Method for forming holographic foil

• US 5,810,957 A
• Filed: 03/26/1997
• Issued: 09/22/1998
• Est. Priority Date: 04/04/1994
• Status: Expired due to Fees

• Current Assignee: National City Bank (The PNC Financial Services Group, Inc.)
• Original Assignee: NovaVision
• Inventors: Boswell, David R.
• Primary Examiner(s): CAMERON, ERMA C
• Application Number:
  US08/824,188
• Time in Patent Office: 545 Days
• Field of Search: 156/219, 156/220, 264/284, 264/294, 427/404, 427/412.1
• US Class Current: 156/220
• CPC Class Codes: B29C 59/046 for layered or coated substantially flat surfaces
• CPC Class Codes: B29D 11/0073 Optical laminates
• CPC Class Codes: B29L 2017/00 Carriers for sound or information
• CPC Class Codes: B32B 15/08 of synthetic resin
• CPC Class Codes: B32B 2309/02 Temperature
• CPC Class Codes: B32B 2425/00 Cards, e.g. identity cards, credit cards
• CPC Class Codes: B32B 2429/00 Carriers for sound or information
• CPC Class Codes: B32B 37/22 involving the assembly of both discrete and continuous layers
• CPC Class Codes: B32B 38/00 Ancillary operations in connection with laminating processes
• CPC Class Codes: B32B 38/06 Embossing
• CPC Class Codes: B32B 38/1841 during laying up
• CPC Class Codes: B32B 7/06 permitting easy separation
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B41M 1/22 Metallic printing; Printing with powdered inks
• CPC Class Codes: B41M 1/24 combined with embossing printing machines for carrying out printing operations combined with embossing B41F19/02
• CPC Class Codes: B41M 3/14 Security printing securities B42D25/29
• CPC Class Codes: B41M 7/0027 using protective coatings or layers by lamination or by fusion of the coatings or layers
• CPC Class Codes: B42D 25/328 Diffraction gratings; Holograms
• CPC Class Codes: B44C 1/1729 Hot stamping techniques
• CPC Class Codes: G03H 1/0244 Surface relief holograms replicating hologram without interference recording G03H1/0276
• CPC Class Codes: G03H 1/0252 : Laminate comprising a hologram layer
• CPC Class Codes: G03H 1/028 : by embossing
• CPC Class Codes: G03H 2227/04 : Production line for mass production
• CPC Class Codes: G03H 2240/55 : Thickness
• CPC Class Codes: G03H 2250/10 : arranged to be transferred onto a carrier body
• CPC Class Codes: G03H 2250/12 : Special arrangement of layers
• CPC Class Codes: G03H 2250/40 : Printed information overlapped with the hologram
• CPC Class Codes: H05K 3/046 : by selective transfer or selective detachment of a conductive layer
• CPC Class Codes: Y10S 428/913 : Material designed to be responsive to temperature, light, moisture
• CPC Class Codes: Y10T 156/1041 : Subsequent to lamination
• CPC Class Codes: Y10T 428/1338 : Elemental metal containing
• CPC Class Codes: Y10T 428/1438 : Metal containing
• CPC Class Codes: Y10T 428/1443 : Aluminum
• CPC Class Codes: Y10T 428/1457 : Silicon
• CPC Class Codes: Y10T 428/24802 : Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/24942 : including components having same physical characteristic in differing degree
• CPC Class Codes: Y10T 428/24975 : No layer or component greater than 5 mils thick
• CPC Class Codes: Y10T 428/263 : Coating layer not in excess of 5 mils thick or equivalent
• CPC Class Codes: Y10T 428/265 : 1 mil or less
• CPC Class Codes: Y10T 428/2804 : Next to metal
• CPC Class Codes: Y10T 428/2813 : Heat or solvent activated or sealable
• CPC Class Codes: Y10T 428/2817 : Heat sealable
• CPC Class Codes: Y10T 428/2826 : Synthetic resin or polymer
• CPC Class Codes: Y10T 428/31504 : Composite [nonstructural laminate]
• CPC Class Codes: Y10T 428/31663 : As siloxane, silicone or silane
• CPC Class Codes: Y10T 428/31667 : Next to addition polymer from unsaturated monomers, or aldehyde or ketone condensation product
• CPC Class Codes: Y10T 428/31678 : Of metal
• CPC Class Codes: Y10T 428/31681 : Next to polyester, polyamide or polyimide [e.g., alkyd, glue, or nylon, etc.]
• CPC Class Codes: Y10T 428/31692 : Next to addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31696 : Including polyene monomers [e.g., butadiene, etc.]
• CPC Class Codes: Y10T 428/31699 : Ester, halide or nitrile of addition polymer
• CPC Class Codes: Y10T 428/31703 : Next to cellulosic
• CPC Class Codes: Y10T 428/31714 : Next to natural gum, natural oil, rosin, lac or wax
• CPC Class Codes: Y10T 428/31786 : Of polyester [e.g., alkyd, etc.]
• CPC Class Codes: Y10T 428/31801 : Of wax or waxy material
• CPC Class Codes: Y10T 428/31935 : Ester, halide or nitrile of addition polymer

Abstract

A foil/composite sheet having a holographic image or diffraction grating image and a method for forming permits the party producing the final document to hot stamp a chip containing the holographic image directly on a substrate forming the major portion of the final document. The foil/composite sheet includes successively a plastic carrier film, a release coating, a hard lacquer coating, a soft lacquer coating, a layer of metal and an embossment receiving coating, the latter three of which become embossed with the holographic image when a heated embossing shim is pressed under pressure against the embossment receiving layer. A heat activatable adhesive is thereafter applied to the embossment receiving coating.

Claims

1. A method for forming a composite sheet to receive a diffraction grating image comprising the steps of:

(a) providing a film of plastic material;

(b) applying a release coating onto said film, said release coating having a thickness in the range of 0.025 microns to 5 microns;

(c) applying a first lacquer coating onto said release coating, said first lacquer having a thickness in the range of 0.5 microns to 5 microns and a softening point as measured by a glass transition temperature of at least 80°

C.;

(d) applying a second lacquer coating onto said first lacquer coating, said second lacquer coating having a thickness in the range of 0.5 microns to 5 microns and having softening point as measured by a glass transition temperature no higher than 70°

C.;

(e) depositing on said second lacquer coating a layer of metal having a thickness in the range of 20 millimicrons to 100 millimicrons; and

(f) applying to said metal layer an embossment receiving coating having a thickness in the range of 0.025 microns to 1 micron, said embossment receiving coating being an esterfied montan wax.

2. The method of claim 1, wherein said first lacquer coating is a member selected from the group consisting of polymethyl methacrylate, styrene acrylonitrile, polyethyleneterephthalate and nitrocellulose.

3. The method of claims 1 or 2, wherein said second lacquer coating is a member selected from the group consisting of acrylic, nitrocellulose and chlorinated rubber.

4. A method for forming a composite sheet with a diffraction grating image comprising the steps of:

(a) providing a film of plastic material;

(b) applying a release coating onto said film, said release coating having a thickness in the range of 0.025 microns to 5 microns;

(c) applying a first lacquer coating onto said release coating, said first lacquer having a thickness in the range of 0.5 microns to 5 microns and a softening point as measured by a glass transition temperature of at least 80°

C.;

(d) applying a second lacquer coating onto said first lacquer coating, said second lacquer coating having a thickness in the range of 0.5 microns to 5 microns and having a softening point as measured by a glass transition temperature no higher than 70°

C.;

(e) depositing on said second lacquer coating a layer of metal having a thickness in the range of 20 millimicrons to 100 millimicrons; and

(f) applying to said metal layer an embossment receiving coating having a thickness in the range of 0.025 microns to 1 micron; and

(g) embossing a diffraction grating image into said embossment receiving coating, said metal layer and said second lacquer coating.

5. The method of claim 4, wherein said embossment receiving coating is an esterfied montan wax.

6. The method of claim 5, wherein said embossing step is performed with a roller having an embossed shim maintained at a temperature in the range of 100°

C. to 250°

C., said shim being applied to said embossment receiving coating under a pressure in the range of 200 to 400 pounds per linear inch.

7. The method of claim 6, wherein said composite sheet engages a chill roller having a temperature in the range of 30°

C. to 55°

C. immediately following said embossing step.

8. The method of claim 6, wherein said first lacquer coating is a member selected from the group consisting of polymethyl methacrylate, acrylic, styrene acrylonitrile, polyethyleneterephthalate and nitrocellulose.

9. The method of claims 6 or 8, wherein said second lacquer coating is a member selected from the group consisting of acrylic, nitrocellulose and chlorinated rubber.

10. The method of claims 4, 5, 6 or 7, further including the step of applying a heat activatable adhesive having a thickness in the range of 0.75 microns to 4 microns to said embossment receiving coating following said embossing step.

11. The method of claim 4 wherein said film of plastic material is polypropylene and further including the step of preheating said composite sheet prior to said embossing step.