EP3259143B1 - System and method for producing book-like identification documents, and method for erecting the production system - Google Patents

Description

Field of the invention:

The present invention relates to a system for producing book-shaped designed identification documents, in particular passport books, the document cards (data pages) and book-shaped arranged book sheets for receiving visa (Visa) have. The present invention also relates to a method for producing such identification documents and to a method for constructing a system for producing book-shaped identification documents. By means of such a production system it is possible to produce both book-shaped identification documents and non-book-shaped identification documents, the latter being formed only by the document holder identifying document cards.

Prior art and background of the invention:

Identification documents, in particular travel documents, such as passport books, serve to verify the identity of a person. Travel documents are issued by public authorities in the exercise of their sovereign obligations, for example to allow the document holder to cross the border into another state. Passbooks therefore have, in addition to identifying the person's data on a document card, which has the ID-3 format according to ISO / IEC 7810 in the German passport, further books on which pages so-called visas (visas) of the States can be attached to the the person enters. The document card, the passbook sheets and a cover are connected together in a stapling process. In addition to passbooks, there are also passport documents, such as identity documents. Such an identification document is the German identity card, which is currently issued in the form of an ID-1 ID card in accordance with ISO / IEC 7810. Identity documents, in contrast to passbooks, have no further sheets in addition to the card.

The document card of a passport document, as well as the identification card of a passport document, identifies the document owner (personalizing) data such as name, date and place of birth, nationality, facial image and the document holder's signature, a serial number identifying the document, the date of issue of the document, and the issuing authority and type of passport. In the case of the ID card, this also indicates the current place of residence as well as further biometric data of the holder (size, eye color). Furthermore, the document card is provided with various security features that allow a third party to verify the authenticity of the identification document, such as a guilloche print, a hologram representing the owner's face and the machine-readable zone of the document card with personal and other data kinegrafischen object, for example, the federal coat of arms shows. The passport pages of a German passport also have authenticity features on their pages, for example a guilloche print and a reproduction of the national coat of arms. In addition, on one of these sheets also individualized data are given, namely information about the place of residence, biometric data (size, eye color), date and place of issue and the serial number of the passport. The latter is attached as a point perforation through all passbook sheets.

There are different types of passport documents. In Germany, a distinction is made between a normal passport, a provisional passport, a child passport, a diplomatic passport and a service passport. In the case of the normal passport, there are also different sized book parts with 16 or 24 booklets, corresponding to 32 or 48 book pages. These passports are distinguished by the color of the respective cover.

The passport document card may typically be in the form of a plastic laminate with a laminated film piece having the required information, for example, a polymeric material. For the production of passport books, the document card is provided with a so-called pass tab which projects laterally beyond the intended format of the document card and is stapled together with the passbook sheets. This goes out DE 10 2008 031 654 A1 show that such document cards, which are made exclusively of polycarbonate layers, not suitable to incorporate this in a passport. Therefore, it is common to produce document cards with a card body, in which at least one layer is incorporated, which consists of another plastic material, which is suitable for incorporation in a passport book and easy turning the document card in the passport book allows. This plastic layer is incorporated so that it forms the tab with which the document card is integrated into the passport book.

Out EP 0 364 730 A2 A method for producing an identification document in book form emerges. The device comprises a personalization device, in which data sheets are provided with data of a passport holder by means of a laser station and a printing device, and a binding station for binding the personalized data sheets with blank sheets and a linen cover to the book form.

The objects underlying the invention:

The above-described identification documents are conventionally manufactured in production facilities based on so-called stand-alone solutions, i. the individual production steps are carried out in only loosely linked plant sections. The required starting materials and resulting intermediates are stored up and down and transported by hand crate by crate from one plant station to the next, i. The documents are produced batchwise. This procedure is disadvantageous, for example because the area required for the system is high and the systems are stationary. In addition, these facilities are inflexible in terms of their ability to produce different types of documents because only one type of document can be produced in a batch, so the lead time for the identification documents is long. It is therefore an object of the present invention to provide a production line that has a smaller footprint and is also very flexible in use, so that identification documents of different types can be produced.

Furthermore, there are two possibilities that the identification documents can be produced centrally or decentrally in a state, for example in the issuing offices for the documents. For a decentralized production, the production equipment usually used are very complex, so that in particular a fast installation in these places is not possible. It is therefore another object of the present invention to provide an apparatus and method for producing book-shaped identification documents and a method for constructing that production facility, the complexity of the facility not allowing for installation and maintenance at a remote location to oppose.

Furthermore, it has been found that the production of identification documents, in particular, requires a considerable amount of time if they are produced at a central production site. Different types of documents have to be produced simultaneously in this case. It is therefore the object of the present invention to provide a system for producing the book-shaped identification documents and a method for the production thereof, with which a rapid production of different types of identification documents is possible.

Furthermore, the production of the identification documents should also be cost-effective and with the least possible scrap and in compliance with the required occupational safety measures, in particular against less intensively trained operating personnel, which is active in a decentralized manufacturing facility, be possible.

definitions:

To the extent that below in each case terms are used in the singular form, for example, 'document card device group', assembly device group, 'document card production unit', 'assembly-manufacturing unit', 'individualized document card,' book sheet ', etc., then among each corresponding plural forms, namely 'document card device groups', 'assembly device groups', 'document card production units', 'assembly manufacturing units' 'individualized document cards', 'book sheets', etc., unless expressly stated otherwise.

Insofar as the terms 'containerized', 'containerization' are used below and in the claims, it is to be understood that the so-called objects, namely the document-card manufacturing units and the assembly-manufacturing units, in terms of their dimensions and their structure to those of Containers are adapted and therefore in particular they have a self-supporting structure that allows to handle / manipulate such items such as containers, for example, to transport, lift, move, rotate and the like. The self-supporting structure can be realized by conventional designs, for example by a truss structure and that a construction without wall elements or wall elements, for example as in the case of containers formed by side walls, a bottom wall and a ceiling wall, the walls along their wall edges together bump. A container therefore represents a support structure for manufacturing devices and other units. By containerization, the objects are stackable and seamless stringed together. Advantageously, the objects are completely stackable and stackable. For this purpose, all objects of a device group, namely a document card device group or a mounting device group, may have the same shape (outer contour) and the same outer dimensions. Within the volume of the containerization formed (Document card, assembly) manufacturing units can be set up any manufacturing devices and other units needed for the production of articles produced therein (individualized document cards, identification documents), these manufacturing devices and other units for both the transport of containerized manufacturing units as well as for the use in the manufacturing units are preferably permanently mounted on a logical position for their function. A fixed assembly / installation also implies that the manufacturing devices and other assemblies are movably mounted in the manufacturing units, for example on a carriage, so that they are located at positions in the manufacturing units for transport to the installation site, which differ from their positions in the corresponding ones Distinguish device groups that they occupy after installation of the production facility at the site.

Insofar as the terms 'individualized' and 'individualizing' are used below, this is to be understood as a property of an identification document, for example a passport or identity document, according to which the identification document can be assigned to a specific subject (person, animal, object). This property results from given security features of the identification document. As far as the terms 'personalized' and 'personalizing' are used below, this is to be understood as the property of an identification document according to which the identification document can be assigned to a person.

As far as the term 'document card' is used below, this is to be understood as an identification document or a part thereof. It is therefore a flat, preferably rectangular support for individualized information to be displayed. Under a document card is to understand both a stiffer and flexible object, so both a no or little bendable or twistable object as well as an easily bendable object. The format of the document card depends on the identification document into which the card is to be integrated or used. For example, it may have one of the formats ID-1, ID-2 or ID-3 according to ISO / IEC 7810. The document card may be made of a material suitable for the purpose of the invention, for example of a plastic (polymer), of paper, cardboard, glass or other materials or mixtures of these materials, and optionally filled with reinforcing materials. The document card is made by lamination of laminate layers, for example made of a material suitable for lamination. The document card may be formed of a polymer that is selected from a group comprising polycarbonate (PC), polyethylene terephthalate (PET), their derivatives such as glycol-modified PET (PETG), polyethylene naphthalate (PEN), polyvinyl chloride (PVC), polyvinyl butyral (PVB), polymethyl methacrylate (PMMA), polyimide (PI), polyvinyl alcohol (PVA), polystyrene (PS), polyvinylphenol (PVP), polypropylene (PP), polyethylene (PE), thermoplastic elastomers (TPE), in particular thermoplastic polyurethane (TPU), acrylonitrile-butadiene-styrene copolymer ( ABS) and their derivatives, polyamide (PA) and / or paper (cellulose) and / or cardboard and / or a glass and / or metal and / or a ceramic. In addition, the document card can also be made of several of these materials, especially if the individual layers are made of different materials. The document card preferably consists of PC or PC / TPU / PC. The polymers may be either filled or unfilled. In the latter case they are preferably transparent or translucent. If the polymers are filled, they are opaque. The thickness of the data card is preferably 250 to 950 μm.

Broad features of the invention and preferred embodiments:

According to a first aspect of the present invention, the above objects are achieved with a facility for producing book-shaped identification documents, in particular passport documents and identity cards.

According to a second aspect of the present invention, the above objects are also achieved by a method of producing the book-shaped identification documents.

According to a third aspect of the present invention, the above objects are also achieved by a method of constructing a plant for producing book-shaped identification documents.

The system according to the invention for producing the book-shaped identification documents has a first part of the installation and a second part of the installation. The first part of the installation is formed by at least one document card device group for producing individualized document cards. The second piece of equipment is formed by at least one assembly device group for assembling a set of (pass) book sheets of the identification document with an associated individualized document card and, if applicable, a cover slip to create the identification document. The at least one document card device group is each from at least one containerized document card manufacturing unit constructed, and the at least one assembly device group is each composed of at least one containerized assembly manufacturing unit.

Thus, the production plant according to the invention is modular, i. from individual containerized document-card manufacturing units forming the document-card-device groups of the first part of the plant and individual containerized assembly-manufacturing units, forming the assembly-device groups of the second part of the plant, i. One or more document-card manufacturing units together form a document-card-device group, and one or more assembly-manufacturing units together form an assembly-device group, wherein the production facility may include one or more document-card-device groups and one or more assembly-device groups. In particular, the modular structure also includes the possibility that the production plant is constructed by a plurality of document card device groups having different configurations of the document card production units forming them and / or a plurality of assembly device groups having different configurations of the assembly manufacturing units forming them. For example, multiple document card device groups may be installed to produce customized document cards of different formats. Further, for example, a plurality of mounting device groups may be installed, with which identification documents of different types can be produced with differently colored cover covers and / or different formats.

The smallest unit of each plant part is a manufacturing unit, which is formed by a container or a container-like structure. The containers or container-like structures are preferably in the form of standardized large-capacity containers, such as ISO containers, but possibly without the side walls, the bottom wall and the ceiling wall, but only in the form of support structures, for example in a truss structure, with the appropriate dimensions. Such trained manufacturing units are easy to transport and thus mobile. As provided for the production of individualized document cards and for mounting the identification document manufacturing devices, such as a laminator for connecting individualized document card layers together to form the individualized document cards and a cutting plotter for the formation of booklets from leaflets, and other manufacturing devices and assemblies within the respective containerized production units are permanently installed, the production units with the therein manufacturing devices and others Easily transported units from their production to a site and assembled and assembled there. The production devices and other assemblies are located in the respective production units in a spatial and functional arrangement to each other, they need for the operation of the production units for the production of individualized document cards and identification documents.

Due to the fixed mounting of the manufacturing devices and other units in the production units already at the place of manufacture, a simple and fast transport of the containerized production units to the site and there a simple and quick installation of the production facility allows. This takes advantage of the fact that manufacturing the individual containerized manufacturing units at a manufacturing location is much cheaper and more efficient than at the site, because the required skilled workers, media, parts lists, software, mounting options and other resources in a central location, such as the place of manufacture Further available, while this is not the case in the case of the different site. By a standardized design of the individual production units with prefabricated arrangements of individual components are on site only the creation of the compounds containerized production units together and transport devices between the device groups and the connections to an external media supply (water, compressed air, electrical supply, steam and the like) and Disposal (exhaust air, waste water and the like) and their commissioning required. Thus, a faster construction of the entire production plant is achieved. Furthermore, this concept achieves a very compact arrangement of the individual plant components, so that only a small footprint is required for the plant.

The containerized document card and assembly production units are characterized on the one hand by a standardized support structure. The outer dimensions of the containerized production units are preferably oriented to standardized dimensions, such as ISO containers, since the production units can be transported in this case together with ISO containers used for the transport of other goods to the site. For example, the manufacturing units 20-foot containers have corresponding support structures. Of course, other dimensions than this measure or even as the ISO containers corresponding dimensions are conceivable. All document card manufacturing units of a document card device group preferably have the same dimensions. The same applies to the assembly manufacturing units of a mounting device group. Further preferred all document-card manufacturing units of all document-card-device groups have the same dimensions and, correspondingly more preferably, all assembly-manufacturing units of all assembly-device groups. And most preferably, all document-card and assembly-manufacturing units of all document-card and assembly-device groups of the production plant have the same dimensions.

It is advantageous if the containerized production units have support structures which allow a mechanical coupling of two production units arranged side by side and / or one above the other. Side walls / ceiling wall / floor wall are not required on the supporting structure, which shield the interior of each unit to the outside, although this is at least temporarily advantageous for transport. It is conceivable, however, that the wall surfaces delimiting the containerized production units in the installed state may in some cases be terminated by (intermediate) walls and / or by a bottom wall and / or ceiling wall, for example as encapsulation against the environment. Overall advantageous in any case is a bottom wall and / or ceiling wall.

The support structures for the containerized document card and assembly production units can be formed by a truss of rods, preferably profile rods, in particular hollow profile rods, for example by a standardized outer frame of hollow profiles, which extend for example along the edges of a cuboid. Alternatively, a conventional (ISO) container can be used with the corresponding walls as a support structure for the containerized production units, then optionally individual side walls and / or the ceiling wall and / or the bottom wall is / are present. Within the volume of space formed by the framework, the manufacturing devices and other building units required for the production of the individualized document cards and identification documents are arranged and permanently installed there.

In a further preferred development of the present invention, the production devices in the device groups are linked together in such a way that the starting materials, intermediates and finished products are transported individually, ie separately from one another. This has many advantages. For example, a reduced throughput time is made possible due to reduced intermediate product inventories. By handling the intermediate products and end products not in batches but in isolated cases, individual quality control of the products is also possible, resulting in the advantage of improved quality and reduced reject rate. In addition, you can various types of identification documents are produced in any order without additional setup effort. Contrary to the previous procedure, the system does not have to be emptied before another document type is produced (Manufacture / Print on demand).

For the accommodation of all manufacturing devices for the production of individualized document cards in a document card device group and all manufacturing devices for producing the finished identification document in a mounting device group and other units can each be several, for example four, containerized production units may be required. These are preferably equipped in accordance with a standard design at the place of manufacture with the respectively required manufacturing devices and other units and transported to the site, where they are placed together and preferably mounted in the composite.

According to a preferred development of the present invention, at least two of the containerized document-card production units of a document-card-device group are arranged in at least two floors arranged one above the other. Furthermore, in a preferred development of the present invention, it can also be provided that at least two of the containerized assembly production units of a mounting device group are arranged in at least two floors arranged one above the other. For example, both the document card device groups and the mounting device groups may require that four containerized document assembly units be provided to accommodate all of the manufacturing devices and other assemblies required therein for each product to be manufactured , For example, in this case, two containerized production units are arranged in a first (lower) floor and two further production units in a second (upper) floor on the lower production units. The production units of the lower floor are preferably mechanically connected to each other, and the production units of the upper floor are also preferably mechanically interconnected. The production units of the upper and lower floors are also preferably mechanically connected to each other. This results in a compact converted production space in which all necessary for the particular purpose manufacturing devices and other units are. Of course, it is also possible to arrange the production units in more than two floors or alternatively in only one floor, for example, at ground level. Device groups with a different number of containerized production units, for example, 2, 3, 5, 6, 7, 8 or even more production units, are also conceivable.

The arrangement of the containerized production units in several levels in a device group has the advantage that the base area covered by the production units is minimized relative to the volume converted. This offers the advantage of optimal utilization of the available base area at the site. In addition, a multi-tiered arrangement over an exclusively one-tier arrangement of the production units also in terms of operation advantageous because the operator in the case of one-tier arrangement because of the most concatenated production equipment longer distances must cover since they are the plant can not cross. The compactness of the device groups achieved in this way also ensures that the operating personnel can not easily penetrate into central spatial areas of the device groups, which offers advantages in terms of occupational safety. Furthermore, this results in short and controlled transport routes for the materials to be processed. This also includes the advantage of short supply routes for media and short disposal routes. This makes the material flow easier and shorter ways for the materials and media feasible. This also includes the advantage that starting materials to be supplied can be offered to the production units more easily. In addition, a high level of automation can be achieved. The compactness of the containerized production units due to this development according to the invention also leads to the fact that an optionally required encapsulation of individual manufacturing devices or groups of manufacturing devices and / or other units against penetrating or leaking impurities (dust) and / or electromagnetic radiation (for example laser radiation) and / / or from sound (sound emission / -immission) or the like can be done easier. For example, it is important to keep the dust generated when cutting the book sheets by means of a cutting plotter in a mounting device group away from a document card device group located close to them, since the manufacturing units of the latter device group are in need of increased air purity in order to meet the quality requirements of the document cards to be able to comply. Encapsulation also offers the possibility of placing the encapsulation volume under increased air pressure, so that virtually a clean-room zone is produced. In addition, more easily controlled climatic conditions, for example, in terms of temperature, humidity and the like, can be adjusted.

In the case of an arrangement of at least two document-card and / or assembly-manufacturing units for forming the corresponding device group in at least two floors can be provided that the cycle times in the two floors are different. In order to achieve a decoupling of the cycle times of both floors, the intermediates can be passed through a buffering conveyor between the production units of both floors. Such a buffer device may, for example, have a memory for the intermediates in which these are stored from the supplying (upstream of the buffering conveyor) manufacturing units in a first floor and taken from the intermediate products in the receiving (the buffering conveyor downstream) manufacturing units in a second floor become. This buffer device can also be used to compensate for any dead times, for example in the event of a disruption of production in the supplying or receiving manufacturing units, i. if production is continued in the supplying manufacturing units on the first floor while production in the receiving manufacturing units on the second floor is interrupted, or if the supplying manufacturing units do not produce any intermediate products, production in the receiving manufacturing units is nevertheless continued if in the buffering apparatus therein Traps are stored to a sufficient extent intermediates. This minimizes downtimes of the entire system.

According to a further development of the present invention, the system further comprises at least one transport device for conveying individualized document cards from the document card device groups to the assembly device groups. This ensures that the individualized document cards move from a document card device group to a mounting device group without manual intervention.

If the manufacturing units are arranged in the device groups in several floors, the output of the individualized document cards from a document card device group is preferably provided on the same floor as the inclusion of the individualized document cards in a mounting device group. Thus, preferably, the individualized document cards do not have to be carried over multiple floors from the document card device groups to the assembly device groups up and down, respectively. In addition, in the case of a multi-level arrangement of the production units, it is also possible for the finished identification documents to be output at ground level from the assembly device groups, so that they are ready for handover directly to the shipping point.

The transport devices may be formed by means for continuously transporting the individualized document cards. It is very particularly preferred if the at least one transport device is designed to store the individualized document cards in isolated form, i. individual individualized document cards separated from each other to transport. Alternatively, the transport devices may also be designed to convey a plurality of individualized document cards at the same time, for example individualized document cards contained in a memory (magazine). The advantage achieved by transporting separate document cards results from the fact that the documents are immediately available after their respective production, so that the production throughput time is minimized.

For continuous transport, in particular individual individualized document cards, continuously operating transport devices, for example conveyor belts on which the individualized document cards rest, vacuum handling devices and grippers can be used. For transporting memories loaded with a plurality of individualized document cards, a movable robot can be used which picks up the loaded memories at the document card device groups and transports them to the assembly device groups.

Since the document card device groups may be formed by a plurality of containerized document card manufacturing units and the mounting device groups may be formed by a plurality of containerized assembly manufacturing units, a plurality of transport devices may also be provided between the individual document card device groups and assembly device groups. This applies in particular to the case of continuously operating transport devices. For example, a transport device may be located between each document card device group and each assembly device group, or associated with each device group, such that any individualized document card that has been produced in any document card device group may be promoted to any assembly device group , Connecting the document card device groups to the mounting device groups achieves their concatenation.

In a further preferred development of the present invention, the at least one transport device has at least one distribution line for conveying the individualized document cards from a predetermined one of several Document card device groups to a predetermined one of several mounting device groups. As a result, in particular in the case of a continuously operating transport device, a simple and clear construction of the production plant can be achieved because the individual individualized document cards can be directed via the distribution line in a targeted manner to a desired destination address in the second component part. For example, if the second equipment part is constituted by a plurality of assembly device groups different in that they respectively make different types of passports (for example, different colored cover sheets), an individualized document card provided for a certain type of passport may be used the corresponding assembly device group. Depending on the complexity of the production plant, one or more distribution lines may be present. In the case of a single distribution line, for example, upstream of the distribution line, first continuous transporting devices may be interposed between the individual document card device groups and the distribution line with which the individualized document cards pass from the document card device groups to the distribution line, and second continuous transport devices downstream of the distribution line the distribution line and the individual assembly device groups, with the aid of which the individualized document cards then pass from the distribution line to the desired assembly device group. In the case of multiple distribution lines, this structure can also be much more complex. In particular, a plurality of such structures can be implemented, each with a distribution line and associated first and second transport devices.

In a further preferred development of the present invention, the production devices and further assemblies in the document card and assembly device groups are controlled by a computer system, so that a largely unmanned operation of the production plant is made possible. This includes the operation of the manufacturing apparatuses, the supply of raw material to the manufacturing apparatus including the material filling of the raw material storages, the conveyance of intermediates between the manufacturing apparatuses and the transport of intermediate and final products between the document card device groups on the one hand and the mounting apparatus groups on the other hand to output the end products from these device groups. With this concept, a self-regulation of the entire production plant is achieved up to a management in case of a partial failure of manufacturing devices, other assemblies or entire production units or device groups.

In a further preferred development of the present invention, the at least one document card device group has at least one printing device for generating individualizing information on document card layers provided for producing the individualized document card, respectively at least one laminating device for assembling the document card layers, in each case at least one laser engraving device for generating individualizing Information, for example of data, structures, patterns or the like, inside the material of the document card layers, at least one hologram generating device and at least one Appliziervorrichtung for applying a hologram having a film element on an outside of a document card intermediate product on. These manufacturing devices in the document card device groups are used to produce the individualized document cards from non-individualized document card stock. This starting material may be formed by the not yet individualized document card ply material.

The printing device is preferably formed by a digital printing device, preferably an ink jet printing device or a digital transfer printing device, for example a xerographic printing device. These devices allow printing without the use of printing plates and are therefore very flexible, making them well suited for use in customizing printing. In addition to information to be individualized, the printing device can also be used to generate non-individualizing information, in particular data, structures, patterns or the like, on the document card layers. These prints are generated on one or both sides of the document card layers as well as on one or all document card layers that are linked together to form an individualized document card.

The laminating apparatus may be a device for hot and cold surface pressing of document card plies known in the art for achieving a strong bond between the plies, especially when the document card plies are made of polymer, and more particularly when the plies are made the same polymer are formed, so that in this case forms a monolithic composite of the layers. Optionally, the laminating apparatus may further be provided with a changing device for the laminating sheets required for lamination, especially if intermediate products of different format are to be laminated or if different surface structures are to be embossed in the intermediates.

The laser engraving device for generating preferably individualizing information in the document card layers may have a conventional structure with a writing laser, in particular an IR laser. A laser beam is focused on the document card and thereby moved, so that the material of the document layer is blackened at the areas crossed by the laser.

The hologram generator (holoprinter) may also be constructed in a conventional manner. In particular, this device may be constituted by a photosensitive film exposure device and a fixing device (thermal treatment device).

The applicator for applying a hologram-containing film member to an outer side of the laminated document card may also be formed in a conventional manner. In particular, this device preferably has a device for applying an adhesive to the document card and a device for laying and pressing (laminating) the hologram-comprising film element onto the adhesive-coated surface on the card.

In addition, the document card device groups may preferably include further manufacturing devices, for example, a device for assembling a plurality of polymer layers into a stack and a device for trimming the intermediate product to the desired outer dimension. Further, the document card device groups may also include other assemblies which also serve to produce the individualized document cards, but which only handle the parent, intermediate or end products without further alteration, for example, memory for providing source material or document card layer intermediates, for example in roll form Elevators for transporting intermediates from one floor in the document card device group to the other and memories for the completed individualized document cards.

Furthermore, the at least one document card device group according to a further preferred development of the present invention each have conveying devices with which the manufacturing devices and further assemblies within the document card device group according to the process flow for manufacturing the individualized document cards are linked together. At the production site for the production facility, the conveyor devices connecting the individual containerized document production units are initially not yet created, so that the containerized production units can be transported individually. These conveyors are first mounted at the site. By contrast, at the place of production, all conveying devices which are exclusively located between production devices and further structural units within a document-card manufacturing unit can already be mounted.

It is very particularly preferred if the conveying devices are designed to convey the document card layers in individual cases. For this example, conveyor belts or, for example translationally movable vacuum handling devices or grippers can be used. Thus, the at least one printing device, the at least one laminating device, the at least one laser engraving device, the at least one hologram producing device and the at least one applicator in a document card device group and the other manufacturing devices according to the process flow for producing the individualized document cards on the conveying devices, the transport the intermediates in the production of the individualized document card, linked together. This makes it possible for each individual document card position at the respective stage of the procedure to be examined for possible quality defects immediately after it has been processed. This procedure has the advantage over existing systems that possible manufacturing defects are not detected only when several faulty individualized document cards have been produced but immediately after their production. This minimizes waste.

In the document card device groups and thus in the individual containerized document card production units, said production devices and further modules are permanently installed and arranged in a spatial and functional relationship required for the production of the individualized document cards. If not all of the production devices and other building units required for production can be accommodated in a containerized document-card manufacturing unit, several such containerized manufacturing units can be provided, which together form a document-card-device group. These production units are arranged in the installed state at the site, as explained above, side by side and / or one above the other and can be handled independently during transport.

In a further preferred embodiment of the present invention, the at least one mounting device group each have at least one cutting device for producing book sheets of book sheets, at least one gathering machine for merging the individualized document card with a set of books and possibly a cover and at least one sewing device for connecting the individualized document card with the set of book sheets on. These production devices in the assembly device groups are used to produce the identification document from the individualized document cards and booklet sheets and possibly cover slips.

The blanking apparatus may be realized by any known apparatus suitable for singulating sheets from a sheet, for example a knife-cutting apparatus, for example a cutting plotter, or a laser cutting apparatus. Collators are well known in the printing art. For this purpose, recourse can be had to known devices of this type. The same applies to sewing devices used in bookbinding.

Furthermore, the assembly device group may preferably comprise further production devices, which also serve to produce the identification documents, namely a laser perforating device for generating in particular individualizing information, such as data, structures, patterns or the like, in the book sheets, for example for generating a serial number of the identification document , and a printing apparatus for generating in particular individualizing information on individual book sheets. In addition, as a further building units also storage for starting products, storage for the finished identification documents and temporary storage for intermediate products may be present.

Laser perforators are known in the field of safety engineering. The printing device may be formed by a digital printing device, as in the case of the document card device groups, in particular an inkjet printer or a transfer printer, for example xerographic printers.

According to a further preferred development of the present invention, the at least one cutting device, the at least one collating machine and the at least one sewing device and optionally the further production devices and other building blocks in the mounting device groups according to the process of producing the identification document via conveyors conveying the individualized document cards, starting materials and intermediates of the identification documents such as book sheets, sets of book sheets and cover sheets. Preferably, the conveying devices are designed to convey the starting materials, intermediates and identification documents in the device group individually, ie separately from each other. The advantage achieved thereby results, as explained in connection with the production of the individualized document cards, from the fact that the quality of the individual materials and products in the production process can be determined promptly in order to minimize rejects. For promotion in isolated form, the assembly device groups may have conveying devices, via which, in particular, the cutting device, the collating machine and the sewing device, optionally further manufacturing devices and further structural units of these device groups, are interconnected in accordance with the process sequence for producing the identification documents. As conveyor devices, for example, conveyor belts or, for example, translationally movable vacuum handling devices or grippers can be used.

If the book-shaped identification document has a binding cover, then it is to be additionally connected to the individualized document card and the book pages, preferably by means of a binding method. If different cover slips are assigned to the individual individualized document cards, these different types must be retained and output as required. For this purpose, the at least one assembly device group according to a further preferred development of the present invention further each having a removable storage for providing more than one of different types of cover book covers for the production of the identification documents. This removable storage is provided in the mounting device groups and thus at least in one of the containerized assembly-manufacturing units and is arranged as the manufacturing devices and other units in a fixed spatial and functional relationship with the other manufacturing devices and other assemblies.

In the assembly device groups and thus in the individual containerized assembly-manufacturing units, said production devices and other units are permanently installed and in a required for the production of book-shaped identification documents spatial and functional relationship to each other arranged. If not all production devices and other assemblies required for production can be accommodated in a containerized assembly manufacturing unit, a plurality of such containerized production units can be provided, which together form a mounting device group. These production units are arranged in the installed state at the site, as explained above, side by side and / or one above the other and can be handled independently during transport.

Preferably, in the document card device groups and mounting device groups, in addition to said manufacturing devices and further assemblies, sensors for detecting the current position of the starting materials, intermediates and end products to be processed (laminate pieces, hologram film elements, document card layers, booklet sheets, book sheets, coverslips and the like) as well as sensors for detecting the quality of the manufactured products. These sensors, both the position detection and the quality detection sensors, are preferably connected to a central computer system and deliver the acquired data to the computer system and are controlled by this system. Based on the acquired data from the sensors, the manufacturing devices and other units are controlled.

The manufacturing devices and other building units in the document card device groups and mounting device groups are preferably logically connected to each other via a suitable computer controller. These controls are preferably computer-aided, formed for example by PLC controls. These controls may also be located in the device groups. The individual controllers can preferably be connected to one another via a central controller. The individual controllers preferably form automated control circuits.

The manufacturing devices and other assemblies in the document card device groups and assembly device groups may eventually be supplied with the necessary media and have appropriate media connections to allow them to be interconnected with each other and with the external supply as well as with disposal in the field installation.

The aforementioned conveying devices, as far as they are to allow a material flow between different production units, and the transport devices and also the media connections and the disposal connections between the Different production units and external supply or disposal connections are not yet created in the intended for transport to the site containerized production units. These conveying devices and transport devices between the production units or device groups and the media and disposal connections between the production units and to the external supply or disposal must be set up at the installation of the production facility at the site.

1. (a) Herstellen mindestens einer containerisierten Dokumentenkarten-Fertigungseinheit, wobei mindestens eine containerisierte Dokumentenkarten-Fertigungseinheit eine Dokumentenkarten-Vorrichtungsgruppe bildet, und mindestens einer containerisierten Montage-Fertigungseinheit, wobei mindestens eine containerisierte Montage-Fertigungseinheit eine Montage-Vorrichtungsgruppe bildet, an einem Herstellungsort;
2. (b) Transportieren der mindestens einen containerisierten Dokumentenkarten-Fertigungseinheit und der mindestens einen containerisierten Montage-Fertigungseinheit zu einem Aufstellungsort; und
3. (c) Zusammenstellen und Montieren der mindestens einen containerisierten Dokumentenkarten-Fertigungseinheit unter Bildung des ersten Anlagenteils und der mindestens einen containerisierten Montage-Fertigungseinheit unter Bildung des zweiten Anlagenteils, am Aufstellungsort, wobei die Anlage gebildet wird.

The method according to the invention for constructing the production plant according to the invention comprises the following method steps:

1. (a) producing at least one containerized document-card manufacturing unit, wherein at least one containerized document-card manufacturing unit forms a document-card-device group, and at least one containerized assembly-manufacturing unit, wherein at least one containerized assembly-manufacturing unit forms a mounting-device group, at a manufacturing location;
2. (b) transporting the at least one containerized document-card manufacturing unit and the at least one containerized assembly-manufacturing unit to a site of installation; and
3. (c) assembling and assembling the at least one containerized document-card manufacturing unit to form the first plant part and the at least one containerized assembly-manufacturing unit to form the second plant part, at the site, wherein the plant is formed.

The containerized document card and assembly manufacturing units are assembled in a conventional manner from the corresponding manufacturing devices and other assemblies in the container or container-like support structures. The manufacturing devices are not to be installed in any arrangement, but such that they can be accommodated within one or more containerized support structures. If the production devices and further units of a device group are to be distributed to a plurality of containerized production units, they are to be arranged and installed according to the functional linkage according to the production process for the identification documents in the individual containerized support structures, so that in each case a device group is formed when assembling a plurality of such production units, all manufacturing devices and more Includes building units in a spatially and functionally logical arrangement. The connections of the individual production devices and other units with each other can be made in a conventional manner.

For transport from the place of manufacture to the site, the individual containerized document card and assembly production units can preferably be clad in a known manner preferably with protective walls. To set up the containerized production units at the site these are positioned at the intended location, with adjacent (juxtaposed / stacked) containerized production units are preferably connected together. In addition to the document card and assembly device groups, transport devices are created, preferably mounted, between the device groups that allow transport of the individualized document cards between the device groups as well as media and disposal connections between the manufacturing units and for external supply.

1. (i) Bereitstellen von Dokumentenkartenlagen zum Herstellen der individualisierten Dokumentenkarten;
2. (ii) Bearbeiten der Dokumentenkartenlagen durch Einbringen von individualisierenden Informationen auf einzelne oder alle Dokumentenkartenlagen und Verbinden der Dokumentenkartenlagen durch Laminieren unter Ausbildung der individualisierten Dokumentenkarten;
3. (iii) Bereitstellen von Buchblattbögen zum Herstellen eines Satzes von Buchblättern ;
4. (iv) Bearbeiten der Buchblattbögen durch Vereinzeln der Buchblätter und Zusammentragen zu einem Satz von Buchblättern;
5. (v) Zusammentragen jeweils einer individualisierten Dokumentenkarte mit einem Satz von Buchblättern in einer Zusammentragmaschine; und
6. (vi) Verbinden der individualisierten Dokumentenkarte mit dem Satz von Buchblättern.

The method according to the invention for producing the book-shaped identification documents is carried out using the production system according to the invention and comprises the following method steps:

1. (i) providing document card layers for producing the individualized document cards;
2. (ii) editing the document card layers by incorporating individualizing information on individual or all document card layers and laminating the document card layers to form the individualized document cards;
3. (iii) providing booklet sheets for making a set of book sheets;
4. (iv) editing the worksheets by separating the books and collating them into a set of booklets;
5. (v) collating each individualized document card with a set of booklets in a collator; and
6. (vi) linking the individualized document card to the set of booklets.

The method steps (i) and (ii) are performed in the document card device groups and the method steps (iii) to (vi) in the mounting device groups.

For the production of the individualized document cards in the document card device group, it is possible to use, for example, films made of polymer material, in particular polycarbonate, and a polymer inner layer already provided with a non-individualizing security print (for example guilloches) and a base print. The starting materials used may be, for example, materials in roll form, which are first cut into the desired formats during processing. If individualized document cards are to be produced in the document card device groups both as end products, for example in the form of identity cards, and as intermediates for further incorporation into a book-shaped identification document, for example a passport, which may have different formats, the materials are in foil pieces to singles that have the target format.

The inner layer can be provided, for example by means of a printing process with the individualizing information. For this purpose, the printing device provided for this purpose is controlled by a computer system which supplies the required data. The inner layer and the outer layers, for example of the polymer, can then be gathered together and joined to form a laminate. Subsequently, further security features, for example, further individualizing security features by means of a laser engraving device can be attached. Furthermore, a film element can be laminated with a hologram, whereby this can also be individualizing. In this case, the computer system controls the assignment of the attachment of the individualizing security features on the already partially individualized intermediate product, so that the individualization is consistent in itself.

The individualized document card produced in this way can be removed from the production plant as a finished document, for example as an identity card, without being further processed in the assembly device group. For this they have been produced in the appropriate format. Alternatively, the finished individualized document card can be further processed into a book-shaped identification document. For this purpose, the document card is transported by means of the transport devices preferably in isolated form to a mounting device group.

For producing the book-shaped identification document in the assembly device group, the individualized document card can be used, for example, with a Set of book sheets, for example made of paper, and possibly a cover to the book-shaped document are connected. For this purpose, the book sheets can be cut from book sheet sheets, for example by means of the blanking device, and stacked to form the booklet set. The booklet sheets may already be provided with a non-individualizing security print (for example guilloche) or another security basic print. In addition, the book sheets can be provided with an individualizing pressure. For this purpose, in turn, a digital printing device can be used. For example, the cover can be removed from a removable storage when using different cover cover types. In this case, the individualized document card may already have a label corresponding to the type of cover sheet. The removable storage is controlled so that the corresponding to the processed individualized document card cover is issued. The assignment of the binding cover to the associated individualized document card can be controlled by means of the computer system. The individualized document card, the set of book sheets and the cover slip are then collected and connected together by means of the sewing device. Thereafter, further individualizing security features can be applied to individual pages of the book sheets, for example by introducing perforations through the book sheets.

Fig. 1

eine Dokumentenkarte in einer schematischen Schnittansicht;

Fig. 2

ein buchförmig ausgestaltetes Identifikationsdokument (Reisepass) in einer schematischen Schnittansicht;

Fig. 3

eine erfindungsgemäße Produktionsanlage in einer schematischen Draufsicht in einer ersten Ausführungsform;

Fig. 4

eine erfindungsgemäße Produktionsanlage in einer schematischen isometrischen Ansicht in einer zweiten Ausführungsform;

Fig. 5

einen Teil einer Dokumentenkarten-Vorrichtungsgruppe in einer schematischen Draufsicht auf die unteren Dokumentenkarten-Fertigungseinheiten;

Fig. 6

einen Teil einer Dokumentenkarten-Vorrichtungsgruppe in einer schematischen Draufsicht auf die oberen Dokumentenkarten-Fertigungseinheiten;

Fig. 7

einen Teil einer Montage-Vorrichtungsgruppe in einer schematischen Draufsicht auf die unteren Montage-Fertigungseinheiten;

Fig. 8

einen Teil einer Montage-Vorrichtungsgruppe in einer schematischen Draufsicht auf die oberen Montage-Fertigungseinheiten;

Fig. 9

eine schematische Darstellung des Verfahrens zum Errichten der erfindungsgemäßen Produktionsanlage.

For a more detailed illustration of the present invention, the figures described below, by means of which the invention is explained by way of example only with exemplary embodiments. They show in detail:

Fig. 1

a document map in a schematic sectional view;

Fig. 2

a book-shaped identification document (passport) in a schematic sectional view;

Fig. 3

a production plant according to the invention in a schematic plan view in a first embodiment;

Fig. 4

a production plant according to the invention in a schematic isometric view in a second embodiment;

Fig. 5

a portion of a document card device group in a schematic plan view of the lower document card manufacturing units;

Fig. 6

a portion of a document card device group in a schematic plan view of the upper document card manufacturing units;

Fig. 7

a part of a mounting device group in a schematic plan view of the lower assembly manufacturing units;

Fig. 8

a part of a mounting device group in a schematic plan view of the upper assembly manufacturing units;

Fig. 9

a schematic representation of the method for building the production plant according to the invention.

In the figures, like reference numerals designate like elements and / or elements having the same function. The figures do not always show the objects to each other in scale. Furthermore, the size ratios of individual elements to those of others in a figure or between the figures are not in each case to scale shown to each other.

In Fig. 1 an individualized document card 100 according to the present invention is shown. In the following description of the figures, a passport is named as an identification document by way of example, as far as the document card is not specified as an independent identification document. In the latter cases, an identification card (identity card) is given by way of example as the identification document. In principle, however, in each case other identification documents are meant as well.

The document card 100 is formed by a laminate of several polymer layers, for example polycarbonate films. The illustration shows the layers although limited by borderlines for purposes of illustration. However, these are no longer visible after performing a lamination. The document layer is formed at the very top by a transparent polymer end layer 110, for example made of polycarbonate, including a layer of an individualized film section 120 and at the bottom a layer composite of a polymer layer stack piece 130. This layer composite is by a central RFID layer based on an opaque polymer support layer 131 with an RFID circuit of RFID chip and RFID antenna (not shown) on the carrier layer, a the RFID chip in a recess receiving compensating layer 132 and below an opaque cover layer 133 is formed. For example, the document card has the ID-3 format in accordance with ISO / IEC 7810 if the card is incorporated into a passport or, for example, the ID-1 format in accordance with ISO / IEC 7810 if the card is used as an identification card. Laterally protruding on the card material is an optional document card flap 140 which is made of a textile material which is fusible or interspersed with a fusible material. This tab is connected to the card material by hot melt welding.

The individualized document card 100 is in Fig. 2 shown incorporated in a passport 200. The passport is formed by a coverlet 210, a flyleaf 220 with folding tape 221, the document card and a plurality of passport sheets 230 (shown here only three). These elements are interconnected by means of a stitching thread 240. In Fig. 2 only the location of this thread is indicated.

In Fig. 3 . 4 Embodiments of production systems 1000 according to the invention for the production of document cards and passports are shown. The production line is formed by one or more document layer device groups 2100, which form a first plant part 2000, and one or more assembly device groups 3100, which form a second plant part 3000, and these connecting transport devices 4000, 4xxx.

According to a in Fig. 3 1, the production facility 1000 has six document layer device groups 2100 forming the first system part 2000 and six assembly device groups 3100 forming the second system part 3000. Each of these device groups may be formed by one or more containerized manufacturing units (not shown). Individualized document cards as well as identity cards are produced in the document card device groups. In the assembly device groups, the individualized document cards are mounted to the passports.

The transport devices 4000 are formed, for example, by conveyor belts that individually transport the individualized document cards 100 produced in the document card device groups 2100 from one another. Each of the document card device groups is preceded by a transport device 4110 upstream of a distribution line 4200. These lead to the distribution line, which may also be designed in the form of a conveyor belt and which extends across the width of the production plant 1000. From the distribution line, in turn, a plurality of conveyor belts 4120 downstream of the distribution line lead to the mounting device groups 3100. By this arrangement of the device groups and transport devices, the individualized document cards produced in the document card device groups may arbitrarily come to any given assembly device group. For this purpose, the individualized document cards are each placed individually on the conveyor belts upstream of the distribution line and reach the distribution line, from where they are placed to the desired conveyor belt downstream of the distribution line and to the associated assembly device group be transported. The transport devices, along with the document card and assembly device groups, are controlled by a central computer system (not shown) so that the individualized document cards can be selectively transported from a particular document card device group to a given assembly device group. The finished passports will be issued at 4140.

Furthermore, there is also the possibility that the individualized document cards 100 are outputted as finished ID cards 200 and are no longer transported to the mounting device groups 3100. For this purpose, appropriately designed output transport devices 4130 may be provided, which are only indicated schematically in the present case.

In Fig. 4 A second embodiment of a production plant 1000 according to the invention is shown, but in this case only a single document device group 2100, which forms the first part of the plant 2000, and a single assembly device group 3100, which forms the second plant part 3000, and a transport device 4000 , which connects the two device groups, is formed. Both device groups are arranged in each case by four containerized production units in two floors Eo, Eu namely two containerized production units 2500, 3500 in a first (lower) floor Eu and two containerized production units 2500 ', 3500' in a second (upper) floor Eo. The individual production units are first created at a production site and placed there after transport to the site and connected together within a device group.

The production of the individualized document cards 100 produced in the document-card-device group 2100 preferably takes place first in the lower floor Eo of the document-card-device group according to the manufacturing flow, and finally in the upper floor Eo after conveying an intermediate product there. From there, the completed individualized document cards are transferred via the transport device 4000 to the assembly device group 3100. The manufacturing devices and other assemblies in the two device groups that are needed to produce the individualized document cards and assembly of passports are in this case so on the respective floors and thus respective production units 2500, 2500 '; 3500, 3500 'that this transfer takes place on the second floor Eo and therefore no floor change is required. Alternatively, the finished document cards, however, also transported back to the lower floor and transported from there to the lower floor of the assembly device group 3100. Within the assembly device group, in the former case, the production of the passports 200 takes place first on the second (upper) floor and after transport of an intermediate product to the first (lower) floor thereof. The completed passports are then issued in the lower floor (4140) and initially collected there. In the latter case it is the other way round.

In Fig. 5 are two interconnected containerized document card manufacturing units 2500 of a document device group 2100 in a lower floor Eu and in FIG Fig. 6 Two coupled containerized document manufacturing units 2500 'of the same documentary card device group are shown on an upper floor Eo. The containerized production units of both floors are also connected to each other (arrangement of the production units in the device group see example Fig. 4 ). The containerized production units are preferably in each case as a support structure of profile bars 2510, 2510 ', in particular hollow profile bars, made, which form the outer container structure. These support structures preferably have only a bottom wall, but not side and ceiling walls (not shown).

The containerized document-card production units 2500, 2500 'contain manufacturing devices and further assemblies for the production of the individualized document cards 100. These units are arranged in the production units according to the material flow intended for production and permanently installed in the support structures. For this purpose, the production devices are linked to one another via conveying devices 5000, for example conveyor belts and conveyor robots with vacuum suction devices or grippers. In Fig. 5 . 6 These conveying devices are only indicated schematically. In addition, the manufacturing devices and other units are connected via external supply and disposal lines with media and disposal. The production path, which is essentially characterized by the conveying devices 5000, is in Fig. 5 . 6 denoted by A.

The document card production units 2500 of the lower floor Eu ( Fig. 5 ) have the following production devices: a feeder 2210 with roller magazines for the starting polymer material and for stapled polymer layer stacks which already have RFID circuits each with an RFID chip and an RFID antenna (not shown), a printing device 2220 with a roller magazine 2225 for polymer material to be printed with individualizing information, a first Transfer station 5010 for feeding laminating sheets to the structure of polymer sheets, a laminating device 2230, a station 2235 for providing various laminating sheets at the first transfer station, and removing the laminating sheets at a second transfer station 5010, the second transfer station, and a trimming device 2240. Further, as further units a quality assurance device 2250, which has suitable sensors for this purpose, as well as conveying devices 5000, for example conveyor belts or other conveying devices. The individual manufacturing devices and other units are permanently installed in these manufacturing units and linked together via the conveyor belts or other conveying devices.

The feeder 2210 supports stock polymer material and a polymer laminate with internal RFID circuits and is further configured to stack a plurality of document layers on a workpiece carrier on a conveyor belt. The printing device 2220 with the roll magazine 2225 is configured and arranged to provide individualized printed polymeric film sections to the feeder 2210. Downstream of the feeder in the production process is the first transfer station 5010, downstream of the laminating device 2230, downstream of the second transfer station 5010, downstream of the trimming device 2240 and downstream of the quality assurance device 2250. The station 2235 for the lamination is assigned to the lamination spatially and functionally.

The document-card manufacturing units 2500 of the upper floor Eo ( Fig. 6 ) are provided with a hologram producing apparatus 2265, an applicator 2260 for applying a hologram film member to one of the outsides of a partially individualized laminate piece supplied from the lower tier of the document card apparatus group 2100, a trimming apparatus 2270 for modifying the laminate piece to the final size Device 2280 for optionally attaching a tab 140 to the laminate piece for incorporating the document card 100 in a passport 200 and a laser engraving device 2290 as manufacturing devices and a quality assurance device 2300 and conveying devices 5000 equipped as further units. These manufacturing devices and other units are permanently installed in the manufacturing units and linked together via conveyor belts 5000.

The hologram generator 2265 is concatenated with the applier 2260 only via a lateral path and spatially and functionally associated with it. The hologram producing device is downstream of the trimming device 2270, this downstream of the device 2280 for attaching the tab 140, this downstream of the laser engraving device 2290 and downstream of the quality assurance device 2300th

Both parts of the document card device group 2100, namely both the lower-level document-card manufacturing units 2500 and the upper-level document-card manufacturing units 2500 'Eo, are connected to each other via a lift and buffer 5020.

The feeder 2210 is provided with a conveyor system on which tool carriers (not shown) are conveyed, which serve to stack the document layers forming the document card in a structure in the correct sequence.

A starting material used for the production of the individualized document card 100 is a transparent polymer film, for example of polycarbonate, which is present in roll form on the feeder 2210 and made of the film pieces formatted by the feeder, for example by punching, for example in the format ID-1 or ID-3, be cut out. These film pieces serve as upper polymer end layers 110 in the document cards, respectively. Furthermore, a stapled layer composite of a polymer layer stack with an RFID circuit contained therein and externally shielded from it by opaque outer polymer layers 131, 133 is also used as the starting material ( Fig. 1 ) held in roll form and also separated by a mechanical separation process into individual pieces in the same format. These polymer ply pieces 130 represent the layer located at the bottom in the structure to be formed. Further, a transparent film is also provided in roll form from a roll magazine 2225. From this material, a film section is cut in the same format in each case. This is aligned, passed in the printing device 2220, for example, an ink-jet printing device on a hexagonal drum, heated, cleaned and deionized. Subsequently, this section for affixing individualizing information (photograph of the document holder, serial number of the document and characteristics of the document type) is printed on one side by means of the printing device. Thereafter, the thus individualized film section 120 is dried. The quality of the print is finally checked, and this film section is discharged from the printing device to form the structure.

To form the structure, in each case a polymer film stack piece 130 with RFID circuit contained therein, one provided with individualizing information Foil section 120 and a transparent piece of film to form the film final layer 110 deposited and transported on the workpiece carrier, the polymer film stack piece in the structure at the bottom, the individualized film section above and the transparent piece of film are arranged at the top. The tool carrier is aligned on the conveyor belt. For aligning grippers are preferably used (not shown).

After forming the stack, it is removed from the workpiece carrier and, after being deflected by 90 ° in the first transfer station 5010, along the production path A by means of conveyor belts 5000 into a laminating device 2230. In the first transfer station, the stack of laminating sheets is edged on both sides on the outside. Thereafter, this package is fed to the laminator and there between rams that heat the package in a first path section while pressurizing (hot pressing), further heating in a second path section (hot pressing) and cooling in a third path section and thereby under increased pressure put (cold pressing). The laminating sheets associated with the individualized document card 100 to be produced are held in a station 2235 and added to the polymeric ply stack. For this purpose, a shuttle is available, which conveys the different laminating sheets to the laminating device. This shuttle can be formed in particular by a conveyor rail. After leaving the press dies in the laminator, the package with the lamination sheets is conveyed to the second transfer station 5010 by the conveyor. There, the laminating sheets are removed from the obtained piece of laminate.

After again deflecting the resulting piece of laminate by 90 ° in the second transfer station 5010 this is guided by means of the conveyor 5000 to the trimming device 2240, in which it is trimmed to a format that comes close to the desired final format, but even greater than this. Thereafter, the trimmed laminate piece is conveyed to a quality assurance device 2250, where the results of the lamination process as well as the trimming operation are checked. Thereafter, it enters the elevator and buffer 5020 and is transferred to the upper floor Eo of the document card device group 2100 constituted by two document-card manufacturing units 2500 '. The elevator and buffer is designed so that the cycle times in the lower floor EU and in the upper floor may differ. For this purpose, the partially individualized laminate pieces produced in the lower level can be buffered in the buffer and retrieved as needed.

In the upper part of the document card device group 2100, after leaving the elevator and buffer 5020, the laminate piece is fed by means of a conveyor 5000 on the production path A to an applicator 2260 for applying a hologram film element. There, a hologram film element produced in the hologram producing device 2265 is adhered to the already individualized side of the laminate piece. For this purpose, an adhesive is first applied to the side of the piece of laminate to be bonded. Then the film element with the desired hologram is applied to the adhesive surface. The formed composite is dried and the carrier film located on top of the applied film member is peeled off. Subsequently, in this device, a transparent lacquer layer is applied to the now exposed hologram so that it is protected. The lacquer layer is dried in the device. Finally, a quality control of this process step takes place in the device.

The hologram is individualizing and must be matched to the already partially individualized piece of laminate. For this purpose, it is necessary to produce the hologram specifically for the upcoming partially individualized piece of laminate. This is done in hologram generator 2265 (holoprinter). There, a photosensitive film carried by a carrier sheet is held as roll material and unwound from the roll for use. The film is aligned. The film is exposed with the desired individualizing hologram pattern. The exposure is then checked. Thereafter, the exposed film is thermally activated so that the hologram is fixed. Subsequently, another quality control takes place in the hologram producing device. Finally, the film web with the hologram thereon is cut to the desired format and the film element formed with the hologram is transferred to the applicator device 2260, in which it is applied to the piece of laminate.

After applying the film element with the hologram on one side of the piece of laminate this is transported by means of a conveyor belt 5000 on the transport path A to the trimming device 2270, in which it is cut to the desired final format for the document card 100.

After further transporting the cut piece of laminate, it is optionally provided in the apparatus 2280 with a side document card tab 140 to allow the document card 100 to be incorporated into a passport 200. This flap can be made of textile material or of a mixture of textile material and a polymeric material. The tab is typically bonded to the laminate piece by a hot melt process in a narrow lateral overlap area of the tab.

Then, in the laser engraving device 2290, further individualizing information (for example name and signature of the passport holder, machine-readable writing) is introduced into the laminate piece. For this, the piece of laminate is first cleaned and then identified. Subsequently, the optical individualization (personalization) takes place by means of the laser. Thereafter, this individualization is checked. The RFID chip located in the laminate piece is also described with data in this device, so that the individualized document card 100 is formed. The writing process is then checked.

Finally, the individualized document card 100 is conveyed to a quality assurance device 2300, where it is subjected to a final inspection according to various criteria. The checked document card is finally conveyed by means of the elevator and buffer 5020 to the lower level Eu of the document card device group 2100.

It is now either available as a completed ID card 200 and can be output via the output transport devices 4130 from the document card device group 2100 ( Fig. 3 . 4 ), or it is for inclusion in a passport 200 and is about the transport devices 4000; 4110, 4200, 4120 to a mounting device group 3100 ( Fig. 3 ).

In Fig. 7 are two coupled assembly manufacturing units 3500 of a mounting device group 3100 in a lower floor Eu and in FIG Fig. 8 two interconnected assembly manufacturing units 3500 'of the same assembly device group shown in an upper floor Eo. The containerized production units of both floors are also connected to each other (arrangement of the production units in the device group see example Fig. 4 ). The containerized production units are preferably made as a support structure of profile bars 3510, 3510 ', in particular hollow profile bars, which form the outer container structure. These support structures preferably have only a bottom wall, but not side and ceiling walls (not shown).

The containerized assembly manufacturing units 3500, 3500 'contain manufacturing devices and other assemblies for the production of the passports 200. These are arranged in the production units according to the material flow intended for production and permanently installed in the support structures. For this purpose, the production devices are linked together by conveying devices 5000 (or 50xx), for example conveyor belts and conveyor robots with vacuum suction devices or grippers. In addition, the manufacturing devices and other units are connected via external supply and disposal lines with media and disposal.

The 3500 containerized assembly manufacturing units in the lower floor of the assembly apparatus group 3500 ( Fig. 7 ) as a manufacturing device, a printing device 3210, for example an inkjet printing device, a trimming device 3220 for separating visa sheets from the visa sheets, a collator 3230 with a manipulator 3231 and a collection point 3235 for individualized visa sheets, a laminating device 3250 for joining a cover sheet with attachment leaves , two suturing devices 3240, a folding device 3260 and a trimming device 3270. Further, the manufacturing units include, as further assemblies, a visa sheet magazine 6010 for storing visa sheets, a transfer gripper 5030 for transferring a visa sheet to the printing device, an auxiliary sheet magazine 6020, conveying trays 5040 for conveying tracing sheets a location near the collection point, a cover cover magazine 6030, a conveyor cross 5070 for conveying a stack of cover cover 210, attachment sheet 220, individualized document card 100 and visa sheets (book sheets) 230 to one of the sewing devices 3240 and a collection magazine 6040 for the completed passports 200.

The transfer gripper 5030 is positioned in proximity to the visa sheet magazine 6010 to allow the gripper to remove a single visa sheet from the stack of visa sheets. The transfer gripper is also arranged in spatial proximity to the printing device 3210, so that the Visabogen can be supplied from the transfer gripper of the printing device. In addition, the transfer gripper is also arranged in spatial proximity to the trimming device 3220, so that a printed visa sheet can be conveyed to the trimming device by means of the gripper. The manipulator 3231 of the collating machine 3230 is also located in close proximity to the blanking device in order to be able to deposit isolated visa sheets 230 on the collecting station 3235 of the collating machine. Spatially and functionally assigned to the collecting point is the laminating device 3250, in which the cover slips 210 with the Attachment leaves 220 are glued so that the unit thus obtained can also be stored on the assembly point. Likewise, the cover cover magazine 6030 is in close proximity to the laminating device so that the coverslips can reach the laminating device. The attachment blade magazine 6020 is assigned spatially and functionally to the delivery trays 5040 for conveying the attachment sheets to the collection station. The further traverse 5070 connects the assembly station to the sewing devices 3240, so that the stacks of cover sheets with attachment leaves, individualized document cards 100 and visa sheets formed at the collection point can be conveyed to the sewing devices. The folding device 3260 and the adjacent trimming device 3270 are disposed adjacent to the sewing devices and to the elevator and buffer 5050 so that the bound passport precursors in these devices can be processed and forwarded.

The containerized assembly manufacturing units 3500 in the upper floor Eo of the assembly device group 3100 ( Fig. 8 ) have, as manufacturing devices, a paging device 3280 for paging the collapsed and bound passport precursor and a laser perforator 3290. In addition, located in these containerized production units as further units a quality assurance device 3300, control cabinets 3700 for controlling the individual manufacturing devices and conveyors 5000 (or 50xx).

The scroll device 3280, the laser perforator 3290, and the quality assurance device 3300 are interconnected with each other and with the elevators and latches 5050, 5060 via a conveyor 5000, such as a conveyor belt, which specifies the transport path A of the document to be processed, the elevator and latches 5050 downstream of the foliar device, downstream of the laser perforating device and downstream of the quality assurance device. The latter is upstream of the elevator and buffer 5060, so that the finished passport 200 can be conveyed via this elevator and buffer into the lower floor Eu of the assembly device group 3100.

Both parts of the mounting device group 3100, namely, both the lower floor mounting units 3500 Eu and the upper floor mounting units 3500 'Eo, are interconnected via the elevators and buffers 5050, 5060.

To produce the passport 200, the cover slips 210 are held in a cover slab magazine 6030. If several types of passports to be produced, this magazine can be designed as a removable storage that outputs the different types of cover covers, if necessary. Furthermore, flyleafs 220 are stored in a flylap magazine 6020. These may already have an attached Fälzelband 221, which is formed of textile material. The endpapers themselves are preferably as well as the visa sheets 230 made of paper.

The cover sheets 210 and attachment sheets 220 attached thereto are individually fed to the laminating device 3250 so that an attachment sheet with the folding strip can be fastened to the inside of the cover sheet. For this purpose, an adhesive is applied to the inside of the cover sheet in the laminating device and then glued the flyleaf on the adhesive-coated surface of the inside of the cover.

Furthermore, visa sheets are provided in the visa sheet magazine 6010. These visa sheets are preferably made of paper and are already provided with a basic security printing, for example with Guilloche and other non-individualizing information. The visa sheets are individually removed by means of the transfer gripper (sheet gripper) 5030 from a stack of visa sheets in the visa sheet magazine and transferred to the printing device 3210, for example an ink jet printer. The visa sheets represent multiple benefits and are printed by the printing device on both sides with individualizing information, such as the eye color and size of passport holders and the issuing authorities.

After individualizing a visa bow, it is conveyed to the cutting device 3220 by means of the transfer device 5030. By means of this device, individual visa sheets (book sheets) 230 are separated from a visa sheet. For this purpose, a mechanical cutting method is used.

The cover sheet 210 with the attached end sheet 220, the separately supplied individualized document card 100 (for example, a suction cup provided with vacuum suction, not shown), whose individualization data correspond to those of meanwhile partially personalized visa sheets 230, and obtained from the cutting device 3220 visa sheets are on the collecting point 3235 of the collating machine 3230 stacked on each other. For this purpose, first the cover with the flyleaf, then the document card and on a certain Number of visa sheets stacked on top of each other. This stacking is done by means of the manipulator 3231 of the collator 3230.

The stack thus produced is then conveyed to one of the sewing devices 3240 by the conveyor bar 5070. There, the components of the stack are sewn together.

The book assembled in this way is then folded in the folding device 3260. Subsequently, the folded book is trimmed on a trimming device 3270 on three sides. For this purpose, a mechanical cutting method, in particular a stamping method, or a water jet cutting method can be used.

The book is then conveyed from the lower floor Eu of the mounting device group 3100 by means of the elevator and buffer 5050 to the upper floor mounting assembly units 3500 'Eo. Also, this elevator and cache is designed so that the cycle times in the lower floor and in the upper floor may differ. For this purpose, the books produced in the lower floor can be cached in the buffer and retrieved as needed.

In the upper floor Eo of the assembly device group 3100, the book is first unfolded in a folder device 3280 and then provided with further individualization data in a laser perforator 3290. For example, in the case of a passport 200, point perforations taken together may reflect the serial number of the passport through all the visa pages 230 and optionally also through the coverlet 210.

Subsequently, a final check of the completed passport 200 in the quality assurance device 3300 takes place. Thereafter, the checked passport is conveyed via the elevator and temporary storage 5060 from the upper floor Eo of the mounting apparatus group 3100 to a passbook collecting magazine 6040 in the lower floor Eu thereof. From there, the passport 200 can be issued.

For the construction of the production plant 1000 according to the invention, for example for the production of passports 200, the following is used in Fig. 9 schematically reproduced method:
According to a first method step (a), for example, two containerized document-card production units 2500, 2500 'and two containerized assembly-production units 3500, 3500' are initially produced at a production location. These production units contain all manufacturing devices and assemblies required for the production of passports 200, as far as they can be installed in the ready for transport to the site containerized manufacturing units. In addition, further assembly units are prepared at the place of manufacture, which are combined together with the pre-assembled production units separately in a container 7000.

The thus prepared for transport components are then transported in step (b) to the site.

According to step (c), the two containerized document-card manufacturing units 2500, 2500 'are assembled and assembled at the site to form a document-card-device group 2100. Likewise, the two assembly manufacturing units 3500, 3500 'are assembled and assembled to form a mounting device group 3100. The two device groups and therein manufacturing devices and other units are interconnected via transport devices 4000. In addition, the device groups are connected to external supplies and disposals.

Reference numerals:

100

individualized document card, identity card

110

transparent polymer liner, document card layer

120

individualized film section, document card position

130

Layer composite, polymer layer stack piece, document card layer

131

opaque polymer backing sheet

132

compensation layer

133

opaque cover layer (polymer layer)

140

Documents Maps tab

200

book-shaped identification document, passport

210

Einbanddecke

220

endpaper

221

Fälzelband

230

(Pass) book sheet, visa sheet

240

basting thread

1000

plant

2000

first part of the plant

2100

Documents card device group

2210

investor

2220

printing device

2225

roll magazine

2230

laminating

2235

Railway station for providing various laminating sheets

2240

trimming device

2250

Quality assurance device

2260

Applicator for applying a hologram

2265

Hologram generating device

2270

trimming device

2280

Device for attaching a tab

2290

laser engraving

2300

Quality assurance device

2500, 2500 '

containerized document card manufacturing unit

2510, 2510 '

Profile bars, supporting structure

3000

second part of the plant

3100

Mounting device group

3210

printing device

3220

cutting device

3230

Collator

3231

manipulator

3235

rallying point

3240

suturing device

3250

laminating

3260

folding device

3270

trimming device

3280

leaves device

3290

laser perforating

3300

Quality assurance device

3500

containerized assembly manufacturing unit

3510, 3510 '

Profile bars, supporting structure

3700

cabinets

4000

transport device

4110

upstream transport devices

4120

downstream transport devices

4130

Output transporters

4140

Output of the finished identification documents

4200

Verteilstraße

5000

Conveying devices in the device groups

5010

transfer station

5020

Elevator and buffer (buffer)

5030

transfer gripper

5040

Conveyor trusses for conveying attachment sheets to the assembly point

5050

Elevator and buffer (buffer)

5060

Elevator and buffer (buffer)

5070

Traverse conveyor

6000

Memory, cache, magazine

6010

Visa arc Magazine

6020

Endpapers Magazine

6030

Binders Magazine

6040

collection magazine

7000

Container for further units

A

Production path in the document card device groups

eu

first (lower) floor in the device groups

eo

second (upper) floor in the device groups

Claims (14)

1. System (1000) for producing book-like identification documents (200),
   wherein the system (1000) comprises a first system part (2000), formed by at least one document card apparatus group (2100) for producing individualised document cards (100), and a second system part (3000), formed by at least one assembly apparatus group (3100) for merging a set of book leafs (230) of the identification document (200), with an associated individualised document card (100), with the formation of the identification document (200),
   characterised in that the at least one document card apparatus group (2100) is composed in each case of at least one containerised document card preparation unit (2500), and the at least one assembly apparatus group (3100) is composed in each case of at least one containerised assembly preparation unit (3500).
2. System (1000) for producing in accordance with claim 1, characterised in that at least two of the at least one containerised document card preparation unit (2500) of a document card apparatus group (2100) are arranged in at least two levels (Eo, Eu) arranged above one another, and that at least two of the at least one containerised document card preparation unit (3500) of a document card apparatus group (3100) are arranged in at least two levels (Eo, Eu) arranged above one another.
3. System (1000) for producing in accordance with any one of the preceding claims, characterised in that the system (1000) further comprises at least one transport device (4000) for the conveying of individualised document cards (100) from a document card apparatus group (2100) to an assembly apparatus group (3100).
4. System (1000) for producing in accordance with claim 3, characterised in that at least one transport device (4000) is configured such as to convey the individualised document cards (100) separated from one another.
5. System (1000) for producing in accordance with one of claims 3 and 4, characterised in that the at least one transport device (4000) comprises a dividing channel (4200) for conveying the individualised document cards (100) from one specified unit of a plurality of document card apparatus groups (2100) to a specified unit of a plurality of assembly apparatus groups (3100).
6. System (1000) for producing in accordance with any one of the preceding claims, characterised in that at least one document card apparatus group (2100) comprises in each case at least one printing apparatus (2220) for producing individualised information items on document card layers (120), provided for producing the individualised document card (100), in each case at least one laminating apparatus (2230) for merging the document card layers (110, 120, 130), in each case at least one laser engraving apparatus (2300) for producing individualised information items in the interior of the document card layers (132, 133), in each case at least one hologram producing apparatus (2265), and in each case at least one application apparatus (2260) for the applying of a film element with a hologram onto an outer side of a laminated document card (100).
7. System (1000) for producing in accordance with claim 6, characterised in that the at least one printing apparatus (2220), the at least one laminating apparatus (2230), the at least one laser engraving device (2300), the at least one hologram producing apparatus (2265), and the at least one application apparatus (2260), corresponding to the process sequence for producing the individualised document cards (100), are linked to one another in a chain by means of conveying devices (5000, 50xx), which convey individually the intermediate products during the production of the individualised document card (100).
8. System (1000) for producing in accordance with any one of the preceding claims, characterised in that the at least one assembly apparatus group (3100) comprises in each case at least one apparatus (3220) for cutting to size, for producing book leafs (230) from book leaf sheets, at least one merging machine (3230) for merging the individualised document card (100) with a set of book leafs (230), as well as least one stitching apparatus (3240) for binding the individualised document card (100) with the set of book leafs (230).
9. System (1000) for producing in accordance with claim 8, characterised in that the at least one apparatus (3220) for cutting to size, the at least one merging machine (3230), and the least stitching apparatus (3240), corresponding to the process sequence for producing the identification document (200), are linked to one another in a chain by means of conveying devices (50xx), which convey individually the individualised document cards (100) and book leafs (230) or sets of book leafs (230).
10. System (1000) for producing in accordance with any one of the preceding claims, characterised in that the at least one assembly apparatus group (3100) further comprises in each case a removable storage device (60xx) for providing more than one of different design variants of cover bindings (210) for the producing of the identification documents (200).
11. System (1000) for producing in accordance with any one of the preceding claims, characterised in that the system (1000) further comprises at least one laser perforating apparatus (3290) for producing individualised information items in the book leafs (230).
12. Method for producing book-like identification documents (200) with the use of a production system (1000), which comprises a first system part (2000), formed by at least one document card apparatus group (2100) for producing individualised document cards, and a second system part (3000), formed by at least one assembly apparatus group (3100) for merging a set of book leafs (230) of the identification document (200), with an associated individualised document card (100), with the production of the identification document (200), wherein the at least one document card apparatus group (2100) is composed in each case of at least one containerised document card preparation unit (2500), and the at least one assembly apparatus group (3100) is composed in each case of at least one containerised assembly preparation unit (3500), comprising the following method steps:

    (i) providing document card layers (110, 120, 130) for producing the individualised document cards (100);

    (ii) processing the document card layers (120) by the introduction of individualised information items and combining of the document card layers (110, 120, 130) by laminating, with the formation of the individualised document cards (100);

    (iii) providing book leaf sheets for producing a set of book leafs (230);

    (iv) individual separation of the book leafs (230) from the book leaf sheets and merging them to form a set of book leafs (230);

    (v) merging in each case of an individualised document card (100) with a set of book leafs (230) in a merging machine (3230);
    and

    (vi) combining the individualised document card (100) with the set of book leafs (230).
13. Method according to claim 12, characterised in that intermediate products, during the production of the individualised document cards (100), are conveyed separated from one another in the at least one document card apparatus group (2100), and that intermediate products, during the production of the identification document (200), are likewise conveyed separated from one another in the at least one assembly apparatus (3100).
14. Method for erecting a system (1000) for producing book-like identification documents (200), wherein the system (1000) comprises a first system part (2000), formed by at least one document card apparatus group (2100) for producing individualised document cards (100), and a second system part (3000), formed by at least one assembly apparatus group (3100) for merging a set of book leafs (230) of the identification document (200), with an associated individualised document card (100), with the formation of an identification document (200),
    and wherein the at least one document card apparatus group (2100) is composed in each case of at least one containerised document card preparation unit (2500), and the at least one assembly apparatus group (3100) is composed in each case of at least one containerised assembly preparation unit (3500), wherein the method comprises the following method steps:

    (a) producing at least one containerised document card preparation unit (2500), wherein at least one containerised document card preparation unit (2500) forms a document card apparatus group (2100), and of at least one containerised assembly preparation unit (3500), wherein at least one containerised assembly preparation unit (3500) forms an assembly apparatus group (3100), at one production location;

    (b) transporting the at least one containerised document card preparation unit (2500) and of the at least one containerised assembly-preparation unit (3500) to a set-up location; and

    (c) merging and mounting of the at least one containerised documentation card preparation unit (2500), with the formation of the first system part (2000) and of the at least one containerised assembly preparation unit (3500), with the formation of the second system part (3000), at the set-up location, wherein the system (1000) is formed.

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