Coextruded foil composite material and its use in card bodies

• US 9,796,122 B2
• Filed: 10/15/2015
• Issued: 10/24/2017
• Est. Priority Date: 02/25/2010
• Status: Active Grant

• Current Assignee: Giesecke + Devrient Mobile Security GmBH (Giesecke & Devrient GmbH)
• Original Assignee: Giesecke + Devrient Mobile Security GmBH (Giesecke & Devrient GmbH)
• Inventors: Riedl, Josef, Regensburger, Cordula, Braun, Andreas
• Primary Examiner(s): Wollschlager, Jeffrey
• Application Number:
  US14/884,008
• Publication Number:
  US 20160031144A1
• Time in Patent Office: 740 Days
• Field of Search: None
• CPC Class Codes: B29C 48/08 flexible, e.g. films
• CPC Class Codes: B29C 48/21 the layers being joined at their surfaces
• CPC Class Codes: B29C 48/307 specially adapted for bringing together components, e.g. melts within the die
• CPC Class Codes: B29K 2067/00 Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2067/003 PET, i.e. poylethylene terephthalate
• CPC Class Codes: B29K 2105/0026 Flame proofing or flame retarding agents
• CPC Class Codes: B29K 2105/0032 Pigments, colouring agents or opacifiyng agents
• CPC Class Codes: B29K 2105/0044 Stabilisers, e.g. against oxydation, light or heat
• CPC Class Codes: B29K 2105/005 Heat sensitisers or absorbers
• CPC Class Codes: B29K 2105/16 Fillers
• CPC Class Codes: B29K 2995/0046 Elastic
• CPC Class Codes: B29L 2007/008 Wide strips, e.g. films, webs
• CPC Class Codes: B29L 2009/00 Layered products
• CPC Class Codes: B32B 2274/00 Thermoplastic elastomer material thermoplastic elastomer fibres B32B2262/0215, thermoplastic elastomer particles B32B2264/0221, thermoplastic elastomer foam B32B2266/0292
• CPC Class Codes: B32B 2307/41 Opaque
• CPC Class Codes: B32B 2307/412 Transparent
• CPC Class Codes: B32B 2307/50 having particular mechanical properties
• CPC Class Codes: B32B 2307/536 Hardness
• CPC Class Codes: B32B 2307/54 Yield strength; Tensile strength
• CPC Class Codes: B32B 2307/546 Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2307/714 : Inert, i.e. inert to chemical degradation, corrosion
• CPC Class Codes: B32B 2307/732 : Dimensional properties
• CPC Class Codes: B32B 2307/734 : Dimensional stability
• CPC Class Codes: B32B 2307/75 : Printability
• 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 27/08 : of synthetic resin
• CPC Class Codes: B32B 27/18 : characterised by the use of special additives
• CPC Class Codes: B32B 27/285 : comprising polyethers
• CPC Class Codes: B32B 27/36 : comprising polyesters
• CPC Class Codes: B32B 37/04 : characterised by the partial melting of at least one layer
• CPC Class Codes: B32B 7/023 : Optical properties
• CPC Class Codes: B32B 7/10 : at least one layer having inter-reactive properties
• CPC Class Codes: B42D 2033/30 : Plastic material
• CPC Class Codes: B42D 25/00 : Information-bearing cards or sheet-like structures characterised by identification or security features; Manufacture thereof printing processes to produce identification or security features B41M3/14
• CPC Class Codes: B42D 25/305 : Associated digital information record carriers for use with machines and with at least a part designed to carry digital markings G06K19/00
• CPC Class Codes: B42D 25/45 : Associating two or more layers
• CPC Class Codes: Y10T 156/10 : Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 428/31786 : Of polyester [e.g., alkyd, etc.]

Abstract

A composite film material usable in a data carrier card body includes a first outer plastic layer, an inner plastic layer and a second outer plastic layer, all the layers together forming a co-extruded composite. The plastic material of the first outer layer is a polyethylene terephthalate glycol copolymer (PETG) or contains a PETG, the plastic material of the inner layer is a thermoplastic elastomer (TPC) or containes a TPC, and the plastic material of the second outer layer is a PETG or contains a PETG.

Claims

1. A method for manufacturing a card body having a plurality of foil composite layers, comprising:

a card core made of at least one inlay foil layer,

at least two cover foil layers for covering both surfaces of the card core, and

wherein the foil composite layers are laminated to each other in one work operation or in several work operations, wherein there is used as at least one of the cover foil layers and/or as the at least one inlay foil layer a foil composite material,

wherein the foil composite material comprises;

an inner layer formed between a first outer layer and a second outer layer,

the first outer layer comprising terephthalate glycol copolymer (PETG),

the second outer layer comprising PETG,

the inner layer comprising a single thermoplastic copolyester elastomer (TPC) and being the thickest layer of the foil composite material.

2. The method according to claim 1, wherein laminating is effected at a temperature of between 120°

C. and 200°

C.

3. The method of claim 1, wherein the first outer layer, the second outer layer and the inner layer of the foil composite material being in the form of a coextrusion comprising:

merging all the materials of the first outer layer, the second outer layer and the inner layer in a molten state, and extruding them through an extruder nozzle that extrudes a foil, to thereby obtain an extruded foil composite material.

4. The method according to claim 1, wherein the inlay foil layer has a thickness in the range of about 50 to 350 μ

m.

5. The method according to claim 1, wherein the cover foil layers have a thickness in the range of about 80 to 130 μ

m.

6. The method according to claim 1, wherein the foil composite material has a total layer thickness made up of 80 to 40% the inner layer and 10 to 30% the first and second outer layers.

7. The method according to claim 1, wherein between the at least one inlay foil layer and the cover foil layers there is located electronic components and imprinted antennas.

8. The method according to claim 1, wherein the card body has a total thickness of 0.5 to 1.0 mm.