WO2024069199A1

WO2024069199A1 - Method and apparatus for producing a multilayer card with a window element and such card

Info

Publication number: WO2024069199A1
Application number: PCT/HU2023/050063
Authority: WO
Inventors: Markku Olavi JOKELA; Zsuzsanna HALABRIN; Krisztina SOMLÓ-FINTA
Original assignee: Pénzjegynyomda Zrt.
Priority date: 2022-09-28
Filing date: 2023-09-26
Publication date: 2024-04-04

Abstract

The invention discloses a method, apparatus for producing a multi-layered card with a window element (2). For the method at least one sheet (10) of a transparent film (4) provided with collating marks (11) is arranged on a flat surface, then at least one sheet (10) containing an opaque core film (1,1a, lb) provided with collating marks (11) and with an opening (5) bounded by an edge (P) is placed on the film (4), placing a transparent window element (2) into the opening (5. Determining photometrically the coordinates (X,Y) of at least two collating marks (11) arranged on the core film (1,1a, lb), determining photometrically the coordinates (X,Y) of at least two collating marks (11) printed on the sheet (10) of the transparent film (4), and changing the coordinates (X,Y) of the collating marks (11) by displacing the sheets (10) until the corresponding coordinates (X,Y) match, and welding the window element (2) to the transparent film (4). The invention also disclose a card (K) produced.

Description

Method and apparatus for producing a multilayer card with a window element and such card

The invention relates to a method for producing a multi-layered card with a window element, the method comprises the steps of: arranging at least one sheet of a transparent film provided with collating marks on a flat surface, then at least one sheet containing an opaque core film provided with collating marks and with an opening bounded by an edge is placed on the film, placing a transparent window element into the opening and placing at least one additional transparent film on the core film, and matching the collating marks arranged on the sheets of the film and the core film, respectively, and laminating the sheets such assembled to each other, then cutting the card out from the laminate along the edge. The invention also discloses an apparatus suitable for the production of a multilayer card with a window' element, in which a sheet assembling bench with a flat surface is arranged, and a multilayer card with a window element, which has a core layer and at least one film layer on both opposite sides of the core layer. In a preferred embodiment the card according to the invention is a data sheet of a document formatted as a booklet.

The card-format documents, data sheets of documents formatted as a. booklet, identity cards, bank cards that are in use today usually contain information suitable for identifying personal or financial data of the owner. The protection of such documents and the data, printed on them against forgery is achieved by using special security printing technologies during card production, by using elements with security properties, e.g. they special graphics, prints made with special paints, various holographic elements, and other protecting means, which cannot be produced without the necessary complex technological background. In particular, the protection of photographs and personal data, but also the protection of the document and its production itself against copying, is an extremely important goal. The more special and unique the tool or procedure required to produce the document, the more difficult is to copy and forge it. The removal of the personalized part of the card in whole or in part is counterworked by the security elements placed in the affected area, or e.g. personalized data is duplicated in one or more fields with special security features. The transparent areas, the so-called windows on the card making significantly difficult to change personal data are considered to be a. very strong line of defence given that both sides of the card’s transparent layers are visible in the transparent area, so e.g. no trace of data removal or masked data can disappear without any trace. The print placed on the transparent film layer of this type of card having a print in the place of the window element is discontinuous, in this area the card remains transparent in the vicinity of the print. Cards can contain several layers laminated on top of each other.

Card-format documents are usually made of PVC (polyvinyl chloride) or PC (polycarbonate), while in the case of booklet-format documents, the data page containing personal data is produced using other materials, e.g. it can also be done with paper. The different layers of PVC-based cards are combined by gluing and lamination at a temperature of around 120 °C. Their significant disadvantage is that their relatively soft base material makes the cardformat document vulnerable to damage, therefore, in the case of high-security documents, preference is given to polycarbonate base material, whose physical and chemical resistance exceeds that of PVC, thus ensuring the long-term durability of the documents, with even more than 10 year service life. However, this does not mean a significant increase of the brittleness and fragility of the material, as a result more durable documents can be made from polycarbonate.

The already mentioned transparent areas or windows used among the security elements of card-format documents are formed by ink-free areas formed on a print applied to a transparent film. The lamination of cards made of polycarbonate film layers requires a higher temperature of around 180 °C instead of the 120 °C used in the case of PVC, but at this temperature, the dye material of the print applied to the layers may crack and become discoloured, resulting in an irreparable manufacturing defect. Such a security element is described in US 2011139024 A1 published patent application, where a security element of window element type is built into the data carrier, such as security paper, share, bond, voucher, document, banknote, or chip card. The card body has a core layer that is laminated between a top and bottom opaque substrate layer. The safety function is provided by a transparent insert built into the core layer. Open and hidden print elements are printed on the upper and lower surfaces of the upper substrate layer, according to the transparent insert. The hidden print element is only visible through the insert by illuminating the partially light-transmitting upper layer. Preferably, the open and hidden print elements are closely embedded into each other that make it difficult to reproduce the resulting harmonized image without authorization. However, the description of the solution avoids the question of how the transparent insert can be securely held in place during production, after being inserted, without moving or falling out. As a solution to the problem, we find a hint in the description that the transparent insert can be omitted, but in this case, the thickness of the core layer containing the window, must be significantly reduced from e.g. 305 pm, so the card loses its strength.

Our objective is therefore to develop a laminated PC (polycarbonate) window card having a window' that, in addi tion to the required temperature of lamination can also be produced safely and without printing errors, while during its production the transparent insert can be held reliably in place, and it is not necessary to reduce the usual thickness of the core layer, thus maintaining the appropriate strength of the card.

We have realized that if the polycarbonate card is produced by laminating an opaque or even coloured core film having an opening of the appropriate shape in the place of a window element, with a window element or insert in the window, and transparent cover films, instead of using a transparent core film printed with a layer of paint having an incomplete area in the place of the window, and the transparent insert is fixed reliably after its insertion, we do not have to worry about the state of the art destruction of the dye material of the print surrounding the window, nor the displacement of the insert neither during procedural material handling nor at the high temperature of lamination, while the original card thickness can be maintained. The structure of PC-based cards according to the invention does not contain adhesives, and they may even contain several opaque, mostly white core films, transparent cover films, RAM chips capable of carrying data, and further layers containing other security elements.

We achieved our object by developing a method for producing a multi-layered card with a window element, the method comprises the steps of: arranging at least one sheet of a transparent film provided with collating marks on a flat surface, then at least one sheet containing an opaque core film provided with collating marks and with an opening bounded by an edge is placed on the film, placing a transparent window element into the opening and placing at least one additional transparent film on the core film, and matching the collating marks arranged on the sheets of the film and the core film, respectively, and laminating the sheets such assembled to each other, then cutting the card out from the laminate along the edge, then determining photometrically, during matching the collating marks and after placing the core film, the coordinates of at least two collating marks arranged on the core film, and then determining photometrically the coordinates of at least two collating marks printed on the sheet of the transparent film, corresponding to the at least two collating marks arranged on the core film, and changing the coordinates of the collating marks by displacing the sheets until the corresponding coordinates match, the core film is attached to the film by ultrasonic welding, then determining photometrically the coordinates of the points forming the edge of the opening, rotating the transparent window element to a position determined by the coordinates of points and placing it into the opening, then welding it to the transparent film using ultrasonic spot welding, and placing at least one transparent film on the sheet of the core film, and attaching the film to the core film by ultrasonic welding.

Determining photometrically the coordinates of at least two collating marks printed on the sheet of the transparent film, corresponding to the at least two collating marks arranged on the core film, and changing the coordinates such determined, as well as the coordinates of the collating mark arranged on the core film by displacing the sheets until corresponding coordinates match.

Arranging a transparent film on the flat surface before arranging the sheet of the transparent film thereon.

Placing an additional transparent film on the transparent film and attaching it to the film by ultrasonic welding.

Placing an insert layer between the core films.

Our object is also achieved by an apparatus for producing a multilayer card equipped with a window element, having a sheet assembling bench, and provided with a assembling head movable above the bench in all directions and rotatable around its axis, the assembling head having a suction cup coaxially with the axis and connected to an air rarefaction device and an ultrasonic welding head for fixing the core film to the film by ultrasonic welding, and the an upper camera is attached to the assembling head, a lower camera is located under the surface of the bench, the cameras and the assembling head are connected to a control unit, and suction cups suitable for connecting to an air suction device are embedded in the surface of the bench.

The apparatus is provided with a bench for storing the window element during production.

The present invention also provides a multi-layered card with a window element containing an opaque core layer made of polycarbonate film, in which an opening is formed, and a transparent or translucent window element in the shape equal to the shape of the opening is arranged in the opening, and the window element is attached to the transparent film layer in the opening by means of at least one ultrasonic spot-welded seam.

The layer of transparent film is attached to the core film by lamination.

The card according to the invention can be a data sheet of a document provided as a booklet.

The invention will be described in detail below with reference to the attached drawing. In the drawing

Figure 1 shows a preferred embodiment of the card with window according to the invention in cross-section,

Figure 2 shows a cross-section of another suitable multi-layered embodiment card with window according to the invention,

Figure 3 shows an embodiment of a sheet of core film printed and provided with collating marks in top view, the

Figure 4 shows a seam formed by ultrasonic spot welding, and

Figure 5 shows a schematic, side elevational view of the sheet assembling apparatus suitable for producing cards according to the invention. Figure 1 shows the simplest embodiment of the card K provided with a window according to the invention in cross-section. In this embodiment, the card K contains a single opaque core film 1 made of polycarbonate, hereinafter referred to as PC, in an opening 5 of which there is a transparent or translucent window element 2 of the shape corresponding to the shape of the opening 5, the material of which is also PC. The window element 2 is fixed with at least one spot-welded seam H in the opening 5, which is created by ultrasonic welding. The number of seams H is at least one, and its task is to prevent the window element 2 from moving out of the opening 5. Transparent film layers 3,4 are arranged on both surfaces 13,14 of the core film 1. Instead of gluing, the film layers 3.4 are attached to the core film 1 by lamination at a temperature of 180 °C.

Figure 2 shows a cross-section of a more complex, seven-layer embodiment of the card K according to the invention. In this embodiment, a window element 2 is cut out of a transparent film, which fits into the openings 5 cut in an opaque core film 1a with appropriate shape. The displacement of the window element 2 from the opening 5 is prevented by the ultrasonic welding seam H created between the window element 2 and at least the film 4. In the illustrated embodiment, two or more opaque core films 1a, 1b are used, on the surfaces 13, 14 of which a print is formed in advance. Between the core films 1a, 1b, data carrier C, e.g. insert layer I containing a chip can be placed. The combined thickness of the films 1a, 1b and the insert layer

1 is the same as the thickness of the 2 window element and contains an opening 5 of the size and shape corresponding to the window element 2. A transparent film 4 is placed on the surface 14 of film 1b. If it becomes necessary to place a safety feature known in the art on the film 4, e.g. a print made with security paint or possibly a holographic element, the film 4 is covered with an additional transparent film 7. Similarly, the surface 13 of the film 1a is covered by at least one transparent film 3, on which an additional transparent film 9 can be applied. Both surfaces of the sheet 10 made of PC material containing the core film 1 shown in Figure 1 can be printed as desired, and collating marks 11 are placed on the edges of the sheet 10, e.g. by printing. A preferred embodiment of the sheet 10 of the core film 1 printed and provided with collating marks 11 can be seen in Figure 3 in a top view. At least one opening 5 in a predetermined position is formed by cutting out the core film 1 within the core film 1 areas marked on the sheet 10. The core film 1 is arranged on the film 4 of the core film 1a, 1b or e.g. on film 4,7, and a window element 2 cut out of a transparent film with a surface corresponding to the opening 5 and having the thickness equal to the thickness of the core film 1 or e.g. to the combined thickness of the core films 1a, 1b are placed in each opening 5. The window element

2 is attached to the film 4 with an ultrasonic spot-welded H seam in at least one location, e.g. as shown in Figure 4. Of course, it is also possible to produce several H seams on the surface of the window element 2 in order to fix the window elements 2. Thus, the window element 2 is properly attached to the film 4, preventing it from moving out of the opening 5.

1. The sheet assembling apparatus according to the invention suitable for the production of cards K according to the invention is shown schematically in Figure 5 in a side elevational view. The apparatus has a sheet assembling bench 15, onto which sheets 10 arrive from a feeding direction A, and an assembling head 19 movable above the bench 15 in directions X,Y,Z and rotatable around its axis T is arranged, the assembling head 19 has a suction cup 19a coaxially with the axis T connected to an air suction device and an ultrasonic welding head 9b for fixing the core film 1, 1a, 1b to the transparent film 4 by ultrasonic welding, where direction Z is perpendicular to the surface 16 of the bench 15. An upper camera 18f is attached to the assembling head 19. A lower camera 18a is located under the plane S of the bench 15, suitable for recognizing collating marks 11. The cameras 18a, 18f and the assembling head 19 are connected to a control unit CPU aimed to control of collating the sheets 10 and making the welding spots H. Suction cups 17 connected to an air suction device not shown in Figures, but known per se, are embedded in the surface 16 of the bench 15. So, any sheet 10 placed on the surface 16 can be fixed by vacuum suction. Using the camera 18f arranged on the connecting head 19 the CPU unit recognizes both the opening 5 for placing the window element 2 and collating marks 11. An integral part of the collating unit is the lower position camera 18a monitoring collating marks facing downward and arranged after a cleaning equipment below the plane S of the bench 15 and outside the cover of the bench 15.

The K card according to the invention can be produced by the method according to the invention, preferably by means of the apparatus according to the invention. The method is described in detail by presenting the production of the card K shown in Figures 1 and 2. For the method, a window element 2 is cut out from a transparent plastic film made of PC material having a thickness equal to the thickness of the core film 1 or to the combined thickness of more, e.g two films 1a, 1b, to be preferably stored it on tray 16a (Figure 5).

During the production of the preferred embodiment of the card K according to the invention shown in Fig. 1 at least one transparent, possibly printed film 4 is placed on the bench 15 in the feeding direction, and then at least one core film 1 containing openings 5 is placed on the film 4. Making the collating marks 11 arranged on the sheets 10 of the printed film 4 and the core film 1 overlapped by photometrically determining the X,Y coordinates of the 11 collating marks arranged on the core film 1, preferably by moving the camera 18f over the collating marks 11 arranged on the core film 1, the X,Y coordinates of the camera 18f are transmitted to the CPU unit comparing it with the X,Y coordinates of the camera 18a located under the collating mark 11 printed on the sheet 10 of the film 4 corrected by the position of the camera 18f If the coordinates are the same for at least two pairs of collating marks 11, the sheets 10 of the core film 1 and the film 4 are in the correct position. In the event of any discrepancy, the relative position of the sheets 10 of core film 1 and film 4 is changed until the coordinates match. After that, the core film 1 is attached to the film 4 by ultrasonic welding, preferably by means of the ultrasonic welding head 19b, then moving the assembling head 19 in the directions X and ¥ over the already cut window element 2 grasped by moving the suction cup 19a arranged on the head 19 in the direction Z, and moving it to the position above the opening 5 determined by the CPU unit based on the image of camera 18f. If the window element 2 and the opening 5 are not circular, the suction cup 19a is rotated to the appropriate position around the T axis and inserted it into the opening 5, then welded to the film 4 by spot welding by the ultrasonic welding head 19b in the position shown in Figure 4. After that, at least one transparent, e.g. printed film 3, is placed and attached to the core film 1 by ultrasonic welding, preferably at the R points shown in Fig. 3 with the welding head 19b. Sheets 10 fixed to each other in this way and equipped with 2 windows are laminated at the lamination temperature of polycarbonate, approx. 180 °C, then the cards K are cut out of the sheet 10 along the edges P.

During producing of the preferred embodiment of the card K according to the invention as shown in Figure 2, a sheet 10 of the transparent film 7 are fixed, preferably on the bench 16, then the 10 sheet of transparent film 4 provided optionally with prints, and then core films 1a, 1b containing 5 openings are placed on the film 7. The collating marks 11 arranged on the sheets 10 of the printed film 4 and the core film 1a, 1b are overlapped with each other, preferably by moving the camera 18f over the collating marks 11 arranged on the core film 1a, the X,Y coordinates of the camera 18f are transmitted to the CPU unit, which compares it with the X,Y coordinates corrected by the position of the camera 18f in relation to the camera 18a located under the collating marks 11 printed on the sheets 10 of the core film 1b and the film 4. If the coordinates X, Y of three collating marks 11 located above each other are the same for at least two such triplets of collating marks 11, the core films 1a, 1b and the sheets 10 of film 4 are in the correct position. In the event of a discrepancy, the relative position of the sheets 10 of core films 1a, 1b and of film the film 4 is changed until the coordinates match. After that, the core films 1a, 1b are attached to the sheets 10 of the films 4, 7 by ultrasonic welding, preferably with the ultrasonic welding head 19b, preferably at the points R shown in Figure 3, and then the assembling head 19 is moved in X,Y directions over the window element 2 already cut out, by moving the suction cup 19a arranged on the assembling head 19 in the Z direction, grabbing the window element 2 and moving it into the position of coordinate X, Y determined by the CPU unit based on the image of the camera 18f, above the opening 5 that is now precisely collated on the 10 sheets of the core film 1a, 1b. If the window element 2 and the opening 5 are not circular, the suction cup 19a is rotated to the appropriate position around the T axis, it is inserted into the opening 5 by moving the assembling head 19 in the Z direction and welded to the core film 1a ,1b by spot welding by means of the ultrasonic welding head 19b in the position shown in Figure 4. After that, one or more transparent film 3,9 e.g. provided with a print is placed on the core film 1a and attached to the core film 1a by ultrasonic welding, e.g. using the welding head 19b. An additional insert layer I is also arranged between the core films 1a, 1b, which may contain e.g. a microchip and an antenna loop. The layers made of PC material such fixed relatively to each other containing sheets 10 of at least three, preferably more, advantageously two opaque core films 1a, 1b provided with at least one window 2, and insert layer I, and transparent films 4, 7, 3, 9 are combined by lamination at the lamination temperature of polycarbonate approx. 180 °C, and then the cards K are cut out of the sheets 10 along the edges P.

The advantage of the card K - or the data sheet of a document of booklet format - according to the invention, he apparatus and method for producing the same is that in comparison to solutions according to the state of the art that the card K can be produced safely and without printing errors even at the required temperature of lamination, while the transparent window 2 element can be held in place reliably during its production, and it is not necessary to reduce the usual thickness of the core film 1, 1a, 1b, thereby maintaining the appropriate strength of the card K.

Claims

1. Method for producing a multi-layered card (K) with a window element (2), the method comprises the steps of: arranging at least one sheet (10) of a transparent film (4) provided with collating marks (11) on a flat surface, then at least one sheet (10) containing an opaque core film (1,1a, 1b) provided with collating marks (11) and with an opening (5) bounded by an edge (P) is placed on the film (4), placing a transparent window element (2) into the opening (5) and placing at least one additional transparent film (3) on the core film (1,1 a, 1b), and matching the collating marks (11) arranged on the sheets (10) of the film (3,4) and the core film (1,1a, 1b), respectively, and laminating the sheets (10) such assembled to each other, then cutting the card (K) out from the laminate along the edge (P), characterized by, determining photometrically, during matching the collating marks (11) and after placing the core film (1,1a, 1b), the coordinates (X,Y) of at least two collating marks (11) arranged on the core film (1,1 a, 1b), and then determining photometrically the coordinates (X,Y) of at least two collating marks (11) printed on the sheet (10) of the transparent film (4), corresponding to the at least two collating marks (11) arranged on the core film (1, 1a, 1b), and changing the coordinates (X,Y) of the collating marks (11) by displacing the sheets (10) until the corresponding coordinates (X,Y) match, the core film (1,1a, 1b) is attached to the film (4) by ultrasonic welding (H), then determining photometrically the coordinates (X, Y) of the points forming the edge (P) of the opening (5), rotating the transparent window element (2) to a position determined by the coordinates of points (P) and placing it into the opening (5), then welding it to the transparent film (4) using ultrasonic spot welding, and placing at least one transparent film (3) on the sheet (10) of the core film (1,1 a, 1b), and attaching the film (39 to the core film (1,1 a, 1b) by ultrasonic welding.

2. The method according to claim 1 for producing a multilayer card (K) with a window element, characterized by determining photometrically the coordinates (X,Y) of at least two collating marks (11) printed on the sheet (10) of the transparent film (3), corresponding to the at least two collating marks (11) arranged on the core film (1, 1a, 1b), and changing the coordinates (X,Y) such determined , as well as the coordinates (X,Y) of the collating mark (11) arranged on the core film (1, 1a, 1b) by displacing the sheets (10) until corresponding coordinates (X,Y) match.

3. The method according to claim 2 for producing a multilayer card (K) with a window element, characterized by arranging a transparent film (7) on the flat surface before arranging the sheet (10) of the transparent film (4) thereon.

4. The method according to claim 3 for producing a multilayer card (K) with a window element, characterized by placing an additional transparent film (9) on the transparent film (3) and attaching it to the film (3) by ultrasonic welding.

5. The method according to claim 4 for producing a multilayer card (K) with a window element, characterized by placing an insert layer (I) between the core films (1a, 1b).

6. Apparatus for producing a multilayer card (K) equipped with a window element (2), having a sheet assembling bench (15), characterized in that it is provided with an assembling head (19) movable above the bench (15) in directions (X,Y,Z) and rotatable around its axis (T), the assembling head (19) having a suction cup (19a) coaxially with the axis (T) and connected to an air rarefaction device and an ultrasonic welding head (19b) for fixing the core film (1,1a, 1b) to the film (4) by ultrasonic welding, and the an upper camera (18f) is attached to the assembling head (19), a lower camera (18a) is located under the surface (16) of the bench (15), the cameras (18a, 18f) and the assembling head (19) are connected to a control unit (CPU), and suction cups (17) suitable for connecting to an air suction device are embedded in the surface (16) of the bench (15).

7. The apparatus according to claim 6 for the production of a multilayer card (K) equipped with a window element (2), characterized in that it is provided with a bench (16a) for storing the window element (2) during production.

8. Multi-layered card (K) with a window element (2), having a core layer (1,1a, 1b) and at least one layer of transparent film (3,4) on both opposite sides of the core layer (1,1 a, 1b), characterized in that it contains an opaque core layer (1,1a, 1b) made of polycarbonate film, in which an opening (5) is formed, and a transparent or translucent window element (2) in the shape equal to the shape of the opening (5) is arranged in the opening (5), and the window element (2) is attached to the transparent film (4) layer in the opening (5) by means of at least one ultrasonic spot-welded seam (H).

9. Multi-layer card (K) with window element (2) according to claim 8, characterized in that the layer of transparent film (3,4) is attached to the core film (1,1a, 1b) by lamination.

10. Multi-layered card (K) provided with a window element (2) according to claim 9, characterized in that the card (K) is a data sheet of a document provided as a booklet.