utilizing ultrasonic welding to create security elements on and/or in the covers, enabling high-resolution embossings, debossings, and optically variable features like diffractive and latent images, which can be personalized and produced efficiently with modular equipment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If blind embossing is done using heat and pressure, then security elements can be produced on covers, but the machinery is big, heavy and expensive, and resolution is low

Engineering Contradiction:

ImproveresolutionVSAvoidmachinery size and cost

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces traditional thermal and mechanical embossing systems with ultrasonic welding technology. Ultrasonic welding uses high-frequency mechanical vibrations (20-100 kHz) to locally melt and fuse materials, eliminating the need for large, expensive heat and pressure machinery while achieving superior resolution and detail in security elements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the fundamental parameters of the embossing process by using ultrasonic vibration frequency and amplitude instead of conventional heat and pressure. This parameter change enables precise local material deformation with high resolution while using compact, cost-effective equipment.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If UV fluorescent printing is used, then security elements can be added to covers, but the resolution is low and it is continuous by nature

Engineering Contradiction:

ImproveresolutionVSAvoidprinting complexity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces UV fluorescent printing with ultrasonic welding to create security elements. Ultrasonic welding directly deforms the cover material to create raised or recessed patterns with high resolution, eliminating the need for continuous printing processes and achieving superior detail without complex printing machinery.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If gold foiling is done in 2D format with flat plates, then security elements can be produced, but the resolution is rather low and microtext cannot be created

Engineering Contradiction:

ImproveresolutionVSAvoidsecurity element variety

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent replaces traditional 2D gold foiling with ultrasonic welding, which can create both 2D and 3D security elements. Ultrasonic welding achieves high resolution by using focused vibrational energy to deform material precisely, enabling microtext and complex patterns that were impossible with flat plate foiling.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent transitions from 2D gold foiling to 3D ultrasonic welding, adding the dimension of depth and relief to security elements. Ultrasonic welding can create raised embossings, recessed debossings, and varied surface topographies, greatly increasing versatility and security element variety.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Manufacturing precision

If existing security elements are used, then covers can be produced, but they suffer from low resolution and high costs

Engineering Contradiction:

ImproveresolutionVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces multiple separate security element processes (embossing, printing, foiling) with a single ultrasonic welding system. This consolidation achieves high resolution through precise vibrational control while reducing manufacturing costs by eliminating the need for multiple expensive specialized machines and processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Ultrasonic welding allows for high-definition, durable, and cost-effective production of secure article covers with fine details and optically variable elements, enhancing security and manufacturability.

Implementation Method 1

The security element is produced by ultrasonic welding. The front cover and/or the reverse cover is/are acted upon by ultrasonic vibrations, whereby the security element is produced.

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Data Source

PatentUS12565057B2Security elements in covers of secure article by ultrasonic welding

Publication Date: 2026.03.03 THALES DIS FRANCE SA

AI summary

Provided is a secure article, preferably a multi-page article, comprising a front cover, a reverse cover, and at least one security element. The security element can be provided on, and/or, in the front cover and/or the reverse cover, and can be produced by ultrasonic welding. The security element comprises or consists of an optically variable element. Other embodiments are disclosed.