CN112078199A - 一种含咖啡渣的智能卡及其制作方法 - Google Patents
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Abstract
本发明涉及智能卡领域,具体是一种含咖啡渣的智能卡及其制作方法,该制作方法先在中间片和咖啡渣复合片材的两面都通过丝网印刷方式涂布热塑性胶粘剂,并经干燥处理后分别得到涂胶中间片和涂胶夹层片;随后在涂胶中间片两面依次叠加涂胶夹层片、印刷基片和透明薄膜得到组坯叠片,再对组坯叠片依次进行热压处理和冷压处理后得到粘合坯;最后按照预设尺寸规格对粘合坯进行冲切得到卡基,在卡基上铣槽并安装IC芯片后得到含咖啡渣的智能卡。该智能卡与石化基材料智能卡的外观特性及机械性能较为接近,并能有效减少石化基材料的使用。
Description
技术领域
本发明涉及智能卡领域,具体是一种含咖啡渣的智能卡及其制作方法。
背景技术
生物基复合材料是指含有可再生的生物质原材料,包括农作物、树木和其他植物及其残体和内含物为原料,通过生物、化学及物理等手段制造的一类新型复合材料。目前智能卡领域仍主要使用不可再生的PVC、PC、PET等石化基材料,考虑到国内人均持有卡片数量以及产品更新换代的频次,智能卡领域对于石化基材料的消耗量十分惊人。目前各类生物基复合材料还不能完全取代智能卡中的石化基材料,鉴于两类材料在物理性能及表面特性上差异较大,要在智能卡中复用这两类材料就必须在卡片结构及工艺上都做出优化。
发明内容
本发明的第一目的在于提供一种用到咖啡渣复合材料的含咖啡渣的智能卡的制作方法。
本发明的第二目的在于提供一种通过前述制作方法制得的含咖啡渣的智能卡。
为实现上述第一目的,本发明提供一种含咖啡渣的智能卡的制作方法,其特殊之处在于,包括下列步骤:
a、在中间片两面通过丝网印刷方式涂布热塑性胶粘剂并经干燥处理后得到涂胶中间片,在咖啡渣复合片材两面通过丝网印刷方式涂布热塑性胶粘剂并经干燥处理后得到涂胶夹层片;
b、在涂胶中间片两面依次叠加涂胶夹层片、印刷基片和透明薄膜得到组坯叠片,对组坯叠片依次进行热压处理和冷压处理后得到粘合坯;
c、按照预设尺寸规格对粘合坯进行冲切得到卡基,在卡基上铣槽并安装IC芯片后得到含咖啡渣的智能卡。
由上述方案可见,咖啡渣复合材料多为具有棕色底色的不透明生物基复合材料,并不适合用作印刷基片、透明薄膜或者需要埋设线圈的中间片,其机械性能通常也不如采用石化基材料的片材,因此只能以夹层片的形式设置到卡坯中。在卡坯中对称地引入两片生物基复合材料夹层片后对于卡片的外观特性及机械性能影响较小,并且通过优化卡坯中各层片材的厚度比例能够大幅减小卡坯中石化基材料的用量。
中间片除内置线圈以外的部分均采用石化基材料,咖啡渣复合片材属于生物基材料,两者的表面特性差异较大,单纯通过热压手段无法实现牢固粘合,由于制作智能卡的材料基本都是热塑性的,故可通过在两类材料之间施以热塑性胶粘剂实现粘接。采取丝网印刷方式可实现均匀涂胶,并能精准控制胶粘剂的用量,在中间片和咖啡渣复合片材上丝印涂胶并充分干燥去除溶剂后可得到表面覆有厚度均匀的薄层热塑性树脂的涂胶中间片和涂胶夹层片。在热压过程中,由于两层薄层热塑性树脂已经分别牢固粘覆在中间片及咖啡渣复合片材的表面,仅通过这两层薄层热塑性树脂之间的受热融合即可实现中间片与咖啡渣复合片材的牢固粘合,而涂胶夹层片表面的薄层热塑性树脂熔化后可将咖啡渣复合片材与印刷基片稳定粘合,随后的冷压处理可将各类片材粘结定型得到一体的粘合坯。
另外,中间片对应于智能卡的核心结构层,对粘结强度的要求较高,相较于咖啡渣复合片材与印刷基片间的粘合所需的用胶量会更大,因此中间片和夹层片均采取两面涂胶可在中间片与咖啡渣复合片材之间引入较多的热塑性树脂以实现稳定粘合。
咖啡渣复合片材可采用市售的PLA-咖啡渣复合材料、ABS-咖啡渣复合材料或PP-咖啡渣复合材料制作,三种材料目前均已实现国产化和商用化,其物理性能与常用的石化基制卡材料较为接近。另外咖啡渣复合片材还可以自制,具体是将咖啡渣与热塑性胶粘剂混合并固化定型后制成坯料,再将坯料切分成所需厚度的片材。
进一步的方案是,步骤a中干燥处理为60℃至75℃下的热风干燥处理。
由上可见,上述温度范围的热风干燥处理能够快速脱除热塑性胶粘剂中的溶剂成分并使之成为厚度均匀的薄层热塑性树脂。
进一步的方案是,中间片两面通过54T至120T的丝网版涂布热塑性胶粘剂。
进一步的方案是,咖啡渣复合片材两面通过15T至54T的丝网版涂布热塑性胶粘剂。
由上可见,T数越小的丝网版对应的丝印涂胶量较大,对应的薄层热塑性树脂厚度也越大,将用于中间片和咖啡渣复合片材的丝印涂胶的丝网版的T数分别控制在上述两个范围内可保证中间片、咖啡渣复合片材与印刷基片三者间的牢固粘合。
进一步的方案是,咖啡渣复合片材为80至95重量份的咖啡渣原料混合5至20重量份的聚氨酯胶粘剂或EVA胶粘剂后固化成型并切分得到的厚度为0.1mm至0.5mm的片材。
由上可见,聚氨酯树脂和EVA树脂的弹性较好,对应的胶粘剂粘结力强,与咖啡渣原料按照上述比例混合后可得到物理性能较为理想的生物基复合材料。
进一步的方案是,咖啡渣原料的目数为100目至150目,咖啡渣原料的含水量在10wt%以内。
由上可见,将咖啡渣原料的目数和含水量控制在上述范围有助于改善咖啡渣复合片材的物理性能。
进一步的方案是,热塑性胶粘剂为丙烯酸酯胶粘剂、聚氨酯胶粘剂或氯醋树脂胶粘剂。
由上可见,上述三种均为智能卡制造领域较为常用的热塑性胶粘剂,能够满足咖啡渣复合片材与石化基片材之间的稳定粘合。
进一步的方案是,步骤c中热压处理在135℃至150℃的温度条件以及5MPa至7MPa的压力条件下进行,处理时间为20min至25min。
进一步的方案是,步骤c中冷压处理在6MPa至11MPa的压力条件下进行,处理时间为20min至25min。
由上可见,上述热压处理条件可保证热塑性胶粘剂形成的薄层热塑性树脂发挥粘结作用,配合上述冷压处理条件可将各类片材粘合定型得到一体的粘合坯。这里的冷压是相对于热压而言的,应理解成层压处理时不对层压钢板进行加热,而不应理解成是在层压过程中将层压设备外接冷水塔等制冷设备并通过循环水冷却层压钢板。
为实现上述第二目的,本发明提供一种含咖啡渣的智能卡,其特殊之处在于,该智能卡通过前述含咖啡渣的智能卡的制作方法制得。
附图说明
图1是本发明在制作含咖啡渣的智能卡的过程中形成的组坯叠片的分解结构图。
以下结合附图及实施例对本发明作进一步说明。
具体实施方式
本发明依照以下步骤制作含咖啡渣的智能卡:
a、对回收的咖啡渣进行分拣、清洗处理并烘干至含水量不超过10wt%后研磨制成100目至150目的咖啡渣原料,取80至95重量份咖啡渣原料与5至20重量份的聚氨酯胶粘剂或EVA胶粘剂充分混合后注入模具,随后在70℃至140℃的温度条件下固化3h至10h并放冷至室温得到坯料,使用切片机将坯料加工成厚度为0.1mm至0.5mm的咖啡渣复合片材;
b、在中间片两面通过54T至120T的丝网版丝印涂布热塑性胶粘剂,随后在60℃至75℃的热风干燥条件下充分干燥得到涂胶中间片1,在咖啡渣复合片材两面通过15T至54T的丝网版丝印涂布热塑性胶粘剂,随后在60℃至75℃的热风干燥条件下充分干燥得到涂胶夹层片2,热塑性胶粘剂为丙烯酸酯胶粘剂、聚氨酯胶粘剂或氯醋树脂胶粘剂;
c、参见图1,在涂胶中间片1两面依次叠加涂胶夹层片2、印刷基片3和透明薄膜4得到组坯叠片,将组坯叠片在135℃至150℃的温度条件以及5MPa至7MPa的压力条件下热压处理20min至25min,之后在6MPa至11MPa的压力条件冷压处理20min至25min后得到粘合坯;
d、按照预设尺寸规格将粘合坯冲切处理得到卡基,在卡基上铣槽并安装IC芯片后即得到含咖啡渣的智能卡成品。
实施例一
本实施例提供一种含咖啡渣的智能卡的制作方法,该制作方法包括以下步骤:
a、对回收的咖啡渣进行分拣、清洗处理并烘干至含水量不超过10wt%后研磨制成100目至150目的咖啡渣原料,取85重量份咖啡渣原料与15重量份的聚氨酯胶粘剂充分混合后注入模具,随后在70℃至140℃的温度条件下固化3h至10h并放冷至室温得到坯料,使用切片机将坯料加工成厚度为0.1mm至0.5mm的咖啡渣复合片材;
b、在中间片两面通过80T的丝网版丝印涂布丙烯酸酯胶粘剂,随后在60℃至75℃的热风干燥条件下充分干燥得到涂胶中间片,在咖啡渣复合片材两面通过16T的丝网版丝印涂布丙烯酸酯胶粘剂,随后在60℃至75℃的热风干燥条件下充分干燥得到涂胶夹层片;
c、在涂胶中间片两面依次叠加涂胶夹层片、印刷基片和透明薄膜得到组坯叠片,将组坯叠片在145℃的温度条件以及5MPa的压力条件下热压处理25min,之后在10MPa的压力条件冷压处理23min后得到粘合坯;
d、按照预设尺寸规格将粘合坯冲切处理得到卡基,在卡基上铣槽并安装IC芯片后即得到含咖啡渣的智能卡成品。
实施例二
本实施例提供一种含咖啡渣的智能卡的制作方法,该制作方法包括以下步骤:
a、对回收的咖啡渣进行分拣、清洗处理并烘干至含水量不超过10wt%后研磨制成100目至150目的咖啡渣原料,取90重量份咖啡渣原料与5重量份的EVA胶粘剂充分混合后注入模具,随后在70℃至140℃的温度条件下固化3h至10h并放冷至室温得到坯料,使用切片机将坯料加工成厚度为0.1mm至0.5mm的咖啡渣复合片材;
b、在中间片两面通过90T的丝网版丝印涂布聚氨酯胶粘剂,随后在60℃至75℃的热风干燥条件下充分干燥得到涂胶中间片,在咖啡渣复合片材两面通过24T的丝网版丝印涂布聚氨酯胶粘剂,随后在60℃至75℃的热风干燥条件下充分干燥得到涂胶夹层片;
c、在涂胶中间片两面均依次叠加涂胶夹层片、印刷基片和透明薄膜得到组坯叠片,将组坯叠片在140℃的温度条件以及6.5MPa的压力条件下热压处理20min,之后在9MPa的压力条件冷压处理24min后得到粘合坯;
d、按照预设尺寸规格将粘合坯冲切处理得到卡基,在卡基上铣槽并安装IC芯片后即得到含咖啡渣的智能卡成品。
实施例三
本实施例提供一种含咖啡渣的智能卡的制作方法,该制作方法包括以下步骤:
a、对回收的咖啡渣进行分拣、清洗处理并烘干至含水量不超过10wt%后研磨制成100目至150目的咖啡渣原料,取80重量份咖啡渣原料与18重量份的聚氨酯胶粘剂充分混合后注入模具,随后在70℃至140℃的温度条件下固化3h至10h并放冷至室温得到坯料,使用切片机将坯料加工成厚度为0.1mm至0.5mm的咖啡渣复合片材;
b、在中间片两面通过120T的丝网版丝印涂布丙烯酸酯胶粘剂,随后在60℃至75℃的热风干燥条件下充分干燥得到涂胶中间片,在咖啡渣复合片材两面通过36T的丝网版丝印涂布丙烯酸酯胶粘剂,随后在60℃至75℃的热风干燥条件下充分干燥得到涂胶夹层片;
c、在涂胶中间片两面均依次叠加涂胶夹层片、印刷基片和透明薄膜得到组坯叠片,将组坯叠片在150℃的温度条件以及7MPa的压力条件下热压处理24min,之后在6MPa的压力条件冷压处理22min后得到粘合坯;
d、按照预设尺寸规格将粘合坯冲切处理得到卡基,在卡基上铣槽并安装IC芯片后即得到含咖啡渣的智能卡成品。
实施例四
本实施例提供一种含咖啡渣的智能卡的制作方法,该制作方法包括以下步骤:
a、对回收的咖啡渣进行分拣、清洗处理并烘干至含水量不超过10wt%后研磨制成100目至150目的咖啡渣原料,取95重量份咖啡渣原料与20重量份的EVA胶粘剂充分混合后注入模具,随后在70℃至140℃的温度条件下固化3h至10h并放冷至室温得到坯料,使用切片机将坯料加工成厚度为0.1mm至0.5mm的咖啡渣复合片材;
b、在中间片两面通过55T的丝网版丝印涂布氯醋树脂胶粘剂,随后在60℃至75℃的热风干燥条件下充分干燥得到涂胶中间片,在咖啡渣复合片材两面通过48T的丝网版丝印涂布氯醋树脂胶粘剂,随后在60℃至75℃的热风干燥条件下充分干燥得到涂胶夹层片;
c、在涂胶中间片两面均依次叠加涂胶夹层片、印刷基片和透明薄膜得到组坯叠片,将组坯叠片在135℃的温度条件以及6MPa的压力条件下热压处理22min,之后在8MPa的压力条件冷压处理25min后得到粘合坯;
d、按照预设尺寸规格将粘合坯冲切处理得到卡基,在卡基上铣槽并安装IC芯片后即得到含咖啡渣的智能卡成品。
实施例五
本实施例提供一种含咖啡渣的智能卡的制作方法,该制作方法包括以下步骤:
a、对回收的咖啡渣进行分拣、清洗处理并烘干至含水量不超过10wt%后研磨制成100目至150目的咖啡渣原料,取92重量份咖啡渣原料与10重量份的聚氨酯胶粘剂充分混合后注入模具,随后在70℃至140℃的温度条件下固化3h至10h并放冷至室温得到坯料,使用切片机将坯料加工成厚度为0.1mm至0.5mm的咖啡渣复合片材;
b、在中间片两面通过64T的丝网版丝印涂布聚氨酯胶粘剂,随后在60℃至75℃的热风干燥条件下充分干燥得到涂胶中间片,在咖啡渣复合片材两面通过51T的丝网版丝印涂布聚氨酯胶粘剂,随后在60℃至75℃的热风干燥条件下充分干燥得到涂胶夹层片;
c、在涂胶中间片两面均依次叠加涂胶夹层片、印刷基片和透明薄膜得到组坯叠片,将组坯叠片在142℃的温度条件以及5.5MPa的压力条件下热压处理23min,之后在11MPa的压力条件冷压处理20min后得到粘合坯;
d、按照预设尺寸规格将粘合坯冲切处理得到卡基,在卡基上铣槽并安装IC芯片后即得到含咖啡渣的智能卡成品。
实施例一至五制得的含咖啡渣的智能卡成品均表面平整,无鼓泡缺陷,并且边缘整齐,无爆边、翘曲缺陷。另外实施例一至五制得的含咖啡渣的智能卡成品的各项机械性能检测结果均接近于PVC材质的智能卡,可通过4000次扭曲试验,并且智能卡成品中对应于中间片的结构层的粘接力不低于15N/cm2。
Claims (10)
1.一种含咖啡渣的智能卡的制作方法,其特征在于,包括下列步骤:
a、在中间片两面通过丝网印刷方式涂布热塑性胶粘剂并经干燥处理后得到涂胶中间片,在咖啡渣复合片材两面通过丝网印刷方式涂布热塑性胶粘剂并经干燥处理后得到涂胶夹层片;
b、在所述涂胶中间片两面依次叠加所述涂胶夹层片、印刷基片和透明薄膜得到组坯叠片,对组坯叠片依次进行热压处理和冷压处理后得到粘合坯;
c、按照预设尺寸规格对所述粘合坯进行冲切得到卡基,在所述卡基上铣槽并安装IC芯片。
2.如权利要求1所述含咖啡渣的智能卡的制作方法,其特征在于:
步骤a中所述干燥处理为60℃至75℃下的热风干燥处理。
3.如权利要求1所述含咖啡渣的智能卡的制作方法,其特征在于:
所述中间片两面通过54T至120T的丝网版涂布热塑性胶粘剂。
4.如权利要求1所述含咖啡渣的智能卡的制作方法,其特征在于:
所述咖啡渣复合片材两面通过15T至54T的丝网版涂布热塑性胶粘剂。
5.如权利要求1所述含咖啡渣的智能卡的制作方法,其特征在于:
所述咖啡渣复合片材为80至95重量份的咖啡渣原料混合5至20重量份的聚氨酯胶粘剂或EVA胶粘剂后固化成型并切分得到的厚度为0.1mm至0.5mm的片材。
6.如权利要求5所述含咖啡渣的智能卡的制作方法,其特征在于:
所述咖啡渣原料的目数为100目至150目,所述咖啡渣原料的含水量在10wt%以内。
7.如权利要求1所述含咖啡渣的智能卡的制作方法,其特征在于:
所述热塑性胶粘剂为丙烯酸酯胶粘剂、聚氨酯胶粘剂或氯醋树脂胶粘剂。
8.如权利要求1所述含咖啡渣的智能卡的制作方法,其特征在于:
步骤c中所述热压处理在135℃至150℃的温度条件以及5MPa至7MPa的压力条件下进行,处理时间为20min至25min。
9.如权利要求1所述含咖啡渣的智能卡的制作方法,其特征在于:
步骤c中所述冷压处理在6MPa至11MPa的压力条件下进行,处理时间为20min至25min。
10.一种含咖啡渣的智能卡,其特征在于:
该智能卡通过权利要求1至9中任意一项所述的含咖啡渣的智能卡的制作方法制得。
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