WO2018046629A1

WO2018046629A1 - Method for producing a composite body

Info

Publication number: WO2018046629A1
Application number: PCT/EP2017/072525
Authority: WO
Inventors: Steffen Baudach; Christoph Von Czapiewski; Alexander GÖDECKE; Roland HERES; Alexander Straub
Original assignee: Bundesdruckerei Gmbh
Priority date: 2016-09-07
Filing date: 2017-09-07
Publication date: 2018-03-15
Also published as: EP3509868B1; EP3509868A1; DE102016217046B3

Abstract

The invention relates to a method for producing a composite body for a document type selected from a plurality of different identification, value, or security document types. The method comprises: collating a selection of material sheets (302) specific to the document type in a sequence specific to the document type order, producing a sheet material booklet (300), wherein the respective immediately following material sheet (302) according to the sequence specific to the document type is fixed successively to each of the collated material sheets (302), such that the relative orientation of the collated material sheets (302) relative to one another is fixed, producing a composite body by lamination of the sheet material booklet (330), wherein the sheet material booklet (300) is subjected to pressure and heat in a pre-defined manner, separating material by carrying out a first material separation process using ultrasound, such that a laminated composite body having a geometric format (502) for a first document type is produced.

Description

Method for producing a composite body

description

The invention relates to a method for producing a composite body and a device for producing a corresponding composite body.

Various methods for producing composite bodies for identity, value or security documents are known from the prior art. The corresponding methods are generally designed to produce a large number of documents of a document type. The invention has for its object to provide a method for producing a composite body, which is efficient and flexible, and a corresponding device for producing a corresponding composite body. In particular, it should make it possible to efficiently produce composite bodies for different types of documents.

The objects underlying the invention are achieved by the features of the independent claims. Preferred embodiments of the invention are indicated in the dependent claims.

Embodiments relate to a method for producing a composite body for a document type selected from a plurality of different badge, value or security document types. The method comprises:

• collecting a document type-specific selection of material sheets in a document type-specific order,

• producing a material sheet, successively fixing, on each of the collected sheets of material, the sheet of material immediately following the document type-specific order, so as to determine the relative orientation of the collated sheets of material relative to one another,

Producing a composite body by laminating the material sheet booklet, wherein the material sheet booklet is subjected to pressure and heat in a predefined manner,

• Disconnect material by performing a first material separation process using ultrasound to create a laminated composite with a geometric format for a first document type.

The created material sheet contains the material sheets that make up a document body of the selected document type. In particular, the material sheet booklet includes the material sheets in a document type specific order. As materials of the material sheets, for example, paper, cardboard or Plastics such as metal foils find use. A sheet of material may also include combinations of these materials.

By way of example, the document body may be a card body if the identification, value or security document is a card-shaped document. The document body may also be a body that is part of a passport, value or security document. For example, it may be a data card which is part of a book-type identity card, value or security document, for example a passport. On such a data card, for example, personal and / or document-specific information such as a passport photograph, name, address of the user or a house number are applied, especially in machine-readable form. In particular, the material sheets may comprise or may be combined with electronic components, such as a chip, an antenna, a display, an input device and / or sensors. The material sheet booklet may in particular comprise a material sheet with a chip which is configured to store personal and / or document type-specific information. The chip can have a secure memory area in which personal and / or document type-specific data is stored.

A "identity, value or security document" is understood below to mean a paper and / or plastic-based document on or in which person-specific and / or document-type-specific information is optically and / or electronically readably incorporated, which identifies the user documents, in particular passports, ID cards, visas and driving licenses, vehicle registration documents, vehicle registration documents, company ID cards, health cards or other ID documents.

Documents as well as chip cards, means of payment, in particular bank cards, credit cards, bills of lading or other credentials. value documents In particular, banknotes or vouchers may be. Likewise, a document may, for example, be an access card.

The material booklet can be provided in particular for producing a data card, i. a paper or plastic based card, which in one

Book block of a passport, value or security document is arranged and are applied to the person-specific and / or document-specific information optically readable, which allows identification of the user or the document, for example, for the release of certain services or functions.

The material sheets from which the material sheet is created have a format that is larger than the geometric format for the first document type. The present method could allow material sheet booklets to be efficiently cut to the appropriate format by material separation. According to embodiments, the contact surfaces of the laminating sheets, which are subjected to pressure and heat during the lamination of the material sheet booklet, are smaller than the geometric format of the material sheet booklet. Thus, only a part of the material sheet, according to embodiments, a central region of the sheet material, is laminated. The corresponding laminated area comprises the so-called benefit. This is the area of the laminated composite that corresponds to the document body made from the laminated composite for the corresponding identification, value or security document. The benefit is surrounded by a laminated area, which in turn is surrounded by an unlaminated area. Embodiments may have the advantage that the material sheet booklet protrudes laterally beyond the laminating sheets and thus prevents direct contact of the laminating sheets with one another. As a result, damage to the laminations can be avoided and their life can be increased. In addition, the risk of rejects due to damaged laminations is reduced.

The first geometric format is, in particular, a geometric format compatible for the subsequent processing steps. In ultrasonic cutting, the composite body is subjected to ultrasound and locally melted by the resulting internal friction. For this purpose, an ultrasonic cutting device, which includes a generator, a transducer or converter and a sonotrode used. The sonotrode is preferably designed as a cutting tool with a cutting edge or comprises a corresponding cutting tool. The generator generates an electrical alternating voltage, which is converted by the sound transducer into a mechanical vibration. The transducer in turn conducts the high-frequency mechanical vibrations, ie ultrasound, in the sonotrode connected to it and puts them into resonance oscillations in the ultrasonic range. Frequently, a transformation piece or booster is arranged between the sound transducer and the sonotrode, which transforms the oscillation amplitude arriving from the sound transducer and transmits it in an enlarged manner to the sonotrode. The magnitude of the resulting oscillation amplitude is influenced by the output amplitude provided by the transducer and by the respective amplification by the transformation piece and the sonotrode itself. The sonotrode, which has been placed in an ultrasonic oscillation, then transmits the ultrasonic oscillation to the composite to be cut. If the heating caused by the ultrasound-induced friction is so great that the composite body melts locally, the sonotrode can be guided through the molten material with little resistance, thereby separating it.

By applying ultrasound, the cutting resistance and thus the wear of the cutting tool are reduced. In addition, a clean separation can be produced without burr formation, since the softened plastic material contracts after cutting in the course of cooling.

Furthermore, the use of ultrasound for material separation enhances the safety of the resulting composite. Although the corresponding composite body is laminated through, but looking at the side surfaces, so are the different layers of the composite as a result of the different material sheets of the sheet material to recognize. It exists thus the risk that a suitable tool, which is flat and sharp, introduced between the layers and this can be at least partially separated despite lamination. This creates the danger of possible manipulations on the composite body or the resulting document, which comprises the composite body in the form of a document body. The melting of the material sheet 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. Furthermore, it can have the advantage that dust formation during the separation process is avoided. In the case of separation processes without ultrasound, the formation of dust always occurs due to minimal chips of brittle material, which can hinder further production and necessitate additional measures in order to dissipate the corresponding dust. In addition, embodiments may have the advantage that they are simple and inexpensive to implement. In particular, apart from a compact ultrasonic generating device, no further additional devices are needed. In contrast, for example, the use of lasers for cutting requires exhaust devices to remove the resulting gases, soot, and free radical components.

According to embodiments, the fixing of the material sheets takes place during the production of the material sheet booklet by means of ultrasonic welding. Embodiments may have the advantage that no additional material for fixing the material sheets of the material sheet booklet is needed, which later must be removed again or involves the risk of complications. In addition, this could make it possible to create the material sheet as such without additional external fixing devices. This is avoided in particular in connection with the lamination process. According to embodiments, the method further comprises: material separation by performing a second material separation process using ultrasound, such that the composite body having the geometric format for the first Document type is a composite body created with the geometric format of a second document type.

Embodiments may have the advantage that a first geometric format is provided, whereby subsequent processing steps for different types of documents can be standardized. Irrespective of the geometric format of the document type for which the composite body is intended, a uniform intermediate format is used for subsequent processing steps, which corresponds to the geometric format for the first document type. This makes it possible to uniformly design the devices for handling and transporting the composite body during further processing, and to reduce the flexibility requirements for handling different formats. The corresponding devices can thus be made mechanically simpler and thus less prone to error during use.

After executing the corresponding further processing steps, the composite is reduced to a final geometric format of a second document type, i. H. the document type for which the composite body is provided brought.

The geometric format for a first document type may in particular be a geometric format of the first document type with oversize. A corresponding format with excess is used, for example, in the production of passport data cards. This may be, for example, a format of the ID3 format in accordance with ISO / IEC 71 10. For example, the geometric format of the second document type may be the ID1 format.

According to embodiments, the composite body having the geometric shape for the first document type comprises a plurality of composite documents for individual documents in the form of partial sections which each have the geometric format of the second document type, wherein the second material separation Process from the subsections each an individual composite body is created with a geometric format of the second document type.

Embodiments may have the advantage that not only is the intermediate format used to produce the composite body unified for different document types, but also that the production of the composite body is also parallelized. The second document type may be, for example, a document type with the geometric format ID1. The geometric format for the first document type may be an excess of the geometric format ID3. In this case, a corresponding material sheet, which is dimensioned such that it comprises the excess of the ID3 format, in two sections with the format ID1 include. Thus, two corresponding composites for two identity, value or security documents of format ID1 can be created. If the material sheet booklet comprises at least one personalized material sheet, this sheet is subdivided according to embodiments into two sections with different personalization.

According to embodiments, the first material separation operation is carried out by means of a first material separation device and the second material separation process by means of a second material separation device, wherein the two material separation devices are arranged spatially spaced from each other.

Embodiments may have the advantage that initially by the first material separation process, a geometric intermediate format for further processing by means of other devices is generated. After the corresponding composite body has been further processed, the second material separation device performs the second material separation process, with which the composite body is brought from the intermediate format to an end format. According to embodiments, the intermediate format already corresponds to the end format, with no second material separation process taking place. According to embodiments, the second material separation process takes place without the use of ultrasonic welding, for example by milling. In one embodiment, the further processing includes, for example, personalization of the composite bodies. For this purpose, for example, a chip inserted in a composite body is personalized with corresponding data of the future owner. In addition, data for personalization by means of laser can be introduced into intermediate layers of the composite body.

According to embodiments, the material separation takes place by means of wedge cutting with a knife, wherein the knife is subjected to ultrasound. Embodiments may have the advantage of providing an efficient, precise and flexible separation method. Wedge cutting is understood to mean a division of a material by one or two wedge-shaped cutting edges in accordance with DIN 8588. According to embodiments, the knife has a cutting edge whose course coincides with the circumference of the geometrical format to be created.

Embodiments may have the advantage that the geometric format to be created is generated by a single cut in a spatial direction. In particular, the fact that the strong edge has the geometry of the desired format ensures that the desired format is precisely produced.

According to embodiments, a plurality of the knives are provided for a plurality of different types of documents and selected for cutting the geometrical format to be created of one of the knives whose cutting edge coincides with the geometric format to be created.

Embodiments may have the advantage of having a flexible format of composite bodies for different types of documents. In this way, in particular the second material separation process can be made more flexible. According to embodiments, the material separation takes place by guiding the knife along the circumference of the geometrical format to be created.

Embodiments may have the advantage that by guiding the knife along another circumference, it is easy to produce a composite body for another geometric format. Thus, a flexible cutting geometry is possible, which ensures in particular with regard to the required flexibility in Industry 4.0. According to embodiments, the material separation takes place by means of a plurality of knives, which each intersect along a section of the circumference of the geometrical format to be created.

Embodiments may have the advantage that the cutting process is parallelized and thus the cutting time is reduced.

According to embodiments, the geometrical format to be created is rectangular and the material separation is effected by means of two knives arranged parallel to one another with an adjustable distance from one another, wherein the material separation comprises:

Cutting along two parallel sides of the geometric format to be created with a first distance between the knives,

Setting the distance to a second distance,

• Cutting along the two remaining parallel sides of the geometric format to be created with the second distance.

Embodiments may have the advantage of allowing flexible adjustment of different geometric formats by adjusting the spacing between the blades accordingly. According to embodiments, the two blades arranged parallel to one another are rotatable, so that they can be rotated for cutting along the remaining parallels. According to embodiments, the composite body is rotatably mounted, so that it is rotated for cutting along the two remaining parallel sides by 90 °. According to embodiments, the material separation takes place by means of shear cutting with a cutting device, which comprises a cutting punch and a cutting plate, and wherein the cutting geometry of the cutting punch coincides with the geometrical format to be created.

Embodiments may have the advantage that they allow a precise generation of the document-typical geometric format to be created. Shear cutting is understood to mean a cutting of a material by two cutting edges moving past one another, for example in accordance with DIN 8288. This can be in particular punching. The fact that the generated geometry is determined by the geometry of the cutting punch and the cutting plate, the appropriate format can be precisely generated. According to embodiments, the cutting punch is subjected to ultrasound. According to embodiments, the cutting plate is subjected to ultrasound.

According to embodiments, the composite body has a first and a second surface, which extend at least partially parallel to one another, wherein the first surface is subjected to ultrasound by means of a sonotrode and wherein the knife of the sonotrode is arranged opposite to the second surface.

Embodiments may have the advantage that they allow a simple configuration of the sonotrode or of the ultrasound tool independently of the geometry of the knife. This is particularly advantageous for machining thin composite bodies.

According to embodiments, a plurality of the cutting devices are provided for a plurality of different types of documents, and for cutting the geometrical format to be created, a cutting device with a cutting punch is selected, the cutting geometry of which matches the geometrical format to be created. Embodiments may have the advantage that by changing the cutting devices different geometrical formats for different types of documents can be realized without having to give up a constant precision of the produced format made possible by the defined cutting geometry of the cutting punch.

According to embodiments, the material separation of the first material separation process by means of wedge cutting and the material separation of the second mate- rialabtrennvorgangs carried out by means of shear cutting.

Embodiments may have the advantage that the first material separation process can be made mechanically simpler and thus less error-prone, while the second material separation process, in which the final format of the composite body is produced, can be implemented with higher precision.

According to embodiments, a control device is provided which is configured to control the result of the lamination. According to embodiments, a control device is provided which is configured to control the result of the first and / or second material separation operation. According to embodiments, the control device has a camera for visually checking the results.

Embodiments may have the advantage that quality defects of the composite body can be detected early and corresponding composites can be sorted out. In particular, the risk can be reduced that personalized composites must be rejected due to lamination errors. This can be advantageous because when disposing of personalized composite body high security requirements must be met. In particular, it must be prevented that sensitive data get out. According to embodiments, the sheet of material for pressure and heat is placed between first and second lamination sheets, the two lamination sheets each having a lamination area which, when laminated, contacts a surface of the sheet of material to be laminated each of the lamination area is smaller than the surface of the sheet of material to leave an unlaminated edge portion of the sheet, and the laminated composite of the first type is made by separating material from a laminated portion of the sheet of material.

Laminatable material sheets are preferably made of thermoplastic material. If individual sheets of material do not consist of lamination-capable material, other sheets of material consisting of or at least enclosing a lamination-capable material are arranged in the sheet of material between these non-lamination sheets. These sheets connect the non-lamination sheets to the remaining sheet of material during the lamination process. Exemplary materials that make up the material sheets are polycarbonate (PC), polyvinyl chloride (PVC), polyesters, for example polyethylene terephthalate (PET), polyolefins, for example polyethylene (PE) and polypropylene (PP), acrylonitrile-butadiene-styrene Copolymer (ABS), polyurethane (PU), polyetheretherketone (PEEK) and other thermoplastically processable materials, as well as composite materials, plastic-laminated paper-like materials, such as Teslin, and others. Particularly preferred is PC. Some of the above materials can also be combined in the material sheets.

During the lamination process, the sheets of material are subjected to pressure and heat, whereby the sheets of material soften and connect with one another when the glass transition temperature is exceeded at their boundary surfaces, so that a material connection of the sheets of material is achieved. The height of the laminating pressure and in particular the laminating temperature are of the

Material type of the individual layers, their thicknesses as well as other parameters. The maximum temperature to which the laminating presses are heated is selected depending on the type of material from which the film layers are made. For example, in the case of PC and PC blends (blends of PC with other plastics), the maximum temperature may be in the range of 170-200 ° C, preferably 180-190 ° C. During the lamination process, the material sheet between the lamination presses is preferably subjected to a pressure perpendicular to the surfaces of the sheet of material. This pressure should be as large as possible so that air, which is possibly between the film layers, is pressed out when softening the layers. The pressure may be, for example, in a range of 25 to 700 N / cm ² , preferably in a range of 50 to 100 N / cm ² , 1.

Embodiments further relate to an apparatus for producing a composite body for a document type selected from a plurality of different badge, value or security document types. The device comprises:

A collating device which is configured to collate a document type-specific selection of material sheets in a document-document-specific order according to the document type,

A fixing device which is configured to produce a material sheet booklet, successively fixing the material sheet immediately following each of the collected material sheets in accordance with the document type-specific order so as to determine the relative orientation of the gathered material sheets relative to one another,

A laminating apparatus configured to produce a composite body by laminating the sheet of material sheet, wherein the sheet of material is subjected to pressure and heat in a predefined manner,

A first severing device configured to sever material by performing a first material severing operation using ultrasound to form a laminated composite body having a geometric format for a first document type.

Embodiments are configured to perform, individually or in combination with one another, all of the previously described methods of operation. According to embodiments, the apparatus further comprises a second separation device configured to separate material by performing a second material separation operation using ultrasound, such that from the composite body having the geometric format for the first document type, a composite body having a geometric format of a second document type is created ,

Embodiments of the invention will be explained in more detail below with reference to the drawings. Show it:

FIG. 1 shows a block diagram of a method for producing a composite body, FIG. 2 shows a schematic view of an exemplary apparatus for producing a composite body,

3 shows schematic views of exemplary material sheets, FIG. 4 shows schematic views of a laminated material sheet,

5 shows schematic views of exemplary geometric formats,

FIGS. 6 are schematic views of exemplary geometric formats;

FIG. 7 shows a schematic view of a first exemplary ultrasonic knife,

8 shows a schematic view of an exemplary material separation device, FIG. 9 shows schematic views of a second exemplary ultrasonic measurement device, FIG. 10 is a schematic view of an exemplary arrangement of the ultrasound meter of FIG. 9,

FIG. 11 is a schematic view of a third exemplary ultrasonic knife;

FIG. 12 shows an exemplary view of different cutting geometries of the ultrasonic knife from FIG. 11 and FIG

Figure 13 is a schematic view of an exemplary Materialabtrennvorrichtung.

Hereinafter, similar elements will be denoted by the same reference numerals.

FIG. 1 shows a block diagram of a method for producing a composite body from a plurality of different badge, value or security document types selected from the document type. In block 100, a selection of a document type is received by a central controller. The central control device comprises, for example, a microprocessor and a memory with program instructions stored therein. Applying the program instructions by the microprocessor causes the central controller and the other devices to perform the method. In block 102, a document type specific selection of material sheets in a document type specific order is compiled and a mathematical booklet is created, successively fixing each of the collated sheets of paper immediately following the sheet of material specific order according to the document type specific order, so that the relative orientation of the collated materials to each other is determined , The fixation is done for example by ultrasonic welding.

In block 104, a composite body is produced by lamination of the created material sheet, the pressure and heat being applied to the metal sheet booklet in a predefined manner. In block 106, a first material separation process is performed in which, using ultrasound, a composite of a geometric format of a first type of document is created. In block 108, a quality control of the lamination of the block 104 takes place, for example by a visual inspection with a camera.

In block 1 10, a personalization of the generated body takes place, for example by introducing person-specific or document-type-specific information onto a chip encompassed by the composite body. Further, the personalization in block 1 10 may include, for example, describing the layers of the composite body with a laser. If the composite body with the geometric format for a first document type comprises a plurality of composite bodies which are provided for a second document type with a second geometric format, individual personalization of the individual composite bodies takes place independently of one another. In block 1 12 there is a quality control of the composite body, which may include, for example, both a visual control of the outer state of the composite body as well as a control of the functions of the composite body. In block 1 14 it is checked whether the composite body already has the intended end format. If the composite body produced is a composite body for the first document type, which therefore already has the intended final format, then the finished composite body is stored in block 120.

If the composite body created is not a composite body for the first type of document, then in block 16, a second material separation operation, such as shear cutting, is performed, bringing the composite body to its final format, ie, the geometric format of the second document type. In block 1 18, a quality control of the second material separation process takes place, which comprises, for example, a visual inspection of the external state of the resulting composite body or of the resulting composite bodies. The composite body comprises a plurality of composite bodies of the geometric format of the second document type, a plurality of composite bodies are accordingly produced and stored in block 120.

FIG. 2 shows a schematic view of an exemplary device 200 for producing a composite body by means of the method according to FIG. 1. The device 200 is controlled by a central controller 218. The apparatus includes a collating apparatus 202 that is configured to collate a document type specific selection of material sheets in a corresponding document type specific order. In addition, the assembly device 202 comprises a fixing device. The fixing device is configured to create a material sheet booklet, wherein each of the collated sheets of material according to the document-type-specific order immediately succeeding material sheet is fixed successively, so that the relative orientation of the collated sheets of material is set to each other. The fixing device is, for example, a device for ultrasonic welding.

In ultrasonic welding, the sheets of material are subjected to ultrasound and joined together by the resulting internal friction in the joining zone. For this purpose, an ultrasonic welder, consisting of a generator, a transducer or converter and a sonotrode, used. The generator generates an electrical alternating voltage, which is converted by the sound transducer into a mechanical vibration. The transducer in turn conducts the high-frequency mechanical vibrations, ie ultrasound, in the sonotrode connected to it and puts them into resonance oscillations in the ultrasonic range. Frequently, a transformation piece or booster is arranged between the sound transducer and the sonotrode, which transforms the oscillation amplitude arriving from the sound transducer and transmits it in an enlarged manner to the sonotrode. The magnitude of the resulting oscillation amplitude is influenced by the output amplitude provided by the transducer and the respective gain by the transformation piece as well as the sonotrode itself. The ultrasonic vibrated sonotrode then transmits the ultrasonic vibration under pressure to one of the two sheets of material to be joined. If the material sheets to be joined come into contact with each other between the two material sheets, in the so-called joining or welding zone, they cause boundary surface friction and thus local heating of the boundary surfaces. If the heating is so great that the interfaces melt, welding of the two material sheets occurs. Through the sonotrode, the two sheets of material are pressed together during welding. Ultrasonic welding allows the creation of a welded joint with a short welding time, as the welding energy is limited to almost the joining zone. This allows accurate welding without affecting other areas of the material sheet.

If in the present case the presence of one or more ultrasound sonotrodes is described, it is understood that the sonotrode is provided by a corresponding ultrasound tool, which for the intended use of the sonotrode at least also includes a generator and sound transducer, possibly also a transformation piece. The laminator 204 is configured to produce a composite by laminating the sheet of material, with pressure and heat applied to the sheet of material in a predefined manner. The severing device 206 is configured to separate material of the composite body by performing a first material separation operation using ultrasound, thereby creating a laminated composite body having a geometric format of a first type of document. The first separating device comprises, for example, an ultrasonic knife for wedge cutting. The result of the lamination or the quality is checked by a control device 208, for example visually by means of a camera. If all predefined quality requirements are met, the composite body is processed further. Personalization device 210 is for personalization of the generated composite. If the personalized composite body already has the desired final format, then a magazine 216 is introduced for the finished products. If the personalized composite does not yet have the desired final format, it is transported to device 212. The device 212 is a second material severing device, which optionally places the geometrical format of the first document type on geometric formats of a second document type. For example, the second material separation device for separating material by means of ultrasound comprises a device for ultrasonic cutting. The result of the second material separation process is checked by the control device 214, for example visually by means of a camera. If all predefined quality requirements are met, the composite body is forwarded to the magazine 216. FIG. 3A shows a material sheet booklet 300 which comprises a plurality of material sheets 302 which are each firmly welded by ultrasonic welding in the region of the joining zone 304 to the material sheet following the document type-specific sequence. Firmly welded means that the material sheets can not be separated from each other without destroying them.

FIG. 3B shows a view of the sheet of material 300 perpendicular to the top. In the corner regions is in each case a joining zone 304 of the ultrasonic welding, which is shown dotted. The joining zones 304 may, for example, be four point-shaped or circular or rectangular regions, for the production of which sonotrodes with circular or rectangular shapes are used

Welding surfaces were used. Embodiments may vary in shape and diameter in the welded regions 304, depending on the shape of the ultrasound sonotrodes used. According to embodiments, material sheets 302 may include benefits for any number of documents of the same document type. This has the advantage that the creation of material sheets for multiple ID, value or documents can be parallelized. Thus, the efficiency and in particular the speed of collation and creation can be increased. FIG. 4A shows a side view and FIG. 4B shows a top view of a laminated material sheet booklet 300 of FIG. 3. The material sheet booklet 300 has a central laminated area 402. The laminated portion comprises a portion 404 of the composite which corresponds to a geometric format for a document type to be created and is referred to as a benefit.

FIG. 5A shows a first exemplary laminated material sheet booklet 300 comprising a laminated region 402. The laminated region 402 comprises a utility 502 which corresponds to a geometric format for a first document type. In the illustrated embodiment, the geometric format for the first document type is an excess of the exact geometric format 504 of the first document type. FIG. 5B shows the composite body resulting from the first material separation process whose geometrical format 502 is the oversize format for the first document type.

FIG. 6A shows the schematic view of an exemplary second material sheet 300. The sheet of material 300 has a laminated portion 402 having a utility 502 with the geometric format for a first type of document. The benefit 502 comprises two partial benefits 602, each corresponding to a composite of a geometric format of a second type of document. Figure 6B shows the benefit 502 after the first material separation operation. Figure 6C shows the two resulting composites 602, each corresponding to a document body of a second document type. FIG. 7 shows a schematic view of an exemplary first ultrasonic knife 700 for wedge-cutting the composite body with ultrasound. The ultrasonic knife 700 comprises a generator 702, a sound transducer 704, a transfer tion piece 706 and a knife-shaped sonotrode 708. The generator generates a high-frequency electrical alternating voltage, which is converted by the sound transducer 704 in a mechanical vibration of the same frequency. The sonic transducer 704 transmits the ultrasonic vibration to the sonotrode 708 tuned to the same frequency and causes it to resonate. If necessary, the vibration amplitude can be enhanced by incorporating a transformation piece 706 between transducer 704 and sonotrode 708. FIG. 8 shows a schematic view of an exemplary material severing device for wedge cutting, which comprises the ultrasonic knife 700 from FIG. The ultrasonic cutting device 800 is implemented in the form of a robot arm 802, at the freely movable end 804 of which the ultrasonic knife 700 is arranged. The ultrasonic cutting device 800 is arranged, for example, with the attachment 806 over the composite body to be processed so that the cutting sonotrode 708 can be guided along the circumference of the geometric format to be produced and cuts.

FIG. 9A shows a schematic view of an exemplary second ultrasonic knife 900. The ultrasonic knife 900 comprises a generator 902, a

Sound transducer 904, a transformation piece 906 and a sonotrode 908. The exemplary sonotrode 908 is a rectangular stage with two slots, i. Slots whose end converges to a cutting edge 910. Figure 9B shows a side view of the ultrasonic knife 900 of Figure 9A.

FIG. 10 shows a schematic arrangement of two ultrasonic blades 900, 900 'from FIG. 9A. The two ultrasonic blades 900, 900 'are arranged so that the two cutting edges 910, 910' are parallel to each other. The distance between the two cutting edges 910, 910 'is adjustable. The dashed lines show the two ultrasonic sonotrodes 900, 900 'with a second distance A2 between the two cutting edges 910, 910'. To create a rectangular format, the first distance is used, for example, the long sides of the format while the second distance A2 is used to cut the transverse sides. According to one embodiment, the two ultrasonic blades 900 are rotatable, for example by 90 °. The cutting of the transverse sides takes place, for example, after a corresponding 90 ° rotation. According to another embodiment, a 90 ° rotation of the cutting edges 910, 910 'relative to the composite body is effected by a corresponding rotation of the composite body.

1 1 shows a schematic view of an exemplary third ultrasonic knife 1 100. The structure of the ultrasonic knife 1 100 essentially corresponds to the structure of the ultrasonic knife of Figures 7 and 9. Essentially differs thereby the sonotrode 1 102. The sonotrode includes 1 102 a circumferential cutting edge 1 104, whose course coincides with the circumference of the geometric format. The blade is inserted into the composite body 300 in a direction perpendicular to the surface, thereby cutting out the geometric format to be created.

FIG. 12 shows different geometric shapes of cutting edges and embodiments of the ultrasonic knife 1 100. The course of the illustrated FIG

Cutting edges 1 104, 1 104 ', 1 104 "corresponds, for example, to an excess of a geometric format of a first document type 1 104, a geometric format of the first document type 1 104' and a geometric format of a second document type 1 104". Finally, FIG. 13 shows an ultrasonic cutting device 1300 for the ultrasonic cutting of a composite body 300 by means of shear cutting. The cutting device 1300 comprises a cutting punch 1302 with a cutting edge 1304, the course of which coincides with the circumference of the geometrical format to be created. In addition, the device 1300 includes a cutting plate 1304 with a recess 1306, whose circumference with that of the geometric to be created

Format matches. The cutting punch is moved vertically down into the recess 1306, so that the geometric format to be created from the Composite body 300 by the shearing action of the cutting edge 1304 of the

Cutting punch 1302 and the edge 1308 of the recess 1306 of the cutting plate 1304 is generated.

Numeral 1 iste

contraption

Assembler

laminating

cut-off

control device

Personalisiervorrichtung

cut-off

control device

magazine

control device

Material sheet stitching

material sheet

welding area

Laminationsbereich

geometric format with oversize geometric format

geometric format

ultrasonic knife

generator

transducer

transformation pieces

sonotrode

cut-off

robot arm

free moving end

fastener

, 900 'ultrasonic knife

'908' sonotrode

, 910 'cutting edge 912 slot

1100 ultrasonic knife

1102 sonotrode

1104, 1104 'cutting edge

1104 "cutting edge

1300 ultrasonic tool

1302 cutting punch

1304 cutting edge

1306 insert

1308 recess

1310 inner edge

Claims

Patent claims

1 . A method of manufacturing a composite body for one of a plurality of different badge, value or security document types

Document type,

the method comprising:

Collecting a document type specific selection of material sheets (302) in a document type specific order,

· Producing a material sheet booklet (300), wherein each of the immediately following according to the document type specific order material sheet (302) is successively fixed to each of the collated sheets of material (302), so that the relative orientation of the collated sheets of material (302) is set to each other,

· Producing a composite by laminating the sheet of material (330), wherein the sheet of material (300) is subjected to pressure and heat in a predefined manner,

• Disconnect material by performing a first material separation process using ultrasound to create a laminated composite with a geometric format (502) for a first document type.

2. The method of claim 1, wherein the method further comprises:

Separating material by performing a second material separation process using ultrasound, such that from the composite body (502) for the first document type, a composite body having the geometric format (504, 602) of a second document type is created.

3. The method of claim 2, wherein the composite body with the geometric format (504) for the first document type comprises a plurality of composite documents for individual documents in the form of subsections, each having the geometric format of the second document type, wherein by the two - Matenalabtrennvorgang is created from the sections each an individual composite body with a geometric format (602) of the second document type.

4. The method according to any one of claims 2 or 3, wherein the first material separation operation by means of a first Materialabtrennvorrichtung (206) and the second Materialabtrennvorgang by means of a second Materialabtrennvorrichtung (212) is performed, wherein the two Materialabtrennvorrichtungen are arranged spatially spaced from each other.

5. The method according to any one of the preceding claims, wherein the material separation by means of wedge cutting with a knife (700, 900, 900 ', 1 100), wherein the knife (700, 900, 900', 1 100) is subjected to ultrasound.

6. The method of claim 5, wherein the knife (1 100) has a cutting edge (1 104, 1 104 ', 1 104 "), whose course coincides with the circumference of the geometric format to be created (502, 504, 602).

The method of claim 6, wherein a plurality of the knives (1100) is provided for a plurality of different document types, and for

Cutting the created geometrical format of one of the knives (1 100) is selected, the cutting edge with the geometric format to be created (502, 504, 602) matches.

8. The method of claim 5, wherein the material separation is performed by guiding the knife (700) along the circumference of the geometric format to be created (502, 504, 602).

9. The method of claim 5, wherein the material separation is by means of a plurality of knives (900, 900 ') each intersecting along a portion of the circumference of the geometric format to be created (502, 504, 602).

10. The method of claim 9, wherein the geometric format to be created (502, 504, 602) is rectangular and the material separation by means of two mutually parallel knives (900, 900 ') with an adjustable distance (A1, A2) to each other, wherein the Material separation includes:

Cutting along two parallel sides of the geometric format (502, 504, 602) to be created with a first distance (A1) between the knives (900, 900 '),

Setting the distance to a second distance (A2),

Cutting along the two remaining parallel sides of the geometric format to be created (502, 504, 602) with the second distance

(A2).

1 1. Method according to one of claims 1 to 4, wherein the material separation by means of shear cutting with a cutting device (1300), which comprises a cutting punch (1302) and a cutting plate (1306), and wherein the

Cutting geometry (1304) of the cutting punch (1302) with the geometric format to be created (502, 504, 602) matches.

12. The method of claim 1 1, wherein the cutting punch (1302) is applied to ultrasound.

13. The method of claim 1, wherein a plurality of cutting devices is provided for a plurality of different types of documents, and a cutting device for cutting the geometric shape to be created is a cutting device (1300). is selected with a cutting punch (1302) whose cutting geometry (1304) coincides with the geometric format (502, 504, 602) to be created.

14. The method of claim any one of claims 5 to 13, wherein the material separation of the first material separation operation by means of wedge cutting and the material separation of the second material separation process by means of shear cutting done.

A method according to any one of the preceding claims, wherein a control device (208) is provided which is configured to control the result of the lamination.

A method according to any one of the preceding claims, wherein a control device (208, 214) is provided which is configured to control the result of the first and / or second material severing operation.

A method according to any of claims 15 or 16, wherein the control device (208, 214) comprises a camera for visually checking the results.

18. The method of claim 1, wherein the material sheet for pressure and heat application is interposed between first and second lamination sheets, the two lamination sheets each having a lamination portion which is laminated with a surface of the sheet material to be laminated wherein the area of the lamination area is in each case smaller than the surface of the material sheet, leaving an unlaminated edge region of the material sheet, and wherein the laminate composite with the geometric format for the first type of document by the material separation from a laminated portion of the Material sheet booklet is created.

19. A device (200) for producing a composite body for a document type selected from a plurality of different badge, value or security document types,

the device comprising:

A collating apparatus (202) configured to collate a document type specific selection of material sheets (302) in a document type specific order according to the document type,

A fixing device (204) which is configured to produce a sheet of material sheets (300), wherein successively at each of the compiled NEN sheets of material (302) each of the immediately following according to the document type specific order material sheet (302) is fixed so that the relative orientation of the collated material sheets (302) to each other,

a laminator (206) configured to produce a composite by laminating the sheet of material (300), wherein the sheet of material (300) is pressurized and heated in a predefined manner,

a first severing device (210) configured to sever material by performing a first material severing operation using ultrasound, thereby forming a laminated composite body having a geometric format (502) for a first type of document.

20. The apparatus of claim 19, wherein the apparatus further comprises a second separator (212) configured to separate material by performing a second material separation operation using ultrasound, such that the composite body of geometric shape (502) for the first document type is a composite body having a geometric format (504, 602) of a second document type.