EP3608123B1 - Method for producing a data card for a security document and an ultrasonic punching tool - Google Patents

Description

Process for producing a data card for a security document and an ultrasonic punching tool

The invention relates to a method for producing a data card for a security document and an ultrasonic punching tool.

From the DE 10 2004 008 841 A1 a book-like document is known. In this exemplary embodiment, this book-like document, which is shown in FIG. 10a, comprises a first and at least one further layer made of a polymer laminate layer. A carrier layer with a microchip is provided between the layers. The laminate layers have an outer, peripheral, closed edge, by which the carrier layer is completely enclosed and embedded between the layers. The laminate layers are made by a roll lamination or an embossing press process. After forming the laminate layer wrapper by the at least two laminate layers, the edges are trimmed to subsequently wrap the laminate layer wrapper with a cover material.

From the DE 10 2013 104 745 A1 a method for producing a laminate composite is also known. A front booklet and back booklet consisting of several layers as well as an intermediate layer positioned in between are placed in a laminating cassette and then welded to form a laminate composite. This laminate composite is then trimmed, so that individual data cards are provided from this laminate composite, which are trimmed to a final size by the trimming.

From the DE 10 2016 217 046 B3 a method is known for producing a composite body for a document type selected from a plurality of different types of identification, value or security documents. In this process, a selection of document-type-specific material sheets is collected in order to laminate them into a composite body. Subsequently, the composite body is ultrasonically processed to a desired one Format. The composite body of sheets of material is cut to size by wedge cutting using an ultrasonic knife. The ultrasonic knife designed as a sonotrode includes a peripheral edge, the course of which corresponds to the circumference of the geometric format. The melting of the material sheet booklet in the area of the cut by ultrasound leads to a sealing of the resulting cut surface. The individual layers are no longer identifiable, which increases the security of the document. After cutting the booklet of material sheets to size, the data card is complete.

From the DE 10 2016 217 041 B3 a system and a method for producing an identification, value or security document is known. To cut a laminate body to a final dimension of the document body, a cutting knife with a sonotrode is used, which has a circumferential cutting edge, the course of which corresponds to a circumference of the geometric format of the document body to be produced.

The invention is based on the object of proposing a method for producing a data card from a raw card and an ultrasonic punching tool, which increases security against forgery.

This object is achieved by a method for producing the data card for a security document, in which several layers are aligned with one another and laminated in a laminating process to form a laminate composite and are cut to a final size, so that a raw card is produced as a laminate composite, the final size cut raw card is laminated with at least one film made of a thermoplastic elastomer and one, several or all front edges of the film extend beyond the raw card and that the film protruding beyond the final dimension of the raw card is cut to the final dimension of the raw card by ultrasonic punching with a processing tool and the at least one end face of the film laminated on and the at least one end face of the raw card are sealed to one another. This procedure allows the raw card for example, personalized in a printing station and then laminated with a film to form a data card, with only the at least one laminated film being cut to the format that corresponds to the raw card that has already been cut to the final dimensions and provided. At the same time, the edge of the at least one end face of the film is sealed in the corresponding end face of the raw card. Separation or splitting as well as detachment of the laminated film is made more difficult, which increases the security of the data card against forgery.

The format of the data card can be, for example, an ID1 format, such as a bank card, credit card, driver's license or an electronic identity card, as well as other access cards. Furthermore, an ID3 format can also be punched, for example to produce a personal data page of a passport. Other formats are also possible.

To produce the data card, it is preferably provided that the end faces of the raw card are processed with the end faces of the film laminated on with an inner sealing surface adjoining the peripheral cutting edge. Through this sealing surface, the respective front edges of the layers can be melted and welded or sealed to one another, so that a common, closed front side of the data card is formed. This is done at the same time as the laminated raw card is punched to the desired format or final format.

Provision is preferably made for the processing tool to produce a sealed edge region of the data card, in which at least one end face, which is preferably aligned at right angles to the plane of extension of the data card, is formed. As a result, ID1 or ID3 documents or other security documents, for example, can be produced with short cycle times. In addition, the protection against counterfeiting is increased by the sealed edge area of the data card.

The raw card cut to the final size is preferably laminated with the at least one layer or film made of a thermoplastic elastomer, with the layer made of thermoplastic elastomer preferably protruding beyond all front edges of the raw card and the layer protruding beyond the raw card being cut to the final size of the raw card with the processing tool and the edge area of the data card is sealed. In this method, it is therefore provided that the raw card itself is no longer cut to a final size, but only the at least one layer laminated thereto and the end faces of the raw card cut to final size are sealed together with the end faces of the at least one laminated layer. In addition, an edge rounding is applied to the laminated film. The outer peripheral edge of the film, which is formed by ultrasonic punching, is at least deburred, preferably rounded. This can improve the feel of the data card.

A further preferred embodiment of the method provides that the raw card cut to the final size and the at least one film laminated thereon, which extends beyond the final size of the raw card, is cut with the processing tool by ultrasonic punching, in which a Shoulder connects, which points towards the middle of the data card, through which a peripheral edge of the data card is rounded and the end face of the at least one laminated layer is sealed to the end faces of the raw card. Additional pressure on the edge of the data card can be achieved by this shoulder in the processing tool in order to securely connect the at least one further layer laminated on the raw card and to ensure the sealing of the end faces with the adjacent end faces of the raw card.

A further preferred embodiment of the method provides that the laminated and preferably previously printed raw card is positioned on an anvil whose support surface corresponds to the final dimensions of the raw card and opposite a counter anvil with its support surface the contact surface of the anvil is moved to a working level in which the support surface rests against the laminated film and the processing tool is then advanced onto the counter anvil. This makes it possible for the film laminated onto the raw card to be trimmed exactly.

Furthermore, it is provided that during the cutting and sealing of the end face of the film with the end faces of the raw card, the cutting edge of the processing tool and the counter anvil are moved together relative to the anvil. As a result, both the trimming of the protruding film over the raw card and the edge sealing of the end faces of the at least one film and the raw card are made possible in one processing step.

Furthermore, it is preferably provided that an edge region of the film protruding beyond the final dimension of the raw card is separated by at least one additional blade during the sealing of the end face of the film to the end face of the raw card. This allows for easy disposal of the supernatant or waste material.

Furthermore, it is preferably provided that at least one identifier and/or one security feature is applied to the raw card before the lamination of the at least one film. As a result, personalization, in particular colored personalization, can be made possible by printing.

The ultrasonic punching is advantageously carried out when the processing tool is excited at a frequency of 10 to 30 kHz, in particular in a range between 18 and 23 kHz.

A preferred embodiment of the method provides that an interior space formed by the sealing surface of the processing tool is vented during the cutting processing of the film laminated onto the raw card and the interior space is then subjected to compressed air and the data card is ejected.

The object on which the invention is based is also achieved by a tool for ultrasonic punching of a data card, in which a processing tool attaches to a revolving The cutting edge has a sealing surface which is adjacent and aligned with the central axis of the processing tool and the cutting edge of the processing tool can be moved against an anvil, the sealing surface being aligned parallel to the longitudinal axis of the processing tool. As a result, an exact cut can be made in the at least one film. The cut end face of the at least one foil can thereby be aligned with the end face of the raw card. The sealing surface adjoining the cutting edge within the processing tool preferably extends in height at least partially along the edge region of the laminate composite to be processed. With such an ultrasonic punching tool, the laminate composite is cut to a final format of the data card by means of a processing step for ultrasonic punching. At the same time, the edge area of the laminate composite is sealed. This can increase security against forgery, since it is more difficult for individual layers of the laminate composite to split open and peel off.

At least one peripheral shoulder is preferably provided opposite the cutting edge of the machining tool and delimiting the sealing surface. As a result, an upper edge of the laminate composite can be acted on with this circumferential shoulder during the ultrasonic stamping, with an increased compressive force and thus a secure seal being achieved in this area. In addition, a contour corresponding to the contour of the shoulder can be transferred to the edge of the data card. The shoulder preferably has a rounded shape, so that in particular a burr-free edge that runs around the data card can be achieved.

The anvil preferably has a bearing surface which is surrounded by a spring-loaded counter-anvil. This makes it possible for the cutting edge to be guided along the edge area of the raw card during the ultrasonic stamping and to be guided past a lower edge of the raw card resting on the support surface. The counter anvil is flexible or can be compared to the Bearing surface are moved in an infeed movement of the machining tool. As a result, the cutting edge of the processing tool can be arranged in a recessed manner in relation to the bearing surface of the anvil in order to carry out a complete sealing of the edge region of the data card.

Furthermore, it is preferably provided that the machining tool has a bore which opens into an interior space delimited by the sealing surface, via which the interior space can be vented or pressurized with compressed air. This allows for easy ejection of the cut data card after the cutting and sealing process.

Furthermore, it is preferably provided that a valve controlling the bore is provided on an outside of the machining tool. Thus, on the one hand, the interior space can be easily vented during the punching and sealing process and, on the other hand, the process of ejecting the data card can be controlled in a targeted manner.

• Figur 1 eine perspektivische Ansicht eines unbeschnittenen Laminatverbundes,
• Figur 2 eine schematische Seitenansicht des Laminatverbundes gemäß Figur 1,
• Figur 3 eine perspektivische Ansicht eines Ultraschallstanzwerkzeuges zum Ultraschall-Stanzen des Laminatverbundes,
• Figur 4 eine schematische Seitenansicht während eines Ultraschalltstanzprozesses,
• Figur 5 eine perspektivische Ansicht eines auf Endmaß geschnittenen Laminatverbundes,
• Figur 6 eine schematische Ansicht eines Schnittabfalls, und
• Figur 7 eine schematische Schnittansicht einer alternativen Ausführungsform eines Bearbeitungswerkzeuges zum Ultraschallstanzen.

The invention and other advantageous embodiments and developments thereof are described and explained in more detail below with reference to the examples shown in the drawings. The features to be found in the description and the drawings can be used according to the invention individually or collectively in any combination. Show it:

• figure 1 a perspective view of an untrimmed laminate composite,
• figure 2 a schematic side view of the laminate composite according to FIG figure 1 ,
• figure 3 a perspective view of an ultrasonic punching tool for ultrasonically punching the laminate composite,
• figure 4 a schematic side view during an ultrasonic stamping process,
• figure 5 a perspective view of a laminate composite cut to final dimensions,
• figure 6 a schematic view of a cutting waste, and
• figure 7 a schematic sectional view of an alternative embodiment of a processing tool for ultrasonic punching.

In figure 1 a raw card 16 consisting of a laminate composite 11 is shown in perspective. the figure 2 16 shows a schematic side view of the raw card 16 according to FIG figure 1 . This laminate composite 11 consists of two or more layers 12, 14, 15, which are laminated to form the raw card 16. The number of layers 12, 14, 15 depends on the intended use of the data card 19 to be produced ( figure 5 ).

Such a raw card 16 is preferably punched to a final dimension of the data card 19 . The raw card 16 can be printed in a separate and subsequent processing operation. For example, an image 21 and/or personalization data 22 can be printed, in particular in accordance with the ICAO standard in an ICAO zone. Additional or different information can also be printed or applied by laser irradiation. To protect the printing, a film 23 is laminated onto the printed raw card 16 as a cover layer. This film 23 has an overhanging edge 24 after lamination. This foil 23 can overhang one, several or all side edges of the raw card 16 . In order to complete the printed and laminated raw card 16 to a final dimension, it is necessary to remove the protruding edge 24 of the raw card 16 .

To produce data cards 19 from the laminated raw card 16, an ultrasonic punching device 41 is provided, which in figure 3 is shown schematically. This ultrasonic punching device 41 includes an infeed device 42 with a lifting cylinder, not shown in detail, through which an ultrasonic drive device 43 can be moved. The ultrasonic punching device 41 also includes at least one ultrasonic punching device 44 with a sonotrode, which is designed as a processing tool 45, and an anvil 46. Through the ultrasonic drive device 43 applies ultrasonic vibrations to the processing tool 45 . The processing tool 45 can be fed onto the anvil 46 by the infeed device 42 .

In figure 4 a schematic sectional view during a working step of the ultrasonic punching device 41 for processing the laminated raw card 16 is shown. The laminated raw card 16 is placed on the anvil 46 . The laminated film 23 with the protruding edge 24 is aligned with the processing tool 45, for example. Alternatively, the laminate composite 11 can also be aligned with the film 23 resting on the anvil 46 .

The processing tool 45 is excited with ultrasonic vibrations of the ultrasonic drive unit 44 and is moved towards the anvil 46 via the infeed device 42 . The ultrasonic vibrations can range from 17 to 25 kHz. The processing tool 45 has a cutting edge 48 which is preferably designed as a circumferential cutting edge and is adapted to the format of the data card 19 to be produced, which corresponds to the final dimensions of the raw card 16 . The cutting edge 48 has a wedge surface 49 directed outwards. A sealing surface 51 is provided opposite the wedge surface 49 . The wedge surface 49 and the sealing surface 51 merge into the cutting edge 48 . The sealing surface 51 can form an inner cutting surface of the blade 48 . In the exemplary embodiment, the sealing surface 51 is preferably aligned at right angles to the plane of extension of the laminated composite 11 . The edge 24 is separated from the raw card 16 by the infeed movement of the processing tool 45 with the application of ultrasonic vibrations. An edge area 26 of the raw card 16 can also be separated. During a further infeed movement, the sealing surface 51 seals the end face 17 of the raw card 16 with the end faces 25 of the film 23. The ultrasonic vibrations melt the end faces of the layers 12, 14, 15 via the sealing surface 51 and together form a circumferential end face 52 welded to the data card 13.

The processing tool 45 is then lifted off the anvil 46 . After this ultrasonic punch processing, the data card 19 is in accordance with figure 5 manufactured. A trimmings formed by the overhanging edge 24 remains as shown in FIG figure 6 is shown.

The machining tool 45 can have at least one additional cutting edge 50 which protrudes laterally opposite the cutting edge 48 or is arranged at right angles thereto. This allows the protruding edge 24 to be severed or separated into several parts, making it easier for the edge 24 to be removed and disposed of.

The data card 19 is preferably punched to a final format. The edge area 26 of the data card 19 consists of the common end face 52 since the individual layers 12, 14, 15 are welded and sealed to one another.

According to the data card 19 figure 5 it can be a security document which has an ID1 format. For example, the data card is embodied as a bank card, credit card, driver's license, electronic identity card or as another access card.

Alternatively, the data card 19 can also be designed to produce a data page in a book-like document, such as a passport. To produce the data page, the data card 19 is connected to a tab made of a foil or a textile strip material or a composite material, in particular by ultrasonic welding. Such an arrangement is, for example, from DE 10 2012 213 913 A1 known. The data page is bound into a book-like document by means of a flap, in particular connected with a seam.

The layers 12, 14, 15 for producing the raw card 16 can consist of one or more plastic materials. For example, 16 plastics can be provided to form the laminate composite 11 for the raw card. In particular, these include polycarbonate (PC) or consist of PC. Other alternatives can be: Bisphenol A polycarbonate, Carboxy-modified PC, polyethylene terephthalate (PET), its derivatives such as glycol-modified PET (PETG), polyvinyl chloride (PVC), polyvinyl butyral (PVB), polymethyl methacrylate (PMMA), polyimide (PI), polybutylene terephthalate (PBT), 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/or derivatives thereof, or made of paper and/or cardboard or mixtures of the aforementioned materials.

In figure 7 is an alternative embodiment of the ultrasonic punching tool 44 to figure 6 shown. The processing tool 45 additionally has a peripheral shoulder 61 that delimits the sealing surface 51 . This shoulder 61 is aligned with the center of the data card 19 or with the longitudinal axis of the processing tool 45 . This shoulder 61 is preferably rounded, in particular with a small radius. This shoulder 61 presses an outer peripheral edge of the film 23 onto the raw card 16 and welds it thereto, so that the edge 24 of the film 23 forms a uniform and closed surface of the data card 19 with the edge area 26 of the laminate composite 11 .

Furthermore, in this alternative embodiment of the ultrasonic punching tool 43, the anvil 46 can be formed in two parts. A first portion of the anvil 46 forms a bearing surface 64 which is fixed. The size of the bearing surface 64 preferably corresponds to the raw card 16. This bearing surface 64 is surrounded by a resilient counter-anvil 65 with a support surface 66. The support surface 66 of the counter anvil 65 can preferably be moved in height, so that this support surface 66 supports an underside of the foil 23 after the laminated raw card 16 is lying on the support surface 64 . During an infeed movement of the processing tool 45, this counter-anvil 65 is moved downwards by the cutting edge 48 in relation to the bearing surface 64, so that the cutting edge 48 is completely on the Edge region 26 adjacent and can be guided past it. As a result, the sealing of the entire edge area 26 of the data card 19 can be further promoted.

As an alternative to a two-part anvil 46, a flexible anvil can also be provided, which enables the cutting edge 48 to penetrate at least partially into a surface of the anvil 46 on which the raw card 16 rests.

The processing tool 45 preferably has a bore 68 which leads into an interior space 67 of the processing tool 45 . This interior space 67 is delimited by the peripheral sealing surface 51 and a base of the processing tool 45 . A valve 69 is provided on an outside of the machining tool 45 . This can be controlled by a controller so that either air trapped in the interior 67 can escape or that compressed air is actively enabled to eject the data card 19 after the ultrasonic cutting. Reference List 11. laminate composite 33 55 12. layer 34 layer 56 surrounding border 13. 35 layer 57 laminate layer wrapping 14 layer 36 layer 58 15 layer 37 layer 59 16 raw card 38 layer 60 17 face 39 layer 61 shoulder 18 40 62 19 data card 41 US punching facility 63 20 42 delivery device 64 bearing surface 21 picture 43 US propulsion device 65 counter anvil 22 personalization data 44 US stamping tool 66 support surface 23 foil 45 editing tool 67 inner space 24 edge 46 anvil 68 drilling 25 face 47 69 Valve 26 edge area 48 cutting edge 70 27 49 wedge surface 71 28 50 Extra cutting edge 72 29 51. sealing surface 73 30 front booklet 52 face of 19 74 31 back cover booklet 53 radius 75 32 liner 54 76

Claims (14)

1. A method for producing a data card (19) for a security document in which several layers (12, 14, 15) are aligned with each other and in the course of a lamination process are laminated together so as to form a laminated composite (11) and are cut to a finished size such that a card blank (16) in the form of a laminated composite (11) is produced,

   - wherein the card blank (16), once cut to its finished size, and at least one film (23) made of thermoplastic elastomer are laminated together so as to form a data carrier (19), with one or several or all of the end faces (25) of the film (23) extending beyond said card blank (16), and

   - wherein the portion of the film protruding from the finished size of the card blank (16) is cut to the finished size of said card blank (16) by means of ultrasonic punching using a processing tool (45), and wherein at least one end face (25) of said at least one laminated film (23) and the end faces (17) of the card blank (16) are sealed together.
2. The method as claimed in claim 1, characterised in that the end faces (17) of the card blank (16) cut to its finished size and the end faces (25) of the laminated film (23) are sealed together during ultrasonic punching by means of a sealing surface (51) of the processing tool (45).
3. The method as claimed in any of the preceding claims, characterised in that the processing tool (45) serves for forming sealed end faces (52) of the data card (19) that are oriented in rectangular alignment with respect to the extension plane of said data card (19).
4. The method as claimed in any of the preceding claims, characterised in that the card blank (16) having said at least one film (23) laminated thereunto is cut by ultrasonic punching using the processing tool (45) which has a shoulder (61) adjoining the sealing surface (51) and facing towards the centre of the processing tool (45), and in that the film (23) undergoes an edge rounding process.
5. The method as claimed in any of the preceding claims, characterised in that the laminated card blank (16) is positioned on an anvil (46) the bearing surface (64) of which corresponds to the finished size of the card blank (16), and in that a counteracting anvil (65) having a support surface (66) is moved into a working plane with respect to said bearing surface (64) of the anvil (46) in which the support surface (66) is applied onto the lower face of the film (23), and in that the processing tool (45) is subsequently moved towards the counteracting anvil (65).
6. The method as claimed in claim 5, characterised in that while the end faces (25) of the film (23) and the end faces (17) of the card blank (16) are being cut and sealed together, the processing tool (45) and the counteracting anvil (65) are moved in conjunction relative to the anvil (46).
7. The method as claimed in any of the preceding claims, characterised in that an edge region (24) of the film (23) protruding from the finished size of the card blank (16) is cut off and/or separated by at least one additional blade (50) as the end faces (25) of the film (23) and the end faces (17) of the card blank (16) are being sealed together.
8. The method as claimed in any of the preceding claims, characterised in that prior to the lamination of the at least one film (23), at least one characteristic and/or security feature is applied and/or printed onto the card blank (16).
9. The method as claimed in any of the preceding claims, characterised in that the processing tool (43) for ultrasonic punching is activated using oscillations in a range of between 10 and 30 kHz, preferably in a range of between 18 and 23 kHz.
10. The method as claimed in any of the preceding claims, characterised in that, while the cutting processing of the film (23) applied onto the card blank (16) is performed, air is withdrawn from an inner space (61) formed by the sealing surface (51) of the processing tool (45), and in that once the end faces (17) of the card blank (16) and the end faces (25) of the film (23) have been sealed, compressed air is injected into said inner space (61) via a drill hole (68) formed on the processing tool (45), and the data card (19) is thus being ejected.
11. An ultrasonic tool for ultrasonic punching of a data card (19) using a processing tool (45) which has at least one circumferential blade (48) including a sealing surface (51) associated with said blade (48) and facing towards the central axis of the processing tool (45), which surface extends along the entirety of the blade (48) and is aligned in parallel with the longitudinal axis of the processing tool (45), wherein an anvil (46) arranged opposite the processing tool (45) has a bearing surface (64) which is surrounded by a counteracting anvil (65) that is resiliently formed as compared to the bearing surface (64), or wherein the anvil (46) has a bearing surface (64) along the outer face of which the at least one blade (48) of the processing tool (45) may be moved.
12. The ultrasonic punching tool as claimed in claim 11, characterised in that the processing tool (45) has a circumferential shoulder (61) which is preferably rounded and which is recessed with respect to the blade (48) and delimits the sealing surface (51).
13. The ultrasonic punching tool as claimed in any one of claims 11 or 12, characterised in that the processing tool (45) has a drill hole (68) opening out into an inner space (67) formed by the sealing surfaces (51) and by means of which compressed air may be injected into said inner space (67).
14. The ultrasonic punching tool as claimed in claim 13, characterised in that a valve (69) for controlling the functioning of the drill hole (68) is provided on the outside of the processing tool (45).

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