CA2769260C - Dimensionally stable polyester foil and data carrier having the polyester foil - Google Patents
Dimensionally stable polyester foil and data carrier having the polyester foil Download PDFInfo
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- CA2769260C CA2769260C CA2769260A CA2769260A CA2769260C CA 2769260 C CA2769260 C CA 2769260C CA 2769260 A CA2769260 A CA 2769260A CA 2769260 A CA2769260 A CA 2769260A CA 2769260 C CA2769260 C CA 2769260C
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
- B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06K—GRAPHICAL DATA READING; PRESENTATION OF DATA; RECORD CARRIERS; HANDLING RECORD CARRIERS
- G06K19/00—Record carriers for use with machines and with at least a part designed to carry digital markings
- G06K19/06—Record carriers for use with machines and with at least a part designed to carry digital markings characterised by the kind of the digital marking, e.g. shape, nature, code
- G06K19/067—Record carriers with conductive marks, printed circuits or semiconductor circuit elements, e.g. credit or identity cards also with resonating or responding marks without active components
- G06K19/07—Record carriers with conductive marks, printed circuits or semiconductor circuit elements, e.g. credit or identity cards also with resonating or responding marks without active components with integrated circuit chips
- G06K19/077—Constructional details, e.g. mounting of circuits in the carrier
- G06K19/0772—Physical layout of the record carrier
- G06K19/07722—Physical layout of the record carrier the record carrier being multilayered, e.g. laminated sheets
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/24—All layers being polymeric
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2270/00—Resin or rubber layer containing a blend of at least two different polymers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/30—Properties of the layers or laminate having particular thermal properties
- B32B2307/306—Resistant to heat
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/30—Properties of the layers or laminate having particular thermal properties
- B32B2307/308—Heat stability
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/40—Properties of the layers or laminate having particular optical properties
- B32B2307/41—Opaque
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/732—Dimensional properties
- B32B2307/734—Dimensional stability
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2425/00—Cards, e.g. identity cards, credit cards
Abstract
The present invention relates to a foil composite material (1) having at least one base layer (2) of a base layer material, which has a first surface (2') and a second surface (2"), and a first cover layer (5) of a first cover layer material, which covers the first surface (2') of the base layer (2) all over. The base layer material is a polybutylene terephthalate material and the first cover layer material is a polyester material different from the base layer material. The foil composite material (1) may have a second cover layer and a first intermediate layer between the base layer and the first cover layer, and a second intermediate layer between the base layer and the second cover layer. Preferred materials for the base layer and the cover layers are polybutylene terephthalate or polyethylene terephthalate glycol copolymer. The invention also relates to a data carrier card (10) which has the foil composite material (1) according to the invention as a carrier foil for a data carrier (11). The invention further relates to methods for manufacturing the foil composite material (1) and the data carrier card (10).
Description
Dimensionally stable polyester foil and data carrier having the polyester foil [00011 The subject matter of the present invention is a foil composite material having at least one base layer of a base layer material, which has a first surface and a second surface, and having a first cover layer of a first cover layer material, which covers the first surface of the base layer. The subject matter of the present invention is also a method for manufacturing the foil composite material, as well as products manufactured with the foil composite material, such as a card having an electronic data carrier, and a method for manufacturing such cards.
[0002] The contactless data transmission is increasingly gaining in importance, for example for the marking of goods, for the purposes of merchandise control, and in particular also for electronic ID documents. The data carrier here typically is a module of IC chip and antenna in the form of an integrated thin-film circuit.
The chip consists of a plurality of electronic components such as transistors, capacitors, resistors, diodes, etc., and the antenna is a conductive layer, typically in a coil form.
The stored information can be read-out and shown for example on a display or transmit certain commands. The data carriers are attached on the surface of objects, for example integrated in labels, or integrated in the layer structure of a card with applications such as ID documents, display cards or in transponder technology.
For this purpose, the data carriers are enclosed between foils, a carrier foil and at least one covering further foil. Carrier foils typically are foils of polyester, polycarbonates, polyamides, polyimides, and in particular biaxially stretched foils like BOPET. Covering foils typically are foils of polyethylene, polypropylene, polystyrene, polyamides, polycarbonates, polyesters and other thermoplastics.
The foils are connected by laminating, whereby temperature loads acting on the foils are inevitable. If the carrier foil is thereby distorted, disruptions in the contacting among the components may occur. In use, such a data carrier card may also be exposed to high temperatures, for example in a parked car in sunlight.
The chip consists of a plurality of electronic components such as transistors, capacitors, resistors, diodes, etc., and the antenna is a conductive layer, typically in a coil form.
The stored information can be read-out and shown for example on a display or transmit certain commands. The data carriers are attached on the surface of objects, for example integrated in labels, or integrated in the layer structure of a card with applications such as ID documents, display cards or in transponder technology.
For this purpose, the data carriers are enclosed between foils, a carrier foil and at least one covering further foil. Carrier foils typically are foils of polyester, polycarbonates, polyamides, polyimides, and in particular biaxially stretched foils like BOPET. Covering foils typically are foils of polyethylene, polypropylene, polystyrene, polyamides, polycarbonates, polyesters and other thermoplastics.
The foils are connected by laminating, whereby temperature loads acting on the foils are inevitable. If the carrier foil is thereby distorted, disruptions in the contacting among the components may occur. In use, such a data carrier card may also be exposed to high temperatures, for example in a parked car in sunlight.
[0003] Because of the high temperature stability required, as carrier foils for electronic components, or also for other elements to be accommodated in a protected fashion in the layer structure of a card, there are often used biaxially . =
oriented semi-crystalline polyester foils, such as biaxially oriented semi-crystalline PET. Such foils are known and available for example under the brand name Melinex or Mylar. Such foils have the advantage that through the stretching they are very dimension-stable and temperature-stable, i.e. the dimensions of the foils hardly change even under laminating temperatures. Furthermore, through the stretching there is achieved a high mechanical stability of the foil.
100041 The biaxially oriented polyester foils, however, also have disadvantages.
For example, the foils lose their inner strength, when they are manufactured with fillers in order to receive opaque foils. In filled foils through the stretching there arise micropores in the material which lead to striking material weaknesses, which in turn has the effect that these foils have the tendency to so-called "cohesive fractures". Furthermore, the foils must not only be mechanically stable and temperature-stable, but also be able to be laminated well to usual card materials and preferably be well printable. The biaxially oriented polyester foils, however, cannot be laminated without auxiliary layers, and a printing is only possible after a preceding priming and/or coating, because the foils normally are manufacturable only without the desired and for the printing necessary surface roughness.
Another disadvantage is that the stretched foils are available only in a limited number of foil types and foil thicknesses and that due to their orientation they can only be incorporated as a core layer in a symmetrical card structure, because otherwise it may come to a warping of the card.
[0005] Other foils which often are employed as carrier foils are for example foils of polycarbonate which have the disadvantage that they are not very scratch-resistant, not very dimensionally stable, difficult to process and also relatively expensive, and foils of polyvinyl chloride which have the disadvantage that they are not dimensionally stable and fracture easily, so that cards manufactured with these foils often have to be replaced after a short time.
[0006] Desirable would be a foil which does not have the above-mentioned disadvantages of the prior art and is suitable as a carrier foil for electronic components and other elements in the layer composite of a card.
100071 It is therefore the object of the present invention to provide a foil which avoids the disadvantages of the foils of the prior art to the greatest extent possible.
[0008] It is in particular the object of the present invention to provide a foil material which has an advantageous combination of the following properties:
¨ It should be as dimension-stable and temperature-stable as possible;
¨ it should have a high mechanical stability;
¨ it should not tend to cohesive fracture;
¨ it should be well laminatable with all usual plastic card materials, also without the use of auxiliary layers;
¨ it should be well printable, also without print pretreatment;
and ¨ it should be manufacturable in an opaque fashion.
[0009] It is also the object of the present invention to provide a dimensionally stable and mechanically stable card, such as a data carrier card, which contains an electronic data carrier or another object in a fashion protected against manipulation.
The card should be manufacturable by means of lamination technology.
[0010] The objects are achieved by the foil composite material, the data carrier card and the methods for the manufacturing thereof that are disclosed herein.
oriented semi-crystalline polyester foils, such as biaxially oriented semi-crystalline PET. Such foils are known and available for example under the brand name Melinex or Mylar. Such foils have the advantage that through the stretching they are very dimension-stable and temperature-stable, i.e. the dimensions of the foils hardly change even under laminating temperatures. Furthermore, through the stretching there is achieved a high mechanical stability of the foil.
100041 The biaxially oriented polyester foils, however, also have disadvantages.
For example, the foils lose their inner strength, when they are manufactured with fillers in order to receive opaque foils. In filled foils through the stretching there arise micropores in the material which lead to striking material weaknesses, which in turn has the effect that these foils have the tendency to so-called "cohesive fractures". Furthermore, the foils must not only be mechanically stable and temperature-stable, but also be able to be laminated well to usual card materials and preferably be well printable. The biaxially oriented polyester foils, however, cannot be laminated without auxiliary layers, and a printing is only possible after a preceding priming and/or coating, because the foils normally are manufacturable only without the desired and for the printing necessary surface roughness.
Another disadvantage is that the stretched foils are available only in a limited number of foil types and foil thicknesses and that due to their orientation they can only be incorporated as a core layer in a symmetrical card structure, because otherwise it may come to a warping of the card.
[0005] Other foils which often are employed as carrier foils are for example foils of polycarbonate which have the disadvantage that they are not very scratch-resistant, not very dimensionally stable, difficult to process and also relatively expensive, and foils of polyvinyl chloride which have the disadvantage that they are not dimensionally stable and fracture easily, so that cards manufactured with these foils often have to be replaced after a short time.
[0006] Desirable would be a foil which does not have the above-mentioned disadvantages of the prior art and is suitable as a carrier foil for electronic components and other elements in the layer composite of a card.
100071 It is therefore the object of the present invention to provide a foil which avoids the disadvantages of the foils of the prior art to the greatest extent possible.
[0008] It is in particular the object of the present invention to provide a foil material which has an advantageous combination of the following properties:
¨ It should be as dimension-stable and temperature-stable as possible;
¨ it should have a high mechanical stability;
¨ it should not tend to cohesive fracture;
¨ it should be well laminatable with all usual plastic card materials, also without the use of auxiliary layers;
¨ it should be well printable, also without print pretreatment;
and ¨ it should be manufacturable in an opaque fashion.
[0009] It is also the object of the present invention to provide a dimensionally stable and mechanically stable card, such as a data carrier card, which contains an electronic data carrier or another object in a fashion protected against manipulation.
The card should be manufacturable by means of lamination technology.
[0010] The objects are achieved by the foil composite material, the data carrier card and the methods for the manufacturing thereof that are disclosed herein.
4 , =
100111 In the simplest embodiment, the foil composite material according to the invention has two layers, a base layer of a base layer material and a first cover layer of a first cover layer material, whereby the first cover layer covers one of the surfaces of the base layer all over. The base layer material is a polybutylene terephthalate material and the first cover layer material is a polyester material different from the base layer material, preferably a co-polyester material, i.e. a polyester copolymer.
[0012] According to preferred embodiments, the foil composite material according to the invention has at least three layers. A foil composite material with three layers has, additionally to the base layer and the first cover layer, a second cover layer of a second cover layer material, whereby the second cover layer covers the other surface of the base layer all over, and whereby the second cover layer material is a polyester material different from the base layer material, preferably a co-polyester material, i.e. a polyester copolymer. The first and the second cover layer material may be the same or different.
[0013] Further embodiments of the foil composite material according to the invention have between the base layer and the first cover layer at least one first intermediate layer of a first intermediate layer material and/or have between the base layer and the second cover layer at least one second intermediate layer of a second intermediate layer material. The first and/or the second intermediate layer is respectively formed all over between the base layer and the first cover layer or the second cover layer. The first intermediate layer material is a polyester material different from the base layer material and the first cover layer material, which contains polybutylene terephthalate (PBT) in a lower quantity than the base layer material, but in a higher quantity than the first cover layer material. The second intermediate layer material is a polyester material different from the base layer material and the second cover layer material, which contains polybutylene terephthalate (PBT) in a lower quantity than the base layer material, but in a higher quantity than the second cover layer material. The first and the second intermediate layer material may be the same or different.
100141 The foil composite material according to the invention may contain further intermediate layers, whereby the quantity of PBT in the intermediate layers decreases respectively from the base layer to the cover layer.
[0015] The base layer material is a polybutylene terephthalate material. A
polybutylene terephthalate material within the terms of the present invention is a material of polymers and, optionally, additives. The polymer portion of the polybutylene terephthalate material is at least 75 weight per cent, preferably at least 85 weight per cent, and the portion of polybutylene terephthalate (PBT) of the polymer is at least 50 weight per cent, preferably 60 to 100 weight per cent, more preferred 80 to 100 weight per cent, particularly prefered 100 weight per cent PBT.
The other polymers, if present, are preferably a polyester and/or copolyester or a mixture of polyesters and/or copolyesters different from PBT. Particularly preferred is polyethylene terephthalate glycol copolymer (PETG). Attention has to be paid to the fact that no polyesters are used which may act as plasticizers. The polymer portion may also contain extenders, but preferably no extenders are contained.
[0016] PBT is a semi-crystalline polyester with a balanced combination of stiffness and strength with at the same time good toughness and high heat resistance and excellent dimensional stability. In this respect, PBT reaches the properties of BOPET foils, in contrast to these, however, without stretching.
Therefore, PBT foils or foils of the above-mentioned polybutylene terephthalate material can be provided with additives such as fillers without problems. As no stretching needs to take place, there will not occur the micropores arising upon the stretching with fillers, nor the associated danger of self-splitting of the foil, i.e. with the polybutylene terephthalate material used according to the invention there is no danger of cohesive fracture. For this reason, the base layer can be easily filled with fillers and thus be manufactured in an opaque fashion.
. =
[0017] As further additives, besides the fillers, there can also be contained color pigments and other usual auxiliary substances such as oxidation stabilizers, flame retardants or optical brighteners. Color pigments at the same time can act as fillers.
Examples of fillers are in particular titanium dioxide (Ti02; white), soot (black) and colored pigments such as various metal oxides, metal silicates, metal sulphates, etc.
[0018] Cover layer materials are laminatable polyester materials, in particular laminatable co-polyester, different from the base layer material. As in the base layer material, the polymer portion is preferably at least 75 weight per cent, more preferred at least 85 weight per cent, remainder usual additives such as fillers, for example color pigments, and optional other auxiliary substances such as oxidation stabilizers, flame retardants, optical brighteners, etc. A preferred filler is titanium dioxide, a white pigment which is preferably used in order to make the foils opaque.
[0019] The polymer portion in the polyester material may contain extenders, but preferably is free from extenders. Preferably, no PBT is contained in the cover layer materials and particularly preferably at least 80 weight per cent of the polymer portion consists of polyethylene terephthalate glycol copolymer (PETG).
In the most preferred embodiment, the polymer portion consists exclusively (100 %) of PETG.
[0020] Intermediate layer materials are polyester materials which at least with respect to the composition of their polymer portion differ from the neighboring layers. They consist of a polyester or of a mixture of polyesters and/or a copolyester or a mixture of copolyesters, whereby the polymer portion is preferably at least 75 weight per cent, particularly preferably at least 85 weight per cent. There can be contained usual additives such as fillers and extenders, as they were mentioned above, whereby extenders are preferably not contained.
[0021] The preferred polyester material for the intermediate layers is a mixture of PBT and one or more polyesters and/or copolyesters different therefrom, whereby PETG is preferred. Particularly preferably, the intermediate layers consist of a mixture of PBT and PETG, optionally with fillers such as for example pigments, in order to achieve opacity or a certain coloring.
[0022] The intermediate layers, if present, establish a transition, in terms of material, between the base layer and the cover layers, and thus preferably consist of the same polymer materials as the adjacent layers, albeit in accordingly modified quantitative portions. I.e., in an intermediate layer between the base layer and the cover layer, the PBT content of the intermediate layer is to range between the PBT
content of the base layer and the PBT content of the cover layer. If for example the base layer has 90 weight per cent PBT, and the cover layer has 3 weight per cent PBT, the PBT content of the intermediate layer ranges between 3 weight per cent and 90 weight per cent.
[0023] In the case of several intermediate layers between the base layer and a cover layer, the PBT content is to decrease from the base layer to the cover layer.
The intermediate layers preferably contain 30 to 60 weight per cent PBT, remainder PETG, and optionally fillers such as for example titanium dioxide.
[0024] When the base layer, the cover layers and the optional intermediate layers contain fillers, then the filler content in the layers preferably ranges respectively between approx. 5 to 15 weight per cent.
[0025] The foil composite material according to the invention consists of at least two layers, one base layer and one cover layer, but preferably has a cover layer on both surfaces of the base layer. Between the base layer and a cover layer, or between the base layer and both cover layers, there can be respectively provided an intermediate layer or also several intermediate layers. If intermediate layers are present, their number is preferably the same on both sides of the base layer.
The foil composite material according to the invention is thus built up "symmetrically"
or at least "partly symmetrically" with respect to the base layer.
. =
[0026] "Symmetric" means, the foil composite material is mirror-symmetric related to the base layer as the plane of symmetry. On both sides of the base layer there is the same number of layers, and each layer is identical with its corresponding mirror layer with respect to thickness and composition.
[0027] "Partly symmetric" means, the foil composite material is mirror-symmetric with respect to the number of layers on both sides of the base layer, but the mirror-symmetric layers differ in their thickness and/or composition (polymer material, fillers, etc.).
[0028] The prefered embodiments have three or five layers and are symmetric or partly symmetric.
[0029] In the particularly preferred embodiment, the base layer consists of PBT, if appropriate with a portion of PETG, optionally with fillers, and the two cover layers consist of PETG, likewise optionally with fillers.
[0030] In the alternative particularly preferred embodiment, between the base layer and the cover layers there is respectively provided an intermediate layer which consists of PBT and PETG, optionally with fillers. The intermediate layers contain less PBT than the base layer. With regard to the composition of the base layer and the cover layer, to the five-layered particularly preferred embodiment applies the same as to the three-layered particularly preferred embodiment.
[0031] The foil composite material according to the invention has, particularly in its preferred embodiments, a number of advantages compared to conventional foils used in the prior art as carrier foils for electronic components. Due to the fact that the base layer, which represents a significant part of the foil composite material, consists of PBT or largely of PBT, the foil composite material as a whole has a high dimensional stability and a high mechanical strength. PBT is a semi-crystalline polyester with a balanced combination of stiffness and strength with at the same time good toughness and good stability of shape against heat and excellent dimensional stability. The cover layers, however, i.e. the outer layers of =
the foil composite material according to the invention, consist of a laminatable material, preferably a co-polyester, and in particular of PETG. These outer layers impart to the foil composite material optimal lamination properties with all common card materials (polyvinyl chloride, polycarbonate, chlorinated polyethylene, acrylonitrile butadiene styrene, polyethylene, polypropylene, thermoplastic polyurethanes, cycloolefin copolymers, etc.) as well as optimal printing properties. The outer layers can be laminated without laminating aids, such as for example primers, adhesives, other coatings, and be printed without preceding priming and/or coating. The foil composite materials do not have to be stretched, but can be used in the unstretched state. Thus, there is also no problem with micropores, as occurs in particular with filled BOPET foils, and the foil composite materials can be filled with fillers in one or in several layers of the layer structure, without there possibly occurring micropores and thus the danger of splitting of the foil in itself (cohesive fracture). Through the high dimensional stability, which among other things is very important upon the population with electronic components so as to ensure their good contact among each another, and through the high mechanical strength the foil composite material according to the invention is also very suitable as a mechanical stabilizer in and with other card materials in the layer structure of a card. Here, the foil composite material needs not to be incorporated as a core layer in a symmetric structure, but can also be used as an outer layer.
[0032] The properties of the foil composite material according to the invention can be varied over a broad spectrum. This is possible by changing the recipes of the individual layers (type and portions of different polymers, type and portions of fillers etc.), the number of layers and changing the individual layer thicknesses.
[0033] The total thickness of the foil composite material according to the invention is approx. 20 m to 1000 pm, preferably approx. 40 pm to 700 m, particularly preferably approx. 80 pm to 500 pm. In a three-layered material the base layer constitutes approx. 60 to 90% of the total thickness of the foil, and in a five-layered material the base layer constitutes approx. 50 to 80% of the total thickness of the foil.
[0034] The foil composite materials according to the invention are preferably manufactured by the coextrusion of the thermoplastic polyesters which are to form the individual layers. Suitable extruders are in principle all commonly used extruders, for example screw-type extruders, such as single-screw extruders or twin-screw extruders or combinations of both types. Fillers and other auxiliary substances can already be added upon the manufacturing of the polymers or polymer mixtures from which the individual layers are to be manufactured, i.e.
the polymer feed materials of the respective extruders already contain in this case the finished layer materials. The desired additives, however, can also be added directly upon the foil extrusion. Exemplary extrusion conditions for a foil composite material having a base layer of PBT (thickness 80 gm) and two cover layers of PETG (thickness 10 gm each), respectively with 10 weight per cent titanium dioxide, are a melting temperature between 250 C and 275 C. By changing the temperature, the melting viscosity of the individual layers is influenced with the aim of achieving substantially matching melting viscosities.
[0035] Alternatively, the individual layers, i.e. base layer, cover layers and optionally intermediate layers, can be respectively separately extruded and then hot-laminated. The lamination conditions are material-dependent, and typical lamination conditions are for instance temperatures of 120 C to 160 C and a pressure of 20 to 150 bar.
[0036] The foil composite material according to the invention can be advantageously integrated as a carrier foil in the layer structure. With regard to the type, number and arrangement of the further card layers there are no specific restrictions. The foil composite material according to the invention can be laminated without problems with all common card materials and may serve alternatively as a core layer of the card or as an outer layer of the card. Of course, a lamination is only possible with such card materials which are laminatable =
themselves. If the card contains for example layers of paper or paperboard, these layers must be adhesively bonded.
[0037] In the card the foil composite material may serve as a carrier foil for different objects, in particular areal objects which are to be accommodated in a protected fashion in the layer structure of the card, for example electronic data carriers.
[0038] The manufacturing of such a card having objects integrated in a protected fashion in the card structure, such as electronic data carriers, is carried out in such a way that the carrier foil is populated with the objects and then is laminated to one or several further foils, so that the object is enclosed between the carrier foil and the further foil or the further foils. Upon populating the carrier foil with the objects, the objects typically are adhesively bonded to the carrier foil. Certain objects, such as antennas, will be applied in the form of a metallization or printing (e.g.
screen printing, flexographic printing etc.) of the carrier foil, i.e. for example by vacuum vapor deposition.
[0039] Depending on the configuration of the card in the individual case, it may be useful to laminate all card layers in one single step with each other, or to carry out the lamination in several steps. A lamination in several steps can be advantageous in particular when objects are to be accommodated not only between the foil composite material according to the invention and a further card foil, but also between other card foils. For example, such a card may contain further objects and/or features, such as security elements in the form of embossed structures, as prints or as independent, inserted or adhesively bonded elements, markings, codings etc., as they are in principle known with respect to their type and mounting.
For the lamination of the card foils, the standard lamination techniques can be used, as they are known to a person skilled in the art. The foil composite material according to the invention does not require any specific measures upon its lamination with other card foils. It maintains its shape substantially unchanged under lamination conditions, so that contact problems in electronic components are . .
avoided, and can be easily manufactured in an opaque fashion, i.e. with fillers, without a possible cohesive fracture of the material having to be feared. The foil composite material namely is preferably used in a non-stretched form, and it also acts in the non-stretched form, because of its high mechanical strength, as a mechanically stabilizing element of the card.
100401 In the following the present invention is still further illustrated with reference to Figures. It is pointed out that the Figures are not true-to-proportion. In addition, it is pointed out that the Figures are only to explain the invention in more detail, and are in no way restrictive. The same reference numbers denote the same or corresponding elements.
Fig 1 shows a section through a foil composite material having three layers according to the invention;
Fig 2 shows a section through a foil composite material having five layers according to the invention, and Fig 3 shows a section through a card with a foil composite material according to the invention as a carrier layer for a data carrier.
[0041] Fig 1 shows an embodiment of a foil composite material 1 according to the invention with a base layer 2 having a first surface 2' and a second surface 2".
On the first surface 2' a first cover layer 5 is located, and on the second surface 2" a second cover layer 6 is located. The first cover layer 5 and the second cover layer 6 are the outer layers of the foil composite material 1. They consist for example of polyethylene terephthalate glycol copolymer (PETG), and the base layer 2 consists for example of 60 to 100 weight per cent polybutylene terephthalate (PBT), remainder optionally PETG. The base layer 2 and/or one or both outer layers may contain fillers in order to make the foils opaque, for example 5 to 15 weight per cent titanium dioxide.
=
[0042] In its simplest version (not shown) the foil composite material 1 according to the invention has only one base layer 2 and one cover layer 5.
When such a foil composite material is integrated in the layer structure of a card, it is usually not used as a core layer of the card, but as an outer layer, whereby the cover layer 5 is laminated to a further card foil, while the base layer 2 serves as an outer layer of the card. Alternatively, it is in principle also possible to use the cover layer as an outer layer, or to use the foil composite material 1 having only two layers as a core layer of a card, whereby then, however, in most cases lamination aids must be used.
[0043] Fig 2 shows a foil composite material 1 having five layers according to the invention, a base layer 2, a first cover layer 5, a second cover layer 6, and with a first intermediate layer 3 between the base layer and the first cover layer 5 and a second intermediate layer 4 between the base layer 2 and the second cover layer 6.
The base layer and the two cover layers consist of the same materials as the base layer and the two cover layers in the embodiment shown in Fig 1, i.e. 60 to weight per cent PBT, remainder PETG as polymer material of the base layer, and PETG as polymer material of the cover layers, whereby the layers respectively may contain, additionally to the polymer material, 5 to 15 weight per cent titanium dioxide (related to the respective total amount of the base layer material or of the cover layer material). The first intermediate layer 3 and the second intermediate layer 4 likewise consist of polymer material plus optionally 5 to 15 weight per cent titanium dioxide, whereby the polymer material in turn consists of 30 to 60 weight per cent PBT, remainder PETG.
[0044] Fig. 1 and Fig. 2 respectively show symmetric embodiments of the foil composite material 1 according to the invention. The symmetric embodiments are preferred, but also other embodiments are within the scope of the present invention.
For example, the embodiment shown in Fig. 2 may have two intermediate layers between the base layer 2 and the first cover layer 5 and/or no second intermediate layer 4 between the base layer 2 and the second cover layer 6. It is also not , =
mandatory, that layers symmetric to each other have the same thickness, as shown in Fig 1 and Fig. 2. Rather, for example the two cover layers can be differently thick. Alternatively, symmetric layers may differ with respect to their composition, for example may contain different portions of PBT and PETG, or may contain different fillers and/or colored pigments, or alternatively no fillers at all.
These embodiments, which merely have the same number of layers on both sides of the base layer, but differ with regard to layer thicknesses and/or composition of the layers, are partly symmetric. Partly symmetric embodiments, too, are preferred embodiments, in particular when they only differ with regard to their content of fillers or pigments. These additives only serve to produce opacity or color.
100451 Fig. 3 shows a data carrier card 10 with a foil composite material 1 according to the invention (as represented in Fig. 1 or Fig. 2) in cross-section. For the sake of a clearer visibility of the structure, the card foils are represented in the unconnected state. The foil composite material is the core foil of the card and serves as a carrier layer for an IC chip 11. The foil composite material 1 is used in the non-stretched state. The card 10 represented in Fig. 3, moreover, has four further layers, namely the outer layers 14, 15, and the layers 12 and 13 between the foil composite material 1 and the outer layer 14 or between the foil composite material 1 and the outer layer 15. The card foils 12 and 13 respectively have a design print layer 16, 17. Suitable are for example opaque foils of polycarbonate, polyester, ABS, PVC, polyethylene, polypropylene etc. with a thickness of for example approx. 100 to 250 gm. The outer layers 14, 15 are preferably transparent foils with a slightly smaller thickness, for example 50 to 105 gm. These foils are to be transparent, so that the design print thereunder can be recognized, and resistant to abrasion and scratching in order to protect the card.
100461 A suitable material is for example PVC. Furthermore, suitable are PVC, PETG, polycarbonate (PC), ABS or so-called blends of different materials, such as PC/PETG, PC/ABS, etc. The outer layers, too, can be provided with additional .
features, for example with security elements or individualization features. In the embodiment shown the outer foil 14 has a diffraction structure 18.
[0047] In Fig. 3, the card foils are shown in their state before the lamination. For manufacturing the card 10, the foils 1, 12, 13, 14 and 15 are brought together and laminated to each other without lamination aids under standard lamination conditions. The card 10 resulting therefrom is, even under thermal load, mechanically very stable, durable and does not tend to break.
100111 In the simplest embodiment, the foil composite material according to the invention has two layers, a base layer of a base layer material and a first cover layer of a first cover layer material, whereby the first cover layer covers one of the surfaces of the base layer all over. The base layer material is a polybutylene terephthalate material and the first cover layer material is a polyester material different from the base layer material, preferably a co-polyester material, i.e. a polyester copolymer.
[0012] According to preferred embodiments, the foil composite material according to the invention has at least three layers. A foil composite material with three layers has, additionally to the base layer and the first cover layer, a second cover layer of a second cover layer material, whereby the second cover layer covers the other surface of the base layer all over, and whereby the second cover layer material is a polyester material different from the base layer material, preferably a co-polyester material, i.e. a polyester copolymer. The first and the second cover layer material may be the same or different.
[0013] Further embodiments of the foil composite material according to the invention have between the base layer and the first cover layer at least one first intermediate layer of a first intermediate layer material and/or have between the base layer and the second cover layer at least one second intermediate layer of a second intermediate layer material. The first and/or the second intermediate layer is respectively formed all over between the base layer and the first cover layer or the second cover layer. The first intermediate layer material is a polyester material different from the base layer material and the first cover layer material, which contains polybutylene terephthalate (PBT) in a lower quantity than the base layer material, but in a higher quantity than the first cover layer material. The second intermediate layer material is a polyester material different from the base layer material and the second cover layer material, which contains polybutylene terephthalate (PBT) in a lower quantity than the base layer material, but in a higher quantity than the second cover layer material. The first and the second intermediate layer material may be the same or different.
100141 The foil composite material according to the invention may contain further intermediate layers, whereby the quantity of PBT in the intermediate layers decreases respectively from the base layer to the cover layer.
[0015] The base layer material is a polybutylene terephthalate material. A
polybutylene terephthalate material within the terms of the present invention is a material of polymers and, optionally, additives. The polymer portion of the polybutylene terephthalate material is at least 75 weight per cent, preferably at least 85 weight per cent, and the portion of polybutylene terephthalate (PBT) of the polymer is at least 50 weight per cent, preferably 60 to 100 weight per cent, more preferred 80 to 100 weight per cent, particularly prefered 100 weight per cent PBT.
The other polymers, if present, are preferably a polyester and/or copolyester or a mixture of polyesters and/or copolyesters different from PBT. Particularly preferred is polyethylene terephthalate glycol copolymer (PETG). Attention has to be paid to the fact that no polyesters are used which may act as plasticizers. The polymer portion may also contain extenders, but preferably no extenders are contained.
[0016] PBT is a semi-crystalline polyester with a balanced combination of stiffness and strength with at the same time good toughness and high heat resistance and excellent dimensional stability. In this respect, PBT reaches the properties of BOPET foils, in contrast to these, however, without stretching.
Therefore, PBT foils or foils of the above-mentioned polybutylene terephthalate material can be provided with additives such as fillers without problems. As no stretching needs to take place, there will not occur the micropores arising upon the stretching with fillers, nor the associated danger of self-splitting of the foil, i.e. with the polybutylene terephthalate material used according to the invention there is no danger of cohesive fracture. For this reason, the base layer can be easily filled with fillers and thus be manufactured in an opaque fashion.
. =
[0017] As further additives, besides the fillers, there can also be contained color pigments and other usual auxiliary substances such as oxidation stabilizers, flame retardants or optical brighteners. Color pigments at the same time can act as fillers.
Examples of fillers are in particular titanium dioxide (Ti02; white), soot (black) and colored pigments such as various metal oxides, metal silicates, metal sulphates, etc.
[0018] Cover layer materials are laminatable polyester materials, in particular laminatable co-polyester, different from the base layer material. As in the base layer material, the polymer portion is preferably at least 75 weight per cent, more preferred at least 85 weight per cent, remainder usual additives such as fillers, for example color pigments, and optional other auxiliary substances such as oxidation stabilizers, flame retardants, optical brighteners, etc. A preferred filler is titanium dioxide, a white pigment which is preferably used in order to make the foils opaque.
[0019] The polymer portion in the polyester material may contain extenders, but preferably is free from extenders. Preferably, no PBT is contained in the cover layer materials and particularly preferably at least 80 weight per cent of the polymer portion consists of polyethylene terephthalate glycol copolymer (PETG).
In the most preferred embodiment, the polymer portion consists exclusively (100 %) of PETG.
[0020] Intermediate layer materials are polyester materials which at least with respect to the composition of their polymer portion differ from the neighboring layers. They consist of a polyester or of a mixture of polyesters and/or a copolyester or a mixture of copolyesters, whereby the polymer portion is preferably at least 75 weight per cent, particularly preferably at least 85 weight per cent. There can be contained usual additives such as fillers and extenders, as they were mentioned above, whereby extenders are preferably not contained.
[0021] The preferred polyester material for the intermediate layers is a mixture of PBT and one or more polyesters and/or copolyesters different therefrom, whereby PETG is preferred. Particularly preferably, the intermediate layers consist of a mixture of PBT and PETG, optionally with fillers such as for example pigments, in order to achieve opacity or a certain coloring.
[0022] The intermediate layers, if present, establish a transition, in terms of material, between the base layer and the cover layers, and thus preferably consist of the same polymer materials as the adjacent layers, albeit in accordingly modified quantitative portions. I.e., in an intermediate layer between the base layer and the cover layer, the PBT content of the intermediate layer is to range between the PBT
content of the base layer and the PBT content of the cover layer. If for example the base layer has 90 weight per cent PBT, and the cover layer has 3 weight per cent PBT, the PBT content of the intermediate layer ranges between 3 weight per cent and 90 weight per cent.
[0023] In the case of several intermediate layers between the base layer and a cover layer, the PBT content is to decrease from the base layer to the cover layer.
The intermediate layers preferably contain 30 to 60 weight per cent PBT, remainder PETG, and optionally fillers such as for example titanium dioxide.
[0024] When the base layer, the cover layers and the optional intermediate layers contain fillers, then the filler content in the layers preferably ranges respectively between approx. 5 to 15 weight per cent.
[0025] The foil composite material according to the invention consists of at least two layers, one base layer and one cover layer, but preferably has a cover layer on both surfaces of the base layer. Between the base layer and a cover layer, or between the base layer and both cover layers, there can be respectively provided an intermediate layer or also several intermediate layers. If intermediate layers are present, their number is preferably the same on both sides of the base layer.
The foil composite material according to the invention is thus built up "symmetrically"
or at least "partly symmetrically" with respect to the base layer.
. =
[0026] "Symmetric" means, the foil composite material is mirror-symmetric related to the base layer as the plane of symmetry. On both sides of the base layer there is the same number of layers, and each layer is identical with its corresponding mirror layer with respect to thickness and composition.
[0027] "Partly symmetric" means, the foil composite material is mirror-symmetric with respect to the number of layers on both sides of the base layer, but the mirror-symmetric layers differ in their thickness and/or composition (polymer material, fillers, etc.).
[0028] The prefered embodiments have three or five layers and are symmetric or partly symmetric.
[0029] In the particularly preferred embodiment, the base layer consists of PBT, if appropriate with a portion of PETG, optionally with fillers, and the two cover layers consist of PETG, likewise optionally with fillers.
[0030] In the alternative particularly preferred embodiment, between the base layer and the cover layers there is respectively provided an intermediate layer which consists of PBT and PETG, optionally with fillers. The intermediate layers contain less PBT than the base layer. With regard to the composition of the base layer and the cover layer, to the five-layered particularly preferred embodiment applies the same as to the three-layered particularly preferred embodiment.
[0031] The foil composite material according to the invention has, particularly in its preferred embodiments, a number of advantages compared to conventional foils used in the prior art as carrier foils for electronic components. Due to the fact that the base layer, which represents a significant part of the foil composite material, consists of PBT or largely of PBT, the foil composite material as a whole has a high dimensional stability and a high mechanical strength. PBT is a semi-crystalline polyester with a balanced combination of stiffness and strength with at the same time good toughness and good stability of shape against heat and excellent dimensional stability. The cover layers, however, i.e. the outer layers of =
the foil composite material according to the invention, consist of a laminatable material, preferably a co-polyester, and in particular of PETG. These outer layers impart to the foil composite material optimal lamination properties with all common card materials (polyvinyl chloride, polycarbonate, chlorinated polyethylene, acrylonitrile butadiene styrene, polyethylene, polypropylene, thermoplastic polyurethanes, cycloolefin copolymers, etc.) as well as optimal printing properties. The outer layers can be laminated without laminating aids, such as for example primers, adhesives, other coatings, and be printed without preceding priming and/or coating. The foil composite materials do not have to be stretched, but can be used in the unstretched state. Thus, there is also no problem with micropores, as occurs in particular with filled BOPET foils, and the foil composite materials can be filled with fillers in one or in several layers of the layer structure, without there possibly occurring micropores and thus the danger of splitting of the foil in itself (cohesive fracture). Through the high dimensional stability, which among other things is very important upon the population with electronic components so as to ensure their good contact among each another, and through the high mechanical strength the foil composite material according to the invention is also very suitable as a mechanical stabilizer in and with other card materials in the layer structure of a card. Here, the foil composite material needs not to be incorporated as a core layer in a symmetric structure, but can also be used as an outer layer.
[0032] The properties of the foil composite material according to the invention can be varied over a broad spectrum. This is possible by changing the recipes of the individual layers (type and portions of different polymers, type and portions of fillers etc.), the number of layers and changing the individual layer thicknesses.
[0033] The total thickness of the foil composite material according to the invention is approx. 20 m to 1000 pm, preferably approx. 40 pm to 700 m, particularly preferably approx. 80 pm to 500 pm. In a three-layered material the base layer constitutes approx. 60 to 90% of the total thickness of the foil, and in a five-layered material the base layer constitutes approx. 50 to 80% of the total thickness of the foil.
[0034] The foil composite materials according to the invention are preferably manufactured by the coextrusion of the thermoplastic polyesters which are to form the individual layers. Suitable extruders are in principle all commonly used extruders, for example screw-type extruders, such as single-screw extruders or twin-screw extruders or combinations of both types. Fillers and other auxiliary substances can already be added upon the manufacturing of the polymers or polymer mixtures from which the individual layers are to be manufactured, i.e.
the polymer feed materials of the respective extruders already contain in this case the finished layer materials. The desired additives, however, can also be added directly upon the foil extrusion. Exemplary extrusion conditions for a foil composite material having a base layer of PBT (thickness 80 gm) and two cover layers of PETG (thickness 10 gm each), respectively with 10 weight per cent titanium dioxide, are a melting temperature between 250 C and 275 C. By changing the temperature, the melting viscosity of the individual layers is influenced with the aim of achieving substantially matching melting viscosities.
[0035] Alternatively, the individual layers, i.e. base layer, cover layers and optionally intermediate layers, can be respectively separately extruded and then hot-laminated. The lamination conditions are material-dependent, and typical lamination conditions are for instance temperatures of 120 C to 160 C and a pressure of 20 to 150 bar.
[0036] The foil composite material according to the invention can be advantageously integrated as a carrier foil in the layer structure. With regard to the type, number and arrangement of the further card layers there are no specific restrictions. The foil composite material according to the invention can be laminated without problems with all common card materials and may serve alternatively as a core layer of the card or as an outer layer of the card. Of course, a lamination is only possible with such card materials which are laminatable =
themselves. If the card contains for example layers of paper or paperboard, these layers must be adhesively bonded.
[0037] In the card the foil composite material may serve as a carrier foil for different objects, in particular areal objects which are to be accommodated in a protected fashion in the layer structure of the card, for example electronic data carriers.
[0038] The manufacturing of such a card having objects integrated in a protected fashion in the card structure, such as electronic data carriers, is carried out in such a way that the carrier foil is populated with the objects and then is laminated to one or several further foils, so that the object is enclosed between the carrier foil and the further foil or the further foils. Upon populating the carrier foil with the objects, the objects typically are adhesively bonded to the carrier foil. Certain objects, such as antennas, will be applied in the form of a metallization or printing (e.g.
screen printing, flexographic printing etc.) of the carrier foil, i.e. for example by vacuum vapor deposition.
[0039] Depending on the configuration of the card in the individual case, it may be useful to laminate all card layers in one single step with each other, or to carry out the lamination in several steps. A lamination in several steps can be advantageous in particular when objects are to be accommodated not only between the foil composite material according to the invention and a further card foil, but also between other card foils. For example, such a card may contain further objects and/or features, such as security elements in the form of embossed structures, as prints or as independent, inserted or adhesively bonded elements, markings, codings etc., as they are in principle known with respect to their type and mounting.
For the lamination of the card foils, the standard lamination techniques can be used, as they are known to a person skilled in the art. The foil composite material according to the invention does not require any specific measures upon its lamination with other card foils. It maintains its shape substantially unchanged under lamination conditions, so that contact problems in electronic components are . .
avoided, and can be easily manufactured in an opaque fashion, i.e. with fillers, without a possible cohesive fracture of the material having to be feared. The foil composite material namely is preferably used in a non-stretched form, and it also acts in the non-stretched form, because of its high mechanical strength, as a mechanically stabilizing element of the card.
100401 In the following the present invention is still further illustrated with reference to Figures. It is pointed out that the Figures are not true-to-proportion. In addition, it is pointed out that the Figures are only to explain the invention in more detail, and are in no way restrictive. The same reference numbers denote the same or corresponding elements.
Fig 1 shows a section through a foil composite material having three layers according to the invention;
Fig 2 shows a section through a foil composite material having five layers according to the invention, and Fig 3 shows a section through a card with a foil composite material according to the invention as a carrier layer for a data carrier.
[0041] Fig 1 shows an embodiment of a foil composite material 1 according to the invention with a base layer 2 having a first surface 2' and a second surface 2".
On the first surface 2' a first cover layer 5 is located, and on the second surface 2" a second cover layer 6 is located. The first cover layer 5 and the second cover layer 6 are the outer layers of the foil composite material 1. They consist for example of polyethylene terephthalate glycol copolymer (PETG), and the base layer 2 consists for example of 60 to 100 weight per cent polybutylene terephthalate (PBT), remainder optionally PETG. The base layer 2 and/or one or both outer layers may contain fillers in order to make the foils opaque, for example 5 to 15 weight per cent titanium dioxide.
=
[0042] In its simplest version (not shown) the foil composite material 1 according to the invention has only one base layer 2 and one cover layer 5.
When such a foil composite material is integrated in the layer structure of a card, it is usually not used as a core layer of the card, but as an outer layer, whereby the cover layer 5 is laminated to a further card foil, while the base layer 2 serves as an outer layer of the card. Alternatively, it is in principle also possible to use the cover layer as an outer layer, or to use the foil composite material 1 having only two layers as a core layer of a card, whereby then, however, in most cases lamination aids must be used.
[0043] Fig 2 shows a foil composite material 1 having five layers according to the invention, a base layer 2, a first cover layer 5, a second cover layer 6, and with a first intermediate layer 3 between the base layer and the first cover layer 5 and a second intermediate layer 4 between the base layer 2 and the second cover layer 6.
The base layer and the two cover layers consist of the same materials as the base layer and the two cover layers in the embodiment shown in Fig 1, i.e. 60 to weight per cent PBT, remainder PETG as polymer material of the base layer, and PETG as polymer material of the cover layers, whereby the layers respectively may contain, additionally to the polymer material, 5 to 15 weight per cent titanium dioxide (related to the respective total amount of the base layer material or of the cover layer material). The first intermediate layer 3 and the second intermediate layer 4 likewise consist of polymer material plus optionally 5 to 15 weight per cent titanium dioxide, whereby the polymer material in turn consists of 30 to 60 weight per cent PBT, remainder PETG.
[0044] Fig. 1 and Fig. 2 respectively show symmetric embodiments of the foil composite material 1 according to the invention. The symmetric embodiments are preferred, but also other embodiments are within the scope of the present invention.
For example, the embodiment shown in Fig. 2 may have two intermediate layers between the base layer 2 and the first cover layer 5 and/or no second intermediate layer 4 between the base layer 2 and the second cover layer 6. It is also not , =
mandatory, that layers symmetric to each other have the same thickness, as shown in Fig 1 and Fig. 2. Rather, for example the two cover layers can be differently thick. Alternatively, symmetric layers may differ with respect to their composition, for example may contain different portions of PBT and PETG, or may contain different fillers and/or colored pigments, or alternatively no fillers at all.
These embodiments, which merely have the same number of layers on both sides of the base layer, but differ with regard to layer thicknesses and/or composition of the layers, are partly symmetric. Partly symmetric embodiments, too, are preferred embodiments, in particular when they only differ with regard to their content of fillers or pigments. These additives only serve to produce opacity or color.
100451 Fig. 3 shows a data carrier card 10 with a foil composite material 1 according to the invention (as represented in Fig. 1 or Fig. 2) in cross-section. For the sake of a clearer visibility of the structure, the card foils are represented in the unconnected state. The foil composite material is the core foil of the card and serves as a carrier layer for an IC chip 11. The foil composite material 1 is used in the non-stretched state. The card 10 represented in Fig. 3, moreover, has four further layers, namely the outer layers 14, 15, and the layers 12 and 13 between the foil composite material 1 and the outer layer 14 or between the foil composite material 1 and the outer layer 15. The card foils 12 and 13 respectively have a design print layer 16, 17. Suitable are for example opaque foils of polycarbonate, polyester, ABS, PVC, polyethylene, polypropylene etc. with a thickness of for example approx. 100 to 250 gm. The outer layers 14, 15 are preferably transparent foils with a slightly smaller thickness, for example 50 to 105 gm. These foils are to be transparent, so that the design print thereunder can be recognized, and resistant to abrasion and scratching in order to protect the card.
100461 A suitable material is for example PVC. Furthermore, suitable are PVC, PETG, polycarbonate (PC), ABS or so-called blends of different materials, such as PC/PETG, PC/ABS, etc. The outer layers, too, can be provided with additional .
features, for example with security elements or individualization features. In the embodiment shown the outer foil 14 has a diffraction structure 18.
[0047] In Fig. 3, the card foils are shown in their state before the lamination. For manufacturing the card 10, the foils 1, 12, 13, 14 and 15 are brought together and laminated to each other without lamination aids under standard lamination conditions. The card 10 resulting therefrom is, even under thermal load, mechanically very stable, durable and does not tend to break.
Claims (23)
1. A foil composite material having at least - one base layer of a base layer material, which has a first surface and a second surface, and - one first cover layer of a first cover layer material, which covers the first surface of the base layer all over, characterized in that - the base layer material is a material that comprises polybutylene terephthalate, - the first cover layer material is a polyester material different from the base layer material, and - between the base layer and the first cover layer there is at least one first intermediate layer of a first intermediate layer material, wherein the first intermediate layer material is a polyester material different from the base layer material and the first cover layer material, which contains PBT in a lower quantity than the base layer material, but in a higher quantity than the first cover layer material.
2. The foil composite material according to claim 1, characterized in that it has a second cover layer of a second cover layer material, which covers the second surface of the base layer all over, wherein the second cover layer material is a polyester material different from the base layer material, and wherein the first and the second cover layer material are the same or different.
3. The foil composite material according to claim 1, characterized in that it has between the base layer and the second cover layer at least one second intermediate layer of a second intermediate layer material, wherein the second intermediate layer material is a polyester material different from the base layer material and the second cover layer material, which contains PBT in a lower quantity than the base layer material, but in a higher quantity than the second cover layer material, and wherein the first and the second intermediate layer material is the same or different.
4. The foil composite material according to any one of claims 1 to 3, characterized in that the base layer material has a polymer portion of at least 75 weight per cent, remainder fillers and/or usual additives, wherein at least 50 weight per cent of the polymer portion consist of PBT.
5. The foil composite material according to any one of claims 1 to 4, characterized in that the first cover layer material has a polymer portion of at least 75 weight per cent, remainder fillers and/or usual additives, wherein at least 80 weight per cent of the polymer portion consist of PETG.
6. The foil composite material according to any one of claims 1 to 5, characterized in that the second cover layer material has a polymer portion of at least 75 weight per cent, remainder fillers and/or usual additives, wherein at least 80 weight per cent of the polymer portion consist of PETG.
7. The foil composite material according to any one of claims 1 or 3-6, characterized in that the first intermediate layer material has a polymer portion of at least 75 weight per cent, remainder fillers and/or usual additives, wherein the polymer portion contains PBT and PETG in quantities which respectively lie between the quantities of PBT and PETG in the base layer material and the first cover layer material.
8. The foil composite material according to any one of claims 3 to 7, characterized in that the second intermediate layer material has a polymer portion of at least 75 weight per cent, remainder fillers and/or usual additives wherein the polymer portion contains PBT and PETG in quantities, which respectively lie between the quantities of PBT and PETG in the base layer material and the second cover layer material.
9. The foil composite material according to any one of claims 1 to 8, characterized in that the base layer material has a polymer portion of at least 80 weight per cent, remainder fillers and/or usual additives, wherein the polymer portion consists of 60 to 100 weight per cent PBT, remainder PETG.
10. The foil composite material according to any one of claims 1 to 9, characterized in that the first cover layer material has a polymer portion of at least 80 weight per cent, remainder fillers and/or usual additives, wherein the polymer portion consists of PETG.
11. The foil composite material according to any one of claims 1 to 10, characterized in that the second cover layer material has a polymer portion of at least 80 weight per cent, remainder fillers and/or usual additives, wherein the polymer portion consists of PETG.
12. The foil composite material according to any one of claims 1 or 3-11, characterized in that the first intermediate layer material has a polymer portion of at least 80 weight per cent, remainder fillers and/or usual additives, wherein the polymer portion consists of 30 to 60 weight per cent PBT, remainder PETG.
13. The foil composite material according to any one of claims 3 to 12, characterized in that the second intermediate layer material has a polymer portion of at least 80 weight per cent, remainder fillers and/or usual additives, wherein the polymer portion consists of 30 to 60 weight per cent PBT, remainder PETG.
14. A method for manufacturing a foil composite material according to any one of claims 1 to 13, comprising a coextrusion of a base layer material, of a first cover layer material, and of a first intermediate layer material, characterized in that - the base layer material has a composition as stated in any one of claims 1, 4 and 9, - the first cover layer material has a composition as stated in any one of claims 1, 5 and 10, and - ___________________ the first intermediate layer material has a composition as stated in any one of claims 1, 7 and 12.
15. The method of claim 14, wherein the foil composite material further comprises a coextrusion of a second cover layer material, the second cover layer material having a composition as stated in any one of claims 2, 6 and 11.
16. The method of any one of claims 14 or 15, wherein the foil composite material further comprises a coextrusion of a second intermediate layer material, the second intermediate layer material having a composition as stated in any one of claims 3, 8 and 13.
17. A method for manufacturing a foil composite material according to any one of claims 1 to 13, comprising a manufacturing of a base layer foil through the extrusion of a base layer material, of a first cover layer foil through the extrusion of a first cover layer material, and of a first intermediate layer foil through the extrusion of a first intermediate layer material, and a lamination of each of said foils to the foil composite material, characterized in that - the base layer material has a composition as stated in any one of claims 1, 4 and 9, - the first cover layer material has a composition as stated in any one of claims 1, 5 and 10, and - the first intermediate layer material has a composition as stated in one any of claims 1, 7 and 12.
18. The method of claim 17, further comprising the manufacturing of a second cover layer foil through the extrusion of a second cover layer material and a lamination of the second cover layer foil to the foil composite material, the second cover layer material having a composition as stated in any one of claims 2, 6 and 11.
19. The method of either claim 17 or 18, further comprising the manufacturing of a second intermediate layer foil through the extrusion of a second intermediate layer material and a lamination of the second intermediate layer foil to the foil composite material, the second intermediate layer material having a composition as stated in any one of claims 3, 8 and 13.
20. A card having a carrier foil, at least one further foil and at least one component between the carrier foil and the further foil, wherein the carrier foil and the further foil are laminated, characterized in that the carrier foil is a foil composite material according to any one of claims 1 to 13.
21. The card according to claim 20, characterized in that the foil composite material is a non-stretched foil.
22. The card according to claim 20 or 21, characterized in that the component is an electronic component.
23. A method for manufacturing a card according to any one of claims 20 to 22, characterized in that the foil composite material and the at least one further foil are connected to each other through laminating without the use of lamination aids.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE102009035415.8 | 2009-07-31 | ||
| DE102009035415A DE102009035415A1 (en) | 2009-07-31 | 2009-07-31 | Dimensionally stable polyester film and data carrier with the polyester film |
| PCT/EP2010/061130 WO2011012703A1 (en) | 2009-07-31 | 2010-07-30 | Dimensionally stable polyester film and data carrier comprising the polyester film |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2769260A1 CA2769260A1 (en) | 2011-02-03 |
| CA2769260C true CA2769260C (en) | 2014-10-14 |
Family
ID=43086290
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2769260A Active CA2769260C (en) | 2009-07-31 | 2010-07-30 | Dimensionally stable polyester foil and data carrier having the polyester foil |
Country Status (4)
| Country | Link |
|---|---|
| EP (1) | EP2459378B8 (en) |
| CA (1) | CA2769260C (en) |
| DE (1) | DE102009035415A1 (en) |
| WO (1) | WO2011012703A1 (en) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE102013017927A1 (en) * | 2013-10-28 | 2015-04-30 | Giesecke & Devrient Gmbh | Method for producing a film and a portable data carrier |
| IT201900020733A1 (en) * | 2019-11-11 | 2021-05-11 | Mf Group S R L | CARD OF A PERFECTED TYPE AND A METHOD OF REALIZATION OF THIS CARD |
Family Cites Families (12)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE69833984T2 (en) * | 1998-01-06 | 2007-03-15 | Toyo Boseki K.K. | Polyester multilayer film, a metal plate coated with this film, and a foil-coated metal container |
| DE19831898B4 (en) * | 1998-07-16 | 2004-01-22 | Rasmussen Gmbh | Fluid line for fuels and fuel vapors |
| US6475608B2 (en) * | 1998-11-16 | 2002-11-05 | Engelhard Corporation | Multi-layer iridescent films |
| EP1057656A4 (en) * | 1998-11-20 | 2002-02-20 | Unitika Ltd | Three-layer polyester resin sheet for cards and polyester resin laminates made by using the same |
| JP4065400B2 (en) * | 2000-06-14 | 2008-03-26 | ハイピリオン カタリシス インターナショナル インコーポレイテッド | Multilayer polymer structure |
| JP3907956B2 (en) * | 2001-02-27 | 2007-04-18 | 三菱樹脂株式会社 | Card sheet |
| DE10113273A1 (en) * | 2001-03-16 | 2002-09-19 | Basf Ag | Plastics composites preparation detail relates to mono or multiple film as extruded or pressed to include driving agents and fixers. |
| KR100668404B1 (en) * | 2002-04-23 | 2007-01-16 | 가부시키가이샤 리코 | Information recording/displaying card, image processing method using same, and image processor |
| DE102004023310A1 (en) * | 2004-05-11 | 2005-12-15 | Giesecke & Devrient Gmbh | Multi-layered portable data carrier |
| DE102004032596A1 (en) * | 2004-07-06 | 2006-02-16 | Mitsubishi Polyester Film Gmbh | Multilayer, matt, thermoformable, IR-reflective polyester film |
| DE102006045495A1 (en) * | 2006-09-27 | 2008-04-03 | Mitsubishi Polyester Film Gmbh | Laser markable film |
| JP4966646B2 (en) * | 2006-12-27 | 2012-07-04 | リケンテクノス株式会社 | Polyester-based resin laminate, method for producing the same, and laminated decorative sheet |
-
2009
- 2009-07-31 DE DE102009035415A patent/DE102009035415A1/en not_active Withdrawn
-
2010
- 2010-07-30 EP EP10739604.6A patent/EP2459378B8/en active Active
- 2010-07-30 CA CA2769260A patent/CA2769260C/en active Active
- 2010-07-30 WO PCT/EP2010/061130 patent/WO2011012703A1/en active Application Filing
Also Published As
| Publication number | Publication date |
|---|---|
| EP2459378B1 (en) | 2017-07-05 |
| EP2459378B8 (en) | 2017-08-30 |
| EP2459378A1 (en) | 2012-06-06 |
| WO2011012703A1 (en) | 2011-02-03 |
| CA2769260A1 (en) | 2011-02-03 |
| DE102009035415A1 (en) | 2011-02-03 |
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| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request |