Ultrasonic-Welded Hinge Security Elements for Secure Articles
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Solution Overview
Problem
Existing connection devices for data devices, particularly those made of polycarbonate, face challenges in being durable, flexible, and resistant to forgery while being difficult to manufacture and requiring high-temperature processes that compromise material integrity.
Innovation Solution
The use of ultrasonic welding to create security elements in connection devices, such as hinges, which are made of polymers or plastics, allowing for the production of embossing, debossing, and deformations without high temperatures, thereby enhancing security and ease of manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-temperature heat moulding is used to create security elements in polyester fabric, then security elements can be produced, but the material properties are compromised and manufacturing becomes difficult
Solution Approach 1:
The patent replaces thermal processing (heat moulding) with ultrasonic welding to create security elements in the connection device. Ultrasonic welding uses mechanical vibrations at ultrasonic frequencies to locally melt and fuse thermoplastic materials, allowing security elements to be produced without subjecting the entire polyester fabric to high temperatures that would compromise material properties.
Solution Approach 2:
The patent changes the processing parameters from high-temperature heat moulding to ultrasonic frequency mechanical vibrations. This parameter change allows security elements to be created with precise local heating only at the welding point, maintaining the overall material integrity and ease of manufacture while achieving the desired security features.
2Reliability
If UV fluorescent printing or colored threads are used as security elements, then security features are added, but they can be easily manipulated and removed
Solution Approach 1:
The patent creates composite security elements by integrating multiple features into the connection device structure itself through ultrasonic welding. The security elements are formed as integral parts of the welded structure, combining the connection function with security features. This makes the security elements inseparable from the connection device, preventing easy removal or manipulation while maintaining strong resistance to forgery attempts.
3Ease of operation
If the connection device is made thin and flexible, then it is easier to use, but durability and resistance to tearing decrease
Solution Approach 1:
The patent applies local quality by creating concentrated security elements through ultrasonic welding at specific locations within the connection device. The welding process locally fuses materials with high energy density, creating strong bonded regions that enhance durability at critical points while allowing the overall device to remain thin and flexible in non-welded areas.
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
The ultrasonic welding method produces irreversible security elements that enhance durability and security against forgery, maintaining the material's properties and enabling efficient, detailed, and economical production.
Implementation Method 1
ultrasonic welding is well-known in the art and corresponds to a process that uses mechanical vibrations in the ultrasonic range. These vibrations, produced by a welding sonotrode
Implementation Method 2
The thus produced security elements are irreversible and thus provide high security. Moreover, the ultrasonic welding does not harm the properties of the connection device. In fact, ultrasonic welding does not require high temperatures
Data Source
AI summary
Provided is a connection device for connection to a data device and for connecting the data device to a secure article comprises at least one security element that is produced by ultrasonic welding. It comprises a protruding area extending from the data device, and may comprise at least one embossing, debossing, deformation and/or melted area. A data carrier for a secure article comprises such a connection device and at least one data device. A secure article comprises or consists of such a data carrier. Other embodiments are disclosed.