WO1996034730A1

WO1996034730A1 - Process for producing plastic cards or discs with a printed label on one or both sides

Info

Publication number: WO1996034730A1
Application number: PCT/CH1996/000151
Authority: WO
Inventors: Hans Auer
Original assignee: Hans Auer
Priority date: 1995-05-02
Filing date: 1996-04-25
Publication date: 1996-11-07
Also published as: AU5330296A

Abstract

In a process for producing plastic cards (22) or discs, especially in the form of smart cards, with a printed label on one or both sides by the in-mould labelling method (IML) in which a thin, large-area sheet of labels of a first plastic is printed, the printed label sheet is divided into a plurality of individual printed labels (4), at least one of the labels is inserted in an injection mould (11) and a card substrate (21) of a second plastic is injected on the label (4), which together with the label (4) forms the plastic card (22) or disc, whereby the inserted label (4) is held flat against a wall (14) of the injection mould (11) during the injection process. Largely faultless production is attained in that the label (4) is held against the wall (14) of the injection mould electrostatically.

Description

METHOD FOR PRODUCING PLASTIC CARDS OR DISKS WITH A PRINTED LABEL ON ONE OR TWO SIDES

TECHNICAL AREA

The present invention relates to the field of injection molding technology. It relates to a process for the production of plastic cards or disks provided with a printed label on one or both sides, in particular in the form of smart cards, according to the in-mold labeling (IML) method, in which process a thin, large-area label film is used is printed from a first plastic, the printed label film is divided into a plurality of individual printed labels, at least one of the labels is placed in an injection mold, and a card substrate made of a second plastic is molded onto the inserted label , which, together with the label, forms the plastic card or disk, the inserted label being held flat against a wall of the injection mold during the injection molding process.

Such a method is known, for example, from EP-A1-0 340 099. STATE OF THE ART

It is well known that in the manufacture of so-called smart cards, i.e. Chip cards, credit cards, identity cards and the like, or in the production of compact disks (CDs) for storing music or data (CD-ROMs) first the card or disk with its functional elements (chip, electrical contacts, magnetic strips, bit patterns, etc .) to manufacture and then to provide at least on one side with an imprint which comprises the most diverse graphic elements and which can serve for information, advertising or other purposes.

Subsequent printing has several disadvantages: On the one hand, it is relatively time-consuming and requires special machines. On the other hand, the printing process e.g. lead to impairment of the electronic functions in the chip cards, so that an increased reject rate arises. Finally, the print itself can be faulty. The corresponding card or disk must then be sorted out, which leads to considerable additional costs, particularly in the case of the relatively expensive chip cards or CDs.

It is also known (EP-Bl-0 298 687) to produce and then to separate a large number of simple, printed credit cards equipped with a magnetic strip in a combined lamination and printing process on large sheets. The printing can take place, for example, by means of UV-crosslinkable ink on a metallized film. To protect against scratches, the printed image can be covered with a transparent layer of a UV-curable lacquer or a transparent film. The disadvantage here is that laminating and printing have to be carried out alternately, so that the process sequence is comparatively complicated. Furthermore, the later- Under certain circumstances, partially or completely separate the mined layers and make the card unusable or at least unsightly. In addition, such a process can only be used with a lot of effort for the production of chip cards, because it is difficult, in the case of a finished card substrate, to bring a recess for receiving the chip into the substrate with the required precision.

It has therefore been proposed on various occasions to use the so-called in-mold labeling (IML) process for the production of printed smart cards. In the IML process, which is known from the labeling of plastic containers (see, for example, EP-Al-0 626 667), the object to be labeled is simultaneously formed in a mold in a single injection molding or molding process and is combined with the Labels previously inserted into the mold are inseparable. In this way, the labels can be printed quickly, easily and flexibly in large numbers beforehand in a conventional printing process, so that the print quality can be checked even before the actual card is produced.

In a variant of this process (transfer process), a printed carrier film is inserted into the mold instead of a printed label. When the plastic is injected into the mold, the printed image detaches from the carrier film and binds to the injected plastic. The carrier film can be removed later. The transfer of the printed image can be facilitated by appropriate separating layers between the printed image and the carrier film and adhesive layers over the printed image.

Examples of the IML and transfer process are in connection with the production of chip cards from the aforementioned EP-A1-0 340 099, EP-B1-0 350 179, EP-A2-0 488 485 or EP- A2-0 606 118 known. The transfer process (EP-A2-0 488 485; FIGS. 13 and 13 in EP-A2-0 606 118; FIGS. 2a, b, 3 and 10 in EP-Al-0 340 099) uses the carrier film is tightly clamped laterally between the two (or three) parts of the injection mold. The plastic injected into the mold with high pressure on the inside of the carrier film then presses the carrier film over the entire surface against the wall of the mold and completely fills the interior of the mold, so that the card has a smooth surface. The injected plastic has no possibility of pressing behind the carrier film and thus partially covering the printed image. A disadvantage of the transfer method, however, is that the carrier film protruding beyond the shape must be positioned exactly by means of additional devices so that the transferred printed image is placed exactly in the correct place on the finished card. Another disadvantage is that in the case of an uneven print image or in the case of uneven temperature and pressure conditions in the form of the image transfer, it is not seldom only partially, which leads to a comparatively high reject rate. Finally, it is disadvantageous that the finished card does not form a layer composite which is distinguished by particularly favorable mechanical properties.

In the normal IML process, in which printed labels whose dimensions are exactly matched to the dimensions of the injection mold are inserted into the mold (FIGS. 12 and 13 of EP-A10 340 099; CH-A5-684 528 ), even if the labels and the injected plastic are made of the same material, a stable layer structure results which has particularly favorable properties for the later use of the card. Since the printed image is integrated into the card together with its carrier (the label), the disadvantages associated with the transfer of the printed image are eliminated.

On the other hand, this procedure must ensure that the label or labels are injected of the plastic - in particular if the injection opening is arranged on the side - lie as closely as possible over the whole area and immovably against the wall of the injection mold, so that the label is not displaced by the plastic which is under pressure or the plastic creeps under the label. In addition, a close contact between the label and the (cooled) mold ensures that the hot plastic does not melt the label and the adhesion of the printed image to the label is not reduced by the action of heat.

In the publication EP-Al-0 340 099 mentioned at the beginning (FIG. 13 and the associated description) it is now proposed to equip both sides of the injection mold with a vacuum device ("systemes ä depression") distributed over the surface, by means of which the inserted labels are equipped to be held on the wall of the mold. In practice, however, it has been found that such vacuum maintenance leads to unsatisfactory results. On the one hand, the openings of the vacuum device leave imprints on the finished card, because when the hot plastic under pressure is injected, it presses the labels into the openings and causes a slight curvature outwards. On the other hand, the suction method is not sufficient to reliably prevent the plastic from creeping under the label.

PRESENTATION OF THE INVENTION

It is therefore an object of the invention to provide an IML process for the production of printed cards or disks which leads to a completely uniform surface in the finished card or disk and which holds the injected plastic securely on the inside of the label. The object is achieved in a method of the type mentioned at the outset in that the label is held electrostatically on the wall of the injection mold. Due to the electrostatic attraction between the wall and the plastic label, it is easy to achieve a full-surface contact of the label on the wall without any openings having to be provided in the wall. The injected plastic thus has no way of crawling behind the label, moving the label, or causing any marks.

According to a first preferred embodiment of the method according to the invention, electrostatic attraction between the label and the wall is achieved in a particularly simple manner by electrostatically charging the label before inserting it into the injection mold and inserting the charged label into the injection mold becomes. For this purpose, the label can be guided past corresponding tip electrodes, for example, before being inserted, or can be processed by means of an insertion device which itself has electrodes arranged in the vicinity of the label.

A second preferred embodiment of the method according to the invention is characterized in that the label is preferably pressed over the entire surface of the respective wall of the injection mold when it is inserted. This ensures that the electrostatic attraction is uniformly effective over the entire surface of the label, in particular also in the peripheral edge area, and that the injected plastic has no possibility of shifting the label or crawling under the label.

In a further preferred embodiment of the method according to the invention, the labels are printed with graphic elements. All conventional printing methods such as offset printing, screen printing, flexographic printing etc. can be used for this become. Likewise, conventional solvent-based inks or UV-crosslinkable, solvent-free inks can be used for printing.

In order to ensure particularly good adhesion of the colors to the label, which remains even under the stress of the injection process, it is advantageous according to a further preferred embodiment of the process according to the invention if the label film is coated with an adhesion promoter layer before the colors are printed becomes. Particularly good results can be achieved if a polyamide mixture dissolved in isopropyl alcohol and toluene is used as the adhesion promoter (primer).

Although an excellent surface is already achieved with a normal color print on the label of the finished card or disc, the surface can be further improved and a high gloss can be achieved if, according to another embodiment, the labels are also applied to the top side before the injection be provided with a preferably transparent cover layer. As a result, not only is the print on the mold additionally protected against detachment, but the finished card is also high-gloss and scratch-resistant.

A further preferred embodiment is characterized in that the labels are provided with functional elements in the form of magnetic strips, kinegrams or conductor tracks designed as antennas before the injection. If such a conductor track is specifically arranged on the underside of the label and is electrically connected to a chip likewise applied to the underside of the label, a contactlessly interrogable chip card can be produced in a very simple manner by the IML method. Further embodiments result from the dependent claims.

BRIEF EXPLANATION OF THE FIGURES

The invention will be explained in more detail below on the basis of exemplary embodiments in connection with the drawing. Show it

1 shows various steps for the production of individual printed labels, as can be used in the method according to the invention;

2 shows an exemplary embodiment for the electrostatic charging of a label, as is used in an embodiment of the method according to the invention;

3 shows the insertion of the label into the injection mold after charging according to FIG. 2;

4 shows various steps in the production of a chip card printed on one side according to an exemplary embodiment of the method according to the invention in the injection mold according to FIG. 3;

5 different steps in the production of a chip card printed on both sides according to another exemplary embodiment of the method according to the invention in an injection mold comparable to FIG. 4;

6 shows a top view and a cross section of various prefabricated labels for use in the method according to the invention; 7 shows method steps comparable to FIG. 5, in which a label with a punched-out opening is used in the region of the projecting molded part; and

8 shows two process steps in punching out the labels or the injection-molded cards in the stack.

WAYS OF CARRYING OUT THE INVENTION

In the method according to the invention, printed labels are first produced, which are used in the subsequent IML process. 1 shows an example of the various steps leading to a single printed label. The starting point is a simple label film 1 (FIG. 1 a) made of a first plastic, which has an upper side 1 a and a lower side 1 b. The label film 1 can be in the form of a wide roll, or in the form of individual, large sheets. The material and thickness of the label film, but also the plastic to be injected, can be selected in the same way as described in the publication CH-A5-684 528 by the same inventor, which is expressly included in the description as a reference.

In a first process step (FIG. 1b), the label film 1 is coated over the entire surface on the upper side la with a thin adhesion promoter layer 2, which improves the adhesion of the subsequently applied printing ink and so the print image is better protected from damage (detachment) when the hot plastic is molded on etc.) protects. A polyamide mixture (adhesive) dissolved in isopropyl alcohol (80%) and toluene (20%) is preferably used as the adhesion promoter (primer). On the label film coated in this way the desired print image 3 for the label is then printed (FIG. 1c). This can be done with all possible printing processes and printing inks (UV-crosslinkable, solvent-free as in CH-A5-684 528, or solvent-containing). A large number of individual repetitive printed images 3 are applied to a sheet, each of which is later assigned to a label. Of course, as can be seen in the top view of FIG. 1d, different printed images 3a and 3b can also be arranged next to one another on a printed sheet, so that different labels and thus also plastic cards can be produced with one printing process. When printing, as is shown for the printed images of the lower row in FIG. 1d, windows 41 can be left open, the purpose of which will be discussed in more detail later in connection with the injection molding process.

After completion of the printed images 3 or 3a, b (not shown in FIG. 1), the sheets can be covered over their entire area with a covering layer (36 in FIG. 6). For this purpose, either a transparent film can be laminated on or a varnish, preferably a UV-curable, solvent-free varnish, can be applied. If windows 41 are provided in the printed images and these windows 41 are not intended to be covered with a cover layer, appropriate precautions must be taken in order to avoid the window areas being coated. For example, a photopolymerizable paint of the type Wessco 7001, which is commercially available from the Swiss company Schmid Rhyner AG, Adliswil-Zurich, has proven itself as a paint. The cover layer 36 is on the one hand an additional protection for the printed image both during the injection process and in the finished card. On the other hand, the cover layer 36 also gives the finished card a high-gloss surface, which is visually particularly appealing. After the printed sheet is finished in this way, the individual labels 4 are punched out of the sheet, for example by a punching process (FIGS. Le and lf).

An exemplary and preferred method for punching out the labels is shown in FIG. 8. The printed label films 1 are first cut (for example in stacks by means of a numerically controlled cutting machine) along the individual printed images (3; 3a,) into individual raw labels which are rectangular and have a protruding edge in relation to the sprayed card (dashed line in Fig. le). Stacks 53 are then formed from the individual raw labels, from which the individual printed labels 4 and 4a-f are punched out in a punching device 42 in a punching process.

The exemplary punching device 42 shown in FIG. 8 comprises a punching knife 43 with a closed peripheral cutting edge 44. The cutting edge is worked with high precision by suitable methods, so that the contour of the cutting edge is exactly (ie with very narrow tolerances) the edge of the edge to be sprayed Card matches. Arranged inside the punching knife 43 is a support piston 46 which is movable in the punching direction and which supports the stack 53 of the raw labels during the punching process. The stack 53 of the cut raw labels is inserted into a stack holder 47 for punching (FIG. 8a). The stack holder 47 essentially consists of a bottom 49, a rear side wall 48 and a rear wall 50, which are each perpendicular to one another. The stack is placed in the stack holder in such a way that the raw labels are oriented parallel to the rear wall 50 and thus perpendicular to the punching direction (arrows in FIG. 8b).

During the punching process (FIG. 8b), stack holder 47 and knife are moved relative to one another and towards one another, so that punch knife 43 is removed from stack 53 of the raw labels successively punched out a part stack 53a with finished labels that became larger. With increasing immersion of the partial stack 53a, the support piston 46 is also withdrawn in the punching knife, in such a way that the stack as a whole is always sufficiently compressed. Remaining ring-shaped cutting remnants 54 remain. In order to avoid a disturbance of the punching process by pushing the ring-shaped cutting remnants 54 open, an additional knife 45 can be arranged on the periphery of the cutting edge 44, which cuts the punched-out ring-shaped cutting remnants 54 at one point, so that they better move sideways ¬ can fall.

So that the lower raw labels of the stack 53 can also be punched out securely and precisely, a movable support plate 51 is inserted in the rear wall 50 of the stack holder 47, which e.g. can be resiliently mounted by means of springs 52 and withdraws when the punching knife 43 hits the rear wall 50. Due to the stacked punching out, a large number of printed labels can be produced in a short time, the dimensions of which are highly precise and fit optimally into the injection mold.

The individual labels 4 can then be fed to an injection molding machine, in which a plastic substrate is injection molded onto them in the IML process. The various steps for producing a chip card printed on one side are shown in FIG. 4. The printed label 4 (shown only in one layer in FIG. 4 for the sake of simplicity) is placed in an injection mold 11, which is usually composed of two parts, an upper and lower half mold 12 and 13 with corresponding walls 14 and 15 (the vertical scale 4 shows a greatly enlarged view so that the individual layers can be recognized better, in reality a chip card with a length of 85 mm and a width of 55 mm has a thickness (height) of only about 0.8 mm ). The closed injection mold 11 encloses an injection chamber 19, the dimensions of which correspond to the dimensions of the finished card. An injection channel 17 leads laterally into the injection chamber 19 and is connected to the injection nozzle of the injection molding machine. The lateral arrangement of the injection channel 17 basically has the advantage that the plastic attachment remaining at the channel outlet after injection molding can easily be removed by punching without the optical quality of the large side surfaces of the card being impaired in any way. In addition, this arrangement has the advantage in the production of cards printed on both sides (FIG. 5) that a hole does not have to be punched in either of the two labels before being inserted, in order to allow one in the walls 14, 15 or 30, 31 arranged injection channel to create an injection opening in the space between the labels.

The label 4 is inserted into the injection mold 11 in such a way that its printed upper side lies as far as possible over the entire surface of the wall 14 of the upper half mold 12. It is particularly important that the label, at least on the side on which the injection channel 17 opens into the injection chamber 19, is as tight as possible over the entire width of the wall 14, so that the hot (> 150 ° C.) under high pressure injected plastic cannot crawl between label 4 and wall 14 and thus partially covers the outer surface of the label and thus the printed image and renders the card unusable. It is particularly expedient if the label with its entire peripheral edge area, better still with its entire surface, lies firmly against the wall 14 and is held there because unevenness is avoided and the print image is cooled from the wall over the entire surface. It is also helpful if the label 4 has exactly the same dimensions as the molded card, so that there is practically no free space remains between the edge of the label 4 and the peripheral side wall of the injection chamber 19.

According to the invention, the label 4 is held on the wall 14 in an electrostatic manner, that is, by an electrostatic attraction between the wall 14 and the label 4. For this purpose, the label 4 is preferably charged electrostatically before being inserted into the open injection mold 11, as shown in FIG 2 and 3 is shown in one embodiment. The printed labels 4, which are kept in bulk on the injection molding machine, are individually picked up by a label holding device 5 which can be moved by means of an arm 7, and the free side of which is moved past an arrangement of tip electrodes 10 at a suitable distance, each with a high voltage are charged from several kV to a few 10 kV and statically charge the label 4 (FIG. 2). The charged label 4 is then placed in the mold (FIG. 3) and held there due to the electrostatic forces. In addition, suction openings 20 (FIGS. 3, 4) that support the electrostatic attraction and secure it in critical cases can also be provided in the injection mold 11 (for example, encircling a ring). However, a disadvantage here is the printing of the openings 20 on the surface of the finished card, as has already been mentioned at the beginning.

The label 4 can be held during transport by means of conventional round (rubber) suction cups which, for example, engage in the middle of the label. However, it is particularly favorable to hold the label 4 at least in its entire peripheral edge area, even better over the entire surface, and to insert it into the injection mold 11 so that the label clings to the wall 14 over the entire surface and without the formation of cavities due to the charging can (Fig. 3). In order to achieve this, the label holder device 5 can, for example according to FIGS. Pressure chamber 6, which is connected to a vacuum connection 8, and from which a plurality of suction openings 9 on the suction side lead outwards in order to hold the label 4 uniformly over the entire label surface. It is furthermore conceivable to arrange a layer of elastically yielding material between the label and the suction surface of the label holding device 5, which presses it securely against the wall 14 when the label is inserted while compensating for any unevenness. However, it is also conceivable to provide open areas in the label holding device 5, in which the held label 4 is accessible from behind, and to arrange the tip electrodes 10 in these areas. The tip electrodes 10 then move with the label holding device 5 and charge the label 4 from behind while it is inserted into the injection mold 11.

As soon as the label is securely placed and held on the wall 14 of the injection mold and the mold has been closed (FIG. 4a), the plastic can be injected into the injection chamber 19. The injected plastic solidifies into a card substrate 21 which is thick in comparison with the label 4 (FIG. 4b). It connects inseparably to the label 4 and forms with it a stable layer structure which can be removed as a plastic card 22 after the injection mold 11 has been opened (FIG. 4c). This layer structure is retained even if the same plastic is used for the label film 1 and the substrate 21, because the film is usually drawn while the substrate is being sprayed.

If the card produced is to be used as a chip card, a depression 18 can be formed in the card at the same time during the injection molding process, for later acceptance of the chip. For this purpose, either in the lower wall 15 (as shown in FIGS. 3, 4) or in the upper wall 14 a correspondingly shaped, projecting molded part 16 is arranged. The molded part 16 can be integrally formed on the wall 15. But it can also be designed as a vertically displaceable stamp. In this way, a card with a precisely fitting recess 18 for inserting the chip can be produced in one work step, without the need for complex and complicated post-processing.

If a double-sided chip card is to be produced instead of the one-sided one, the analog constellation shown in FIG. 5 results. In this case, two labels 4a and 4b are placed in the injection mold 23 consisting of the semi-molds 24 and 25 and are held electrostatically on the upper and lower walls 30 and 31 and possibly with the support of suction openings 26, 28 ( Fig. 5a). The lower label 4b stretches over the molded part 32 for the chip holder. The plastic for the card substrate 33 is then injected into the injection chamber 29 through the injection channel 27 (FIG. 5b) and connects to the two labels 4a and 4b). Here, the lower label 4b is pressed against the wall 31 at the same time such that it is "punched" by the molded part 32. After solidification, the plastic card 35 printed on both sides with the recess 34 for the chip can be removed from the opened mold (FIG. 5c). The lower label 4b is of particular importance in connection with the recess 34. The "punched" part of the lower label, which is located on the bottom of the recess 34, must be of such a surface that the chip to be inserted into the recess can be stuck on easily and safely. If the printing inks of the printed image printed on the lower label 4b and / or the cover layer prevent the chip from being stuck securely due to their nature, it is expedient and advantageous to print or coat the later lower label 4b to leave open the window 41 shown in FIG. 1 in the area of the later recess 34, measurements corresponds exactly to the dimensions of the recess 34. In this way, the readily adhesive label film (with or without primer coating) is exposed in the recess 34 in the finished molded card and the chip can be securely bonded into the recess 34.

A further possibility consists in completely punching out the lower labels 4b in the area of the window 41 after printing. The spraying process then takes place as shown in FIG. 7. The lower label 4b can be inserted into the lower half mold 25 without difficulty because of the punched-out window 41, the projecting molded part 32 protruding unhindered through the punched-out area (FIG. 7a). After the plastic has been injected (FIG. 1b), a finished card can be removed from the injection mold 23 (FIG. 7c), which has a depression 34, the bottom of which is not covered with a label section and is therefore freely accessible.

In principle, the labels can be printed with graphic elements (pictures, numbers, letters, etc.), as was assumed in the previous explanation in FIG. 1. Such a label 4c has the structure shown again in plan view and cross section in FIG. 6a with the label film 1, the printed image 3 and possibly an overlying cover layer 36 (the additional adhesive layer possibly present between the label film 1 and the printed image) is not shown here).

However, it is also conceivable for a label (4d in FIG. 6b) to be embedded on the upper side in the printed image 3 or printed over the printed image 3 to carry a magnetic strip 37 on which information is electronically stored and read out in a manner known per se can. In order to protect the magnetic strip 37, it can also be advisable here to provide a cover layer 36. But basically it is too conceivable to print the magnetic strip 37 on the underside of the label 4d. The magnetic strip 37 is thus securely embedded in the plastic when the substrate is molded on.

Another possibility is to accommodate a complete electronic circuit for a contactlessly interrogable chip card on the underside of a label (4e in FIG. 6c). For this purpose, a loop-shaped conductor track 38 formed as an antenna and made of an electrically conductive printing ink is printed on the underside of the label 4e. The printed conductor 38 is preferably formed by depositing a metal layer, e.g. by galvanic means or by another method such as, for example, "electroless plating", reinforced and then connected at both ends to a glued-on chip 39. When injection molding, conductor track 38 and chip 39 are also securely embedded in the plastic. This makes it much easier to manufacture such a chip card than is possible with known methods (see, for example, EP-B1-0 350 179) in which the circuit is initially set up separately.

Finally, it is also conceivable to accommodate a kinegram 40 or hologram in a label 4f according to FIG. 6d, which is either embedded in the printed image 3 or applied above it. In this context, however, it is also possible to provide a kinegram or hologram which covers the entire card or at least a large area of the later card. In this case, the printed image 3 is printed on the kinegram / hologram.

In the previous explanation of the invention, it was assumed that the die-cut labels and the injection mold have exactly the outer dimensions of the finished plastic card, so that when the IML process is carried out, the finished card is produced, of which, at most, the card was produced during the injection molding process Burrs must be removed sen. However, it can be expedient and advantageous to first use the IML method in the manner described above to produce labeled cards with an oversize, and then to bring the resulting raw cards to the final external dimensions of the finished card by means of a punching process. In this way, possible errors at the edge of the card, which were caused by injection molding by crawling under the plastic under the labels inserted into the injection mold, can be reliably eliminated.

In this case, the IML method is carried out in the same way as it was already explained in connection with FIGS. 1-5 above, with the difference that the outer dimensions of the stamped labels and the injection mold compared to the finished plastic card have an excess of one or more millimeters. The resulting raw cards are then reduced to the final dimensions of the card by means of a punching process, a peripheral edge preferably being removed. This punching process advantageously also removes the burrs that formed on the edge of the raw card during the spraying process.

The raw cards can be punched individually or in a stack. In principle, the same device and method can be used for punching in the stack, which are shown in FIG. 8 and have already been described in connection with the punching of the raw labels. In this case, the stack 53 is the stack of raw cards, while the partial stack 53a is the partial stack of the finished cards. The production process for labeled plastic cards can be made even more reliable by the production of raw cards with excessive dimensions and subsequent punching out of the finished cards. In particular, this means that the requirements for the application of the labels in the injection molding form can be reduced, so that in individual cases there is even no need to electrically charge the labels.

Although the invention has been explained in connection with the production of plastic cards such as credit or chip cards, it can also be used in the production of plastic discs such as music CDs or CD-ROMs.

Overall, the invention results in a method with which a plastic card or disk printed on one or two sides with graphic or functional elements can be produced simply and securely

LIST OF DESIGNATIONS

1 label film la top (label film) lb bottom (label film)

2 adhesion promoter layer 3; 3a, b printed image

4; 4a-f label

5 label holder

6 vacuum chamber

7 arm

8 vacuum connection

9 suction opening

10 tip electrode

11.23 Injection mold

12.24 upper half-shape

13.25 lower half form

14.30 wall (injection mold)

15.31 wall (injection mold)

16.32 molded part (protruding) 17,27 injection channel

18.34 deepening , 29 injection chamber, 26.28 suction opening, 33 card substrate, 35 plastic card

Cover layer

Magnetic stripe

Trace (antenna)

chip

Kinegram

window

Punching device

Punch knife

Cutting edge

Additional knife

Support piston

Stack bracket

Side wall

ground

Back wall

Support plate

feather

Stack (raw labels or raw cards) a partial stack (labels or cards)

Cut remnant

Claims

PATENT CLAIMS

1. Process for the production of plastic cards provided on one or both sides with a printed label (4; 4a-f)

(22, 35) or disks, in particular in the form of smart cards, according to the in-mold labeling (IML) method, in which method a thin, large-area label film

(1) is printed from a first plastic, the printed label film (1) is divided into a multiplicity of individual printed labels (4; 4a-f), in each case at least one of the labels (4; 4a-f) in an injection mold (11 , 23) is inserted, and a card substrate (21, 33) made of a second plastic is molded onto the inserted label (4; 4a, b), which together with the label (4; 4a, b) the plastic card ( 22, 35) or disk, the inserted label (4; 4a, b) being held flat against a wall (14, 30, 31) of the injection mold (11, 23) during the injection process, characterized in that the label (4, 4a, b) is held electrostatically on the wall (14, 30, 31) of the injection mold (11, 23).

2. The method according to claim 1, characterized in that the label (4, 4a, b) is electrostatically charged before insertion into the injection mold (11, 23), and the charged label (4, 4a, b) into the injection mold ( 11, 23) is inserted.

3. The method according to claim 2, characterized in that the label (4, 4a, b) is preferably pressed over the entire surface of the respective wall (14, 30, 31) of the injection mold (11, 23) during insertion.

4. The method according to any one of claims 1 to 3, characterized ge indicates that the label (4, 4a, b) is additionally held by vacuum on the wall (14, 30, 31).

5. The method according to any one of claims 1 to 4, characterized ge indicates that the material of the label film (1) and the injected plastic are the same.

6. The method according to any one of claims 1 to 5, characterized ge indicates that the labels (4, 4a-f) are printed with graphic elements.

7. The method according to claim 6, characterized in that solvent-containing inks are used for printing.

8. The method according to claim 6, characterized in that UV-crosslinkable, solvent-free inks are used for printing.

9. The method according to any one of claims 6 to 8, characterized ge indicates that the label film (1) is coated with an adhesive layer (2) before printing the colors.

10. The method according to claim 9, characterized in that a polyamide mixture dissolved in isopropyl alcohol and toluene is used as the adhesion promoter.

11. The method according to any one of claims 1 to 10, characterized ge indicates that the labels (4, 4a-f) are provided with functional elements (37, 38, 39, 40) before injection.

12. The method according to claim 11, characterized in that the functional element is a magnetic strip (37).

13. The method according to claim 11, characterized in that the functional element is a kinegram (40).

14. The method according to claim 11, characterized in that the functional element is a conductor track (38) designed as an antenna.

15. The method according to claim 14, characterized in that the conductor track is arranged on the underside (lb) of the label (4e) and is electrically connected to a chip (39) also applied to the underside (lb) of the label (4e) .

16. The method according to any one of claims 1 to 15, characterized ge indicates that the labels (4, 4a-f) are provided with a preferably transparent cover layer (36) before the injection on the top (la).

17. The method according to claim 16, characterized in that a film is laminated as the cover layer (36).

18. The method according to claim 16, characterized in that a lacquer, preferably a UV-curable, solvent-free lacquer, is applied as the cover layer (36).

19. The method according to any one of claims 1 to 18, characterized ge indicates that labels (4; 4a, b) are used, in each of which at least one window (41) is provided, in which the labels (4; 4a, b ) are not printed.

20. The method according to claim 19, characterized in that the labels (4; 4a, b) are not printed when printing in the region of the window (41).

21. The method according to claim 19, characterized in that the labels (4; 4a, b) are punched out in the region of the window (41) after printing.

22. The method according to any one of claims 1-21, characterized gekenn¬ characterized in that for dividing the printed label film (1) into a plurality of individual printed labels (4; 4a-f), the label film (1) along the individual Druckbild¬ (3; 3a, b) are cut into individual raw labels, stacks (53) are formed from the individual raw labels, and the individual printed labels (4; 4a-f.) Are cut from the stacks (53) in a punching device (42) in one punching process ) are punched out.

23. The method according to claim 22, characterized in that a punching knife (43) with a closed peripheral cutting edge (44) is used for the punching device, the contour of which corresponds exactly to the edge of the card (22, 35) to be produced.

24. The method according to claim 23, characterized in that in the interior of the punching knife (43) a supporting piston (46) which is movable in the punching direction and which supports the stack (53) during the punching process and together with the already punched out partial stack (53a ) is withdrawn in the punching knife (43).

25. The method according to any one of claims 1-24, characterized gekenn¬ characterized in that the injection mold (11, 23) corresponds in its outer dimensions to the finished plastic card or disk.

26. The method according to any one of claims 1-24, characterized gekenn¬ characterized in that the injection mold (11, 23) compared to the finished plastic card or disk has an excessive dimension, and that the IML - Processed raw cards or disks are subsequently reduced to the final dimensions of the card or disk by a punching process.

27. The method according to claim 26, characterized in that the raw cards or disks are punched individually.

28. The method according to claim 16, characterized in that the raw cards or disks in a stack (53) are punched into several at the same time.

29. The method according to any one of claims 26-28, characterized gekenn¬ characterized in that a peripheral edge is removed when punching the raw cards or discs.

30. The method according to claim 29, characterized in that the width of the punched edge is one or more millimeters.