U.S. patent application number 09/297753 was filed with the patent office on 2002-01-24 for method for making cards and cards obtained by this method.
Invention is credited to DROZ, FRANCOIS.
Application Number | 20020007906 09/297753 |
Document ID | / |
Family ID | 4550461 |
Filed Date | 2002-01-24 |
United States Patent
Application |
20020007906 |
Kind Code |
A1 |
DROZ, FRANCOIS |
January 24, 2002 |
METHOD FOR MAKING CARDS AND CARDS OBTAINED BY THIS METHOD
Abstract
The invention concerns a method for making smart cards by
rolling. A first synthetic sheet (1) is first smoothed by hot
pressing against a first smoothing plate (4). Likewise a second
synthetic sheet (2) is smoothed against a second smoothing plate
(5). Without being unstuck from their smoothing plates, these two
sheets are rolled with other layers (3, 6, 7), said synthetic
sheets (1, 2) serving as external layers. One of the smoothing
plates may comprise a three-dimensional pattern to be relief
printed on the synthetic sheet. The rolling is carried out by cold
pressing the different layers (1, 6, 3, 7, 2) which the laminated
card comprises between the two smoothing plates (4, 5). After being
rolled, different cards with adapted dimensions can be cut out from
the laminated sheets. The invention is advantageous in that the
same plates (4, 5) are used for the hot pressing and the cold
rolling. The external surface of the synthetic sheets (1, 2) thus
remains protected between these two operations and the cards have
better inherent flatness.
Inventors: |
DROZ, FRANCOIS; (LA
CHAUX-DE-FONDS, CH) |
Correspondence
Address: |
CLIFFORD W BROWNING
WOODARD EMHARDT NAUGHTON MORIARTY MCNETT
111 MONUMENT CIRCLE SUITE 3700
BANK ONE CENTER TOWER
INDIANAPOLIS
IN
462045137
|
Family ID: |
4550461 |
Appl. No.: |
09/297753 |
Filed: |
June 18, 1999 |
PCT Filed: |
November 12, 1996 |
PCT NO: |
PCT/CH96/00404 |
Current U.S.
Class: |
156/269 |
Current CPC
Class: |
G06K 19/077 20130101;
Y10T 156/1002 20150115; Y10T 156/1093 20150115; Y10T 156/1084
20150115; B32B 2425/00 20130101; B32B 2307/406 20130101; B32B 38/00
20130101 |
Class at
Publication: |
156/269 |
International
Class: |
B32B 031/00 |
Claims
1. Method for making laminated cards, comprising the following
operations: --smoothing of at least one first synthetic sheet (1)
against a first smoothing plate (4), --lamination of at least one
card, using said first synthetic sheet (1) as the outer layer,
characterized in that said laminating operation is carried out by
the cold pressing of various layers (1, 6, 6', 3, 7, 2, 2') and
elements (31, 32, 33) between said first smoothing plate (4) and a
second plate (5).
2. Method for making laminated cards according to the preceding
claim, characterized in that it comprises, furthermore, an
operation of smoothing a second synthetic sheet (2) against a
second smoothing plate (5), in order to improve the surface state
of the outer face (20) of said second synthetic sheet, in that said
second synthetic sheet (2) is used as the second outer layer of
said card, and in that said laminating operation is carried out by
the cold pressing of the various layers (1, 6, 6', 3, 7, 2, 2') and
elements (31, 32, 33) forming the laminated card between said first
smoothing plate (4) and said second smoothing plate (5).
3. Method for making laminated cards according to one of the
preceding claims, characterized in that said operation or
operations of smoothing a synthetic sheet are carried out by the
hot pressing of the synthetic sheet (1 or 2) between its smoothing
plate (4 or 5) and a pressing plate (8).
4. Method for making laminated cards according to one of the
preceding claims, characterized in that said operation or
operations of smoothing a synthetic sheet are carried out by the
spraying or coating of a synthetic covering against a smoothing
plate (4 or 5).
5. Method for making laminated cards according to one of the
preceding claims, characterized in that said operation or
operations of smoothing synthetic sheets (1, 2) are carried out
with the same press as said laminating operation.
6. Method for making laminated cards according to one of the
preceding claims, wherein said synthetic sheet or sheets (1, 2)
have a size corresponding to a plurality of cards, said method
comprising finally an operation of cutting out individual
cards.
7. Method for making laminated cards according to the preceding
claim, wherein said synthetic sheet or sheets (1, 2) each consist
of a continuous synthetic web.
8. Method for making laminated cards according to one of the
preceding claims, wherein the face of at least one of said
smoothing plates (4 or 5) which is opposite the corresponding
synthetic sheet (1 or 2) comprises a three-dimensional pattern
intended to be printed in relief on the corresponding synthetic
sheet.
9. Method for making laminated cards according to the preceding
claim, wherein said three-dimensional pattern comprises polishing
in variable directions or with variable roughnesses, so as to
imprint a visible pattern on the corresponding synthetic sheet (1,
2).
10. Method for making laminated cards according to one of the
preceding claims, wherein at least one of the first (4) and/or
second (5) smoothing plates is made of polished or satin-finished
stainless steel.
11. Method for making laminated cards according to one of the
preceding claims, comprising a prior step of printing on at least
one of the first and/or second synthetic sheets (1, 2).
12. Method for making laminated cards according to one of the
preceding claims, wherein the inner face (11 or 21) of at least one
of said synthetic sheets (1 or 2) is previously machined with at
least one recess intended for receiving a component or components
(31, 32, 33) contained in the card.
13. Method for making laminated cards according to one of claims 1
to 11, wherein, during at least one of said smoothing operations,
at least one of said synthetic sheets (1 or 2) is pressed between
the corresponding smoothing plate (4 or 5) and a pressing plate
(8') comprising a three-dimensional structure in relief.
14. Method for making laminated cards according to the preceding
claim, wherein, during at least one of said smoothing operations,
at least one of said synthetic sheets (1 or 2) is pressed between
the corresponding smoothing plate (4 or 5) and a pressing plate
(8') comprising at least one projecting portion (81) intended for
molding in the inner face (11 or 21) of the synthetic sheet a
recess (21) and/or an orifice (22) corresponding to an electronic
component (31, 32) of the finished card.
15. Method for making laminated cards according to one of the
preceding claims, wherein an electronic component (31) is
previously positioned with its connecting contacts (34) flush with
the outer face (10 or 20) of at least one of said synthetic sheets
(1 or 2).
16. Method for making laminated cards according to the preceding
claim, wherein holding means (2'; 35) are provided for holding the
connecting contacts (34) of said electronic component (31) flush
with the outer face (10 or 20) of the corresponding synthetic sheet
(1 or 2).
17. Method for making laminated cards according to the preceding
claim, wherein said holding means consist of an additional
synthetic sheet (2').
18. Method for making laminated cards according to claim 16,
wherein said holding means consist of a projecting portion (35) on
the lateral face of the electronic component (31).
19. Method for making laminated cards according to one of the
preceding claims, comprising, between the smoothing and laminating
operations, an additional operation of welding electronic
components (31).
20. Method for making laminated cards according to one of claims 5
to 19, wherein said first and second synthetic sheets (1, 2) are
smoothed on smoothing plates placed side by side and are
articulated so as to be capable of being closed in the same way as
the cover of a book, so as to superpose said synthetic sheets (1,
2) in order to carry out said operation of laminating the various
layers (1, 6, 6' , 3, 7, 2, 2') and elements (31, 32, 33) forming
the laminated card.
21. Card made by the method of one of the preceding claims.
22. Smart card made by the method of one of claims 1 to 20.
Description
[0001] The present invention relates to a method for making cards
according to the precharacterizing clause of claim 1 and to a card
made by this method. The present invention relates more
specifically to a method for making cards, in particular smart
cards or bank cards, laminated by cold pressing.
[0002] Although the description describes, above all, the
particular case of the manufacture of smart cards, the invention
may also apply to the manufacture of any other type of laminated
cards, for example plasticized bank cards, telephone cards or
visiting cards. However, the invention proves more particularly
advantageous for making cards intended to be used in a reader or
automatic machine, especially for cards comprising an optical,
magnetic or electronic storage portion.
[0003] Most known smart cards are made by laminating layers of
various materials, such as polyvinyl chloride (PVC), polycarbonate
(PC) or ABS, at least one of the layers accommodating an integrated
circuit. Of the known manufacturing methods, hot-laminating methods
and cold-pressing laminating methods are particularly
important.
[0004] According to hot-laminating methods, the multiple layers
forming a card are pressed between two plates and simultaneously
heated to a temperature usually close to 160.degree., making it
possible to fuse the layers together. A second cold press is
sometimes used after the first, in order to cool the layers as a
whole. Such methods are mentioned, in particular, in the patent
documents WO 94/22111, DE 4444788, EP0163534 and EP0488754.
[0005] These methods are difficult to use in order to make smart
cards comprising fragile electronic components which risk being
destroyed by the intense heat and high pressure which are
necessary. In particular, these methods are unsuitable for making
cards comprising an accumulator or battery which does not withstand
the interise heat released.
[0006] For this reason, cold-pressing laminating methods are
sometimes preferred. According to these methods, the various layers
forming the cards are assembled together by means of a binder or an
adhesive which cures at a temperature below the melting point of
the layers forming the card. WO 94/22110 describes an example of a
method of this type. The various layers and the circuit are
compressed in a press, the thickness and distribution of the binder
being accurately controlled.
[0007] The outer faces of the card must be perfectly plane. This is
particularly the case if the card is to be used in an automatic
machine. For this purpose, the card manufacturers employ, for the
outer faces, synthetic sheets which have undergone prior surface
treatment. This may involve, for example, hot pressing of the
synthetic sheets against a smoothing plate, for example against a
polished smoothing plate which makes it possible to eliminate
surface irregularities. After smoothing, the synthetic sheets are
cooled, detached from the polished metal surface and stacked, or
sometimes wound on themselves, for the purpose of selling them and
transporting them to the card manufacturer. The synthetic sheets
obtained must be sufficiently smooth to be used as outer layers of
the laminate.
[0008] The present invention relates to an improvement to the
methods for making cards. In particular, the invention relates to
an improvement to these methods which is particularly advantageous
when it is applied to making cards intended to be used in automatic
machines.
[0009] According to the invention, this improvement is afforded by
means of the elements of the characterizing clause of claim 1.
[0010] More specifically, this improvement is afforded by carrying
out the laminating operation by the cold pressing of the various
layers and elements forming the laminated card between the
smoothing plate, used during the previous hot-pressing smoothing
operation, and at least one other plate. In this way, the synthetic
sheets forming the outer layers of the laminated card are protected
by the smoothing plates during transport and cold pressing. It is
thus impossible for the outer surfaces of these sheets to be
scratched or be covered with dust before or during the
cold-pressing laminating operation.
[0011] By cold pressing is meant pressing without the addition of
heat or, at least, pressing carried out at a temperature below the
melting point of the outer layers of the laminate. If the outer
layers are made of PVC, laminating is therefore carried out at a
temperature below 140.degree. or, preferably, below
120.degree..
[0012] Other advantages and particular features of the invention
may be gathered from the dependent claims and from the description
given by way of example and illustrated by the figures, in
which:
[0013] FIG. 1 shows an exploded view of the various layers forming
a smart card.
[0014] FIG. 2a shows a diagrammatic section through the second
synthetic sheet before the hot-smoothing operation, according to a
first variant of the invention.
[0015] FIG. 3a shows a diagrammatic section through a synthetic
sheet during the hot-smoothing operation, according to the first
variant of the invention.
[0016] FIG. 4a shows a diagrammatic section through a synthetic
sheet after the hot-smoothing operation, according to the first
variant of the invention.
[0017] FIG. 5a shows a diagrammatic section through the various
layers forming the card, before the coldpressing laminating
operation, according to the first variant of the invention.
[0018] FIG.6a shows a diagrammatic section through the various
layers forming the card, during the cold-pressing laminating
operation, according to the first variant of the invention.
[0019] FIG. 2b shows a diagrammatic section through the various
layers forming the card, before the hot-smoothing operation,
according to a second variant of the invention.
[0020] FIG. 3b shows a diagrammatic section through a synthetic
sheet during the hot-smoothing operation, according to the second
variant of the invention.
[0021] FIG. 4b shows a diagrammatic section through a synthetic
sheet after the hot-smoothing operation, according to the second
variant of the invention.
[0022] FIG. 2c shows a diagrammatic section through two synthetic
sheets before the hot-smoothing operation, according to a third
variant of the invention.
[0023] FIG. 3c shows a diagrammatic section through two synthetic
sheets during the hot-smoothing operation, according to the third
variant of the invention.
[0024] FIG. 4c shows a diagrammatic section through two synthetic
sheets after the hot-smoothing operation, according to the third
variant of the invention.
[0025] FIG. 5c shows a diagrammatic section through the various
layers forming the card, before the cold-pressing laminating
operation, according to the third variant of the invention.
[0026] FIG. 6c shows a diagrammatic section through the various
layers forming the card, during the cold-pressing laminating
operation, according to the third variant of the invention.
[0027] FIG. 7c shows a diagrammatic section through a finished card
after the cold-pressing laminating operation, according to the
third variant of the invention.
[0028] FIG. 2d shows a diagrammatic section through a synthetic
sheet before the hot-pressing operation, according to a fourth
variant of the invention.
[0029] FIG. 3d shows a diagrammatic section through a synthetic
sheet during the hot-smoothing operation, according to the fourth
variant of the invention.
[0030] FIG. 8 shows a perspective view of means for superposing the
sheets.
[0031] The figures are diagrammatic. It is therefore not generally
possible to deduce dimensions from them. In particular, the
thickness of the cards in the sectional views has been deliberately
exaggerated, in order to show the various layers clearly. In
practice, the cards will generally have the standardized ISO
dimensions of 53.98 .times.85.60 .times.0.76 mm.
[0032] FIG. 1 illustrates an exploded view of various smart card
layers made by cold-pressing lamination. The upper layer 1 consists
of a synthetic sheet, for example made of polyvinyl chloride (PVC),
polycarbonate (PC) or ABS, cut to the required dimensions. The
outer face 10 may be printed, for example with the name of the
holder and of the banking institution, if a bank card is concerned.
In one variant, the upper layer 1 is transparent, and the print may
be provided on the inner face 11. The outer face 10 must be as
smooth as possible for esthetic reasons, so that the card can
easily be read and written in automatic machines and to make
printing and subsequent personalization of the card easier.
[0033] The lower layer 2 is similar and symmetrical to the upper
layer 1; in the same way, the outer face 20, which must be as
smooth as possible, may be provided with a print and, if
appropriate, with a magnetic or optical data storage zone. The
inner face of the layer 2 is designated by the numeral 21.
[0034] Where a smart card is concerned, electric contacts may, if
necessary, be provided at least on one of the outer faces 10 or 20.
Cards are also known, the outer faces of which are provided with
photovoltaic cells making it possible to supply an electronic
circuit in the card.
[0035] The layer 3 is provided with various electronic components
31, 32, 33 illustrated diagrammatically and connected to one
another. The electronic components may, for example, comprise
integrated circuits, such as memories, microprocessors or
microcontrollers, coils, accumulators, etc.
[0036] The layers 1, 2 and 3 are held together by means of two
binder layers 6 and 7. The layers 6 and 7 may consist, for example,
of double-faced adhesive sheets or of a binder in the form of a
solid or viscous sheet. It is also possible, however, to use any
type of binder, for example a two-component adhesive, a cold
adhesive (that is to say, one which cures at a temperature below
the melting point of the layers 1 and 2) or a resin which cures in
air, under ultraviolet light or by means of photoinitiating agents.
The outer layers 1, 2, the surface of which is critical, rest,
during cold pressing, on the smoothing plates 4, 5 used for
smoothing the outer layers 10, 20. Pressure is exerted on the
layers 1 to 7 in order to bind them and ensure good adhesion.
[0037] This smart card configuration is given only as an
illustrative example. Depending on requirements, the invention may
also apply to smart cards comprising different layers, for example
positioning layers, compressible layers, layers of other electronic
elements, etc. The invention also applies to the manufacture of
cards formed solely from two outer layers 1, 2 laminated relative
to one another. It is also possible to use the invention in order
to make cards formed from two outer layers 1, 2 assembled together
by means of a binder layer 6 coating various electronic
components.
[0038] FIGS. 2a and 3a illustrate the operation of smoothing the
lower layer 2 by hot pressing. The synthetic sheet 2 is first
placed on a smoothing plate 5. The smoothing plate 5 preferably
consists of a stainless steel plate with a polished or
satin-finished upper surface 50; a pressing plate 8 makes it
possible to apply pressure (symbolized by an arrow) to the sheet 2.
The covering of the plate 8 is nonadhesive; it is not necessary for
it to be particularly polished. In order to make it easier for the
synthetic sheet 2 to be subsequently detached, it is possible to
use a nonadhering intermediate sheet between the pressing plate 8
and the sheet 2, for example a nonadhering polyamide film. If the
smoothing plate 5 is too thin to support the pressure of the
pressing plate 8 without undergoing deformation, a support plate,
not illustrated, will be used under the smoothing plate 5. Heating
means 90 are provided for softening the sheet 2. The heating means
are represented, here, by an electric filament; however, other
means may be used, for example steam heating, etc. The selected
pressure and temperature depend on the material used for the sheet
2; however, since, in this variant, no electronic component is
mounted on the sheet 2 during heating, it is possible to employ
temperatures higher than the melting point of the synthetic sheet
2, preferably temperatures of the order of 150.degree. or even
higher than 180.degree. C. In order to avoid deformations and
tensions in the sheet 2, the heat is simultaneously applied from
each side of the sheet 2. In this way, the outer face 20 of the
sheet 2 is smoothed by molding against the polished surface 50.
Additional means may be provided for cooling the sheet 2 rapidly
after the hot-pressing operation.
[0039] In a new variant, not illustrated, the smoothed synthetic
sheet 2 is obtained by spraying or coating with an acrylic varnish
or with another synthetic covering against the smoothing plate 5.
If necessary, the pressing plate 8 is lowered after spraying or
coating, so as to make the thickness of the varnish layer uniform.
No addition of heat is necessary for the curing of the varnish. A
thin varnish layer is thus obtained, which is sufficiently smooth
and uniform to serve as an outer layer 1, 2.
[0040] In the prior art, the sheet 2 was subsequently detached from
the smoothing plate 5, then transported to the cold-laminating
machine which may possibly be situated in another factory. The same
procedure was adopted for the synthetic sheet 1. The sheets 1, 2
were often damaged during transport between the smoothing machine
and the cold-pressing laminating machine. The sheets may be
scratched, and dust or impurities risk adhering to the outer faces
10 or 20. These impurities produce marks on the surface 10, 20
during laminating by cold pressing. Moreover, it is difficult for
the sheets 1 and 2 to be laid against the pressing plates of the
cold press without any air bubbles. These air bubbles are obviously
detrimental to the planeness of the card obtained.
[0041] In a first variant of the invention, these problems are
solved by means of the steps of the method which are illustrated in
FIGS. 4a, 5a and 6a. After smoothing, the pressing plate 8 is
raised (FIG. 4a), but the sheet 2 is not detached from the metal
smoothing plate 5. In the same way, the upper sheet 1 is not
detached from the corresponding smoothing plate 4. The sheets 1, 2
remain laid on the smoothing plates 4, 5 between the smoothing
operations and the laminating operations. If the synthetic sheets
have to be transported to another machine, the smoothing plates 4,
5 are demounted and transported together with the synthetic sheets.
The outer faces 10, 20 thereby remain completely protected from
impurities and scratches.
[0042] Lamination is carried out by the various layers 1, 2, 3, 6,
7 which form the laminate being superposed in the appropriate way
(FIG. 5a), the outer layers 1 and 2 remaining on their respective
smoothing plates 4 and 5. The stack of layers together with the
plates 4 and 5 is subsequently compressed between two plates 9 in a
cold press (FIG. 6a). It is only after this operation of cold
lamination and curing of the binder that the smoothing plates 4, 5
are finally detached (this is not illustrated).
[0043] After the smoothing plates 4, 5 have been removed, the stack
of layers which is obtained may, if necessary, be cut to the
prescribed card dimensions by means of known methods.
[0044] FIGS. 2b, 3b and 4b illustrate a variant of the steps of
smoothing by hot pressing. These steps may be used instead of the
steps illustrated in FIGS. 2a, 3a and 4a, particularly for the
manufacture of smart cards comprising electronic components of a
particular thickness. In this case, as seen in FIG. 2b, a pressing
plate 8' with projecting portions, here two portions 81, 82, will
preferably be used. When the pressing plate 8' is lowered against
the smoothing plate 5, the projecting portions penetrate and mark
the inner face 21 of the sheet 2 (FIG. 3b). The pressing plate 8'
functions, in fact, as a stamping punch which pushes back or cuts
out particular portions of the synthetic sheet 2. The heating means
90 make it possible to soften the synthetic sheet 2. In this
example, the two projecting portions 81 and 82 illustrated are of
different height, so that the projection 81 penetrates only a
little depth into the synthetic sheet 2, whereas the higher
projection 82 passes completely through the sheet. If necessary,
the projection 82 may be provided with cutting edges, so as
actually to cut out the synthetic sheet 2. In one variant, the
projection 82 may be replaced by a projecting blade having solely a
cutting contact surface with the sheet 2.
[0045] In addition to the projections 81, 82, the pressing plate 8'
may also comprise a three-dimensional relief structure. This
structure makes it possible to reduce the tensions and deformations
attributable to the pressing of the synthetic sheet 2.
[0046] FIG. 4b shows the imprint left by the pressing plate 8' in
the synthetic sheet 2. The projection 81 has left only a shallow
recess 21 on the inner face 21, whereas the orifice 22 left by the
projection 82 passes through the synthetic sheet 2. The recess 21
will have been provided opposite an electronic component,
subsequently mounted in the card, and makes it possible to use
relatively thick components, without causing a bulge in the outer
faces 10, 20 of the finished smart card. The orifice 22 makes it
possible, for example, to access the contacts of a component
mounted in the card. It goes without saying that any number of
recesses and/or orifices may be provided, as required, on the two
outer faces of the smart card.
[0047] The synthetic sheet 2 thus smoothed and stamped is
laminated, as in FIGS. 5a and 6a, with the other layers forming the
finished card. It goes without saying that similar recesses or
orifices may also be provided in the other outer sheet 1. An
additional operation of welding, connecting and/or fastening
additional components in the orifice 22 may be provided, if
appropriate.
[0048] FIGS. 2c to 7c illustrate steps in the manufacture of a
smart card according to a third variant of the invention. These
steps may replace the steps described above with reference to FIGS.
2a to 6a respectively. In this variant, the synthetic sheet 2 is
cut beforehand at the appropriate locations 24 during operations
which are not illustrated, in order to allow the connecting
contacts 34 of an electronic component 31 to pass through. The
synthetic sheet 2 is positioned, as before, on the polished metal
smoothing plate 5, and the electronic component 31 is placed in the
orifice 24, with its connecting contacts 34 laid on the plate 5. A
second synthetic sheet 2' is subsequently applied over the sheet 2.
The second sheet 2' likewise has orifices 24' which are slightly
smaller than the orifices 24, but are placed at the same locations,
in such a way that the sheet 2' covers particular portions of the
circuit 31. It is possible to change the order of these operations
slightly by inserting the component or components 31 into the
corresponding orifices 24' of the sheet 2' beforehand. It is
subsequently sufficient, in a single operation, to apply the sheet
2' provided with the components 31 over the sheet 2.
[0049] The second synthetic sheet 2' may be of the same material as
the first sheet 2 or of a different material. It prevents the
component 31 from being buried toward the interior of the card, so
as to keep the contacts 34 flush with the outer face 20. Moreover,
the second sheet 2' improves the sealing of the orifice 24, 24'
around the component 31.
[0050] In FIG. 3c, pressure is applied to the layers 2, 2' by the
pressing plate 8" and the smoothing plate 5, in order to smooth the
outer face 20. The pressing plate 8" comprises a receptacle 83, in
order to avoid the crushing of the circuit 31. Heating means 90'
are provided for softening the sheet 2 and also for fusing the two
synthetic sheets 2, 2'. The heating temperature and duration
employed will be selected so as to prevent any risk of the
component 31 being destroyed. Means, not illustrated, for example
radiator fins or an air stream, may be provided in order to cool
the component 31 during this heating operation. If, depending on
the component selected, it is impossible for the sheets 2, 2' to be
sufficiently heated to cause them to fuse sufficiently, a double
adhesive sheet 2' or a layer of adhesive or of resin between the
two layers 2, 2' will preferably be used.
[0051] In FIG. 4c, the pressing plate 8" is subsequently raised,
whilst the two sheets 2, 2' and the component 31 remain on the
smoothing plate 5. Connecting wires 36 may be welded at this
moment, in order to connect the electronic component 31 to other
components in the smart card, for example to a coil. A binder 6' is
subsequently poured over the layer 2'. Depending on the fluidity of
the binder selected, a positioning frame (not illustrated) around
the card will be employed. The binder may, for example, consist of
one of the materials mentioned by way of example above. It is, of
course, possible, however to use a binder in the form of a solid
sheet or a double-faced adhesive sheet, as illustrated in the
preceding variants.
[0052] The other layers of the laminate are subsequently applied
(FIG. 5c). In this example, only the outer sheet 1 with its
smoothing plate 4 is applied over the binder layer 6' . This sheet
was smoothed beforehand by hot pressing on the plate 4. Other
layers may, of course, be provided, for example a printed circuit
layer with other electronic components. Various electronic
components may be embedded in the binder layer 6' before curing.
During the step illustrated in FIG. 6c, pressure is applied by the
plates 9 to the stack of layers which is obtained. The excess
binder 6' can flow off laterally during this step.
[0053] FIG. 7c illustrates diagrammatically the card obtained after
the curing of the binder, the detachment of the smoothing plates 4
and 5 and, if appropriate, cutting out. This method makes it
possible to obtain perfectly plane outer faces 10, 20 flush with
the contacts 34 of the component 31.
[0054] FIGS. 2d and 3d illustrate a variant of the steps of the
hot-pressing smoothing of a sheet already provided with an
electronic component 31. These steps may replace the steps of the
third variant which are illustrated in FIGS. 2c and 3c. Here, the
component 31 is held flush with the outer face 20 by means of the
frustoconical portion 35 of said component. Other mechanical
fastening systems, for example any other form of protuberance on
the lateral surface of the component 31, may, of course, be
envisaged. The component 31 is first placed on the smoothing plate
5, then the synthetic sheet 2 is slipped over the component 31,
with a little force being applied in the region of the orifice 24
previously cut out in the sheet 2. During the step illustrated in
FIG. 3e, the pressing plate 8" is lowered so as to exert pressure
on the synthetic sheet 2 which is simultaneously fused by the
heating means 90'. The orifice 24 is thereby matched to the
frustoconical shape 35 of the component 31; the latter can no
longer be buried toward the interior of the card. The cold
laminating of the synthetic sheet 2 thus smoothed and provided with
a circuit 31 may subsequently be carried out in the way described
in FIGS. 4a to 6a or in the way described in FIGS. 4c to 6c. As
compared with the preceding variant, this solution makes it
possible to save a synthetic sheet 2' and, where appropriate,
reduce the thickness of the card.
[0055] Although, above all, a method for making cards one by one
was illustrated above, all the variants also apply to the
simultaneous manufacture of a plurality of cards from sheets 1, 2,
2' of sufficient dimensions, which will be cut during a final
operation which is not illustrated. Continuous manufacture from
laminates of sheets, for example PVC sheets, is also perfectly
conceivable. In this case, the unwound laminates are first
hot-pressed in successive portions, one portion corresponding to
one or more individual cards. The portions thus smoothed are
subsequently cold-laminated over the polished plate used for hot
pressing, in a similar way to FIGS. 4 to 7.
[0056] Hot smoothing was discussed above mainly in connection with
the lower layer 2. In some uses, only one of the two faces 10, 20
of the card needs to be perfectly plane. This applies, for example,
when only one of the faces of the card is subsequently to be
printed or provided, for example, with a magnetic or optical
storage zone (bar code) or with connecting contacts. In general,
however, it is necessary and preferable to use smoothed synthetic
sheets for both faces 1, 2 of the card. In this case, the upper
sheet 1 will be treated in the same way as the lower sheet 2.
[0057] Many means are conceivable for transporting the smoothed
synthetic sheets 1 and 2 to the laminating machine and for
superposing them for the purpose of laminating them. The sheets may
be smoothed and laminated at very different locations and moments,
provided that they can be stored and transported together with the
smoothing plates 4, 5. FIG. 8 illustrates an advantageous
possibility employing a single press for smoothing the synthetic
sheets 1 and 2 and for laminating them with the other layers. The
two sheets 1 and 2 are smoothed beforehand against two polished
smoothing plates 4 and 5 placed side by side. A pressing plate 8,
not illustrated, and heating means 90, not illustrated, are used to
smooth the surfaces 10, 20. This arrangement makes it possible
simultaneously to heat and apply pressure to the two sheets 1 and
2. It is possible to employ a common pressing plate 8 of double
dimension or at least two separate plates in order to smooth the
two synthetic sheets 1, 2.
[0058] After smoothing, the sheets are cooled, then the
intermediate layers 7, 3 and 6 are positioned above the lower layer
2. The upper sheet 1 and its smoothing plate 4 are subsequently
overturned above the stack of intermediate layers, at the same time
being pivoted about a hinge 41, in the manner of a book which is
being closed. The hinge 41 is preferably a double hinge or another
type of hinge making it possible to superpose the two sheets 1 and
2 without any offsets. In order to bind the layers together,
pressure is applied by means of the pressing plates 9 to the two
smoothing plates 4, 5 which are closed in the same way as the cover
of a book. In order to prevent the sheet 1 from slipping when the
smoothing plate 4 is being closed, care will be taken to use a
smoothing plate 4 provided with a polished upper surface which is
slightly adhesive or is charged with static electricity. Suction
means may be provided, if appropriate, in order to lay the sheet 1
against the smoothing surface, this means then acting through holes
passing through the smoothing plate 4 in zones not corresponding to
the cut-out cards. This measure may prove necessary, in particular,
if sheets 1, 2 of large dimension, corresponding to a plurality of
cards, are laminated during each operation. In one variant, a
plurality of separate sheets, each corresponding to a plurality of
cards, may be laminated simultaneously.
[0059] In all the variants, the smoothing plates 4 and 5 may be
produced from any sufficiently smooth material, for example from
stainless steel or Teflon (registered trademark). The smoothing
surface is preferably perfectly polished and/or satin-finished. In
one variant, it is also possible to use smoothing plates 4, 5
having at least one slightly rough or granulated portion. Depending
on the texture imparted to the roughnesses of the rough or
granulated portion, it is possible to obtain outer surfaces 10, 20
of varied appearance. For example, it is possible to make cards
having a perfectly smooth face, with the exception of particular
portions, corresponding, for example, to a text or logo, which have
a matt or rough appearance. Moreover, the smoothing plates may, for
some uses, comprise projecting portions intended for molding, in at
least one face of the card, a recess which may, for example, be
used in order to insert a photograph, a hologram or any security
element.
[0060] The different variants discussed above may, to a large
extent, be combined with one another, as required. For example, a
pressing plate 8' forming a stamping punch (cf. FIGS. 2b-3b-4b )
may be used with all the variants, instead of plane plates 8,
8'.
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