U.S. patent application number 12/917186 was filed with the patent office on 2011-11-03 for contact smart cards having a document core, contactless smart cards including multi-layered structure, pet-based identification document, and methods of making same.
This patent application is currently assigned to L-1 Secure Credentialing, Inc.. Invention is credited to Daoshen Bi, Robert Jones.
Application Number | 20110266349 12/917186 |
Document ID | / |
Family ID | 27407640 |
Filed Date | 2011-11-03 |
United States Patent
Application |
20110266349 |
Kind Code |
A1 |
Bi; Daoshen ; et
al. |
November 3, 2011 |
CONTACT SMART CARDS HAVING A DOCUMENT CORE, CONTACTLESS SMART CARDS
INCLUDING MULTI-LAYERED STRUCTURE, PET-BASED IDENTIFICATION
DOCUMENT, AND METHODS OF MAKING SAME
Abstract
The present invention relates to identification documents and
smart cards. In one implementation, we provide a contactless smart
identification document comprising a first contact layer, a second
contact layer, and a carrier layer. The carrier layer is sandwiched
in between the first and second contact layers, and the carrier
layer includes least a transceiver and electronic circuitry. At
least a portion of the first and second contact layers migrate into
the carrier layer. This migration helps to secure at least a
portion of the transceiver or electronic circuitry to the first and
second contact layers,
Inventors: |
Bi; Daoshen; (Boxborugh,
MA) ; Jones; Robert; (Andover, MA) |
Assignee: |
L-1 Secure Credentialing,
Inc.
Burlington
MA
|
Family ID: |
27407640 |
Appl. No.: |
12/917186 |
Filed: |
November 1, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10836639 |
Apr 29, 2004 |
7823792 |
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12917186 |
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10329318 |
Dec 23, 2002 |
6843422 |
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10836639 |
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60344673 |
Dec 24, 2001 |
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60344717 |
Dec 24, 2001 |
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60344719 |
Dec 24, 2001 |
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Current U.S.
Class: |
235/488 ; 407/30;
409/131 |
Current CPC
Class: |
B23C 5/10 20130101; B32B
2367/00 20130101; G06K 19/07722 20130101; B32B 2425/00 20130101;
Y10T 407/19 20150115; B32B 2519/02 20130101; B23C 2210/0442
20130101; B32B 2305/342 20130101; G06K 19/077 20130101; H01L
2924/0002 20130101; G06K 19/07745 20130101; H01L 2924/00 20130101;
G06K 19/07749 20130101; H01L 2924/0002 20130101; G06K 19/07728
20130101; Y10T 409/303752 20150115 |
Class at
Publication: |
235/488 ;
409/131; 407/30 |
International
Class: |
G06K 19/067 20060101
G06K019/067; B23C 5/10 20060101 B23C005/10; B23C 3/00 20060101
B23C003/00 |
Claims
1. A contactless smart identification document comprising: a first
contact layer; a second contact layer; and a carrier layer
sandwiched in between the first and second contact layers, the
carrier layer including at least a transceiver and an electronic
circuitry, wherein at least a portion of the first and second
contact layers has migrated into the carrier layer, the migration
helping to secure at least a portion of the transceiver or the
electronic circuitry to at least one of the first and second
contact layers.
2. The contactless smart identification document of claim 1,
wherein the carrier layer comprises at least one of a scrim and a
mesh.
3. The contactless smart identification document of claim 1,
further comprising a laminate layer covering at least one of the
first and second contact layers.
4. The contactless smart identification document of claim 1,
wherein at least one of the first and second contact layers
comprises a digital watermark formed thereon.
5. The contactless smart identification document of claim 1,
wherein the electronic circuitry operates to process or store
data.
6. The contactless smart identification document of claim 1,
wherein at least one of the first and second contact layers
comprises a digital watermark formed thereon, wherein the
electronic circuitry operates to store data, and wherein at least
some information contained in the digital watermark correlates to
at least some data stored in the electronic circuitry.
7. A method of milling a cavity using a milling tool in an
identification document to receive a smart card module, the
identification document comprising at least a laminate
layer-document core sandwich structure, wherein the laminate layer
comprises a substantially different material than does the document
core, said method comprising: providing a first cut in the laminate
layer to create a rough upper cavity, the rough upper cavity
including a first aperture; providing a second cut to create a
rough lower cavity, the rough lower cavity including a second
aperture and extending through the laminate layer into the document
core, the rough lower cavity and the rough upper cavity being
approximately centered on a common axis, wherein the second
aperture is smaller than the first aperture resulting in a shelf in
the laminate layer; and providing a third cut around the rough
lower cavity to create a finished lower cavity, the finished lower
cavity having a third aperture, which is larger than the second
aperture, the finished lower cavity being approximately centered on
the common axis.
8. The method of claim 7, further comprising: providing a fourth
cut around the rough upper cavity to create a finished upper
cavity, the finished upper cavity having a fourth aperture, which
is larger than the first aperture, the finished upper cavity being
approximately centered on the common axis.
9. A milling tool for milling a cavity in an identification
document comprising: a fluted shaft having a first section and a
second section; a first cutting edge disposed on the first section,
the first cutting edge having a first bevel; and a second cutting
edge disposed on the second section, the second cutting edge having
a second bevel, wherein the first and second cutting edges are
off-centered.
10. The milling tool of claim 9, wherein at least one of the first
and second bevels is tapered in a first angle in the range of about
5-35 degrees.
11. The milling tool of claim 10, wherein the first angle comprises
about 15 degrees.
12. The milling tool of claim 9, wherein at least one of the first
and second cutting edges comprises a relief.
13. The milling tool of claim 12, wherein the relief is in a second
angle in the range of about 30-60 degrees.
14. The milling tool of claim 13, wherein the second angle
comprises about 45 degrees.
Description
RELATED APPLICATION DATA
[0001] The present application is a Continuation of U.S. patent
application Ser. No. 10/836,639, filed Apr. 29, 2004 which is a
Continuation of U.S. patent Ser. No. 10/329,318, filed Dec. 23,
2002 which claims the benefit of U.S. Provisional Patent
Application Nos. 60/344,673, 60/344,717, and 60/344,719, each filed
on Dec. 24, 2001. The present application is also related to U.S.
patent application Ser. No. 09/969,200, filed Oct. 2, 2001. Each of
the above U.S. patent documents is herein incorporated by
reference.
TECHNICAL FIELD
[0002] The present invention relates generally to identification
documents and smart cards.
BACKGROUND AND SUMMARY
[0003] Verifying one's true identity is an ever-increasing problem.
Identify theft is rampant, and stolen identifies have even been
used to facilitate terrorist attacks. Computer networks and secure
areas have been breached with misappropriated keys, passwords and
codes. Conventional solutions typically include a photo
identification document having a photographic quality image of the
license holder on the document protected from tampering by one or
more security feature. Another solution is the use of so-called
"smart cards."
[0004] The term "smart card" as used herein is defined broadly to
generally include a device that carries information. (The
definition of a smart card used in this application is broad enough
to include so-called radio frequency identification cards or RFID
cards.). Typically, a smart card includes a microprocessor (or
electronic processing circuitry) and/or memory circuitry embedded
therein. The electronic circuitry is often packaged as a module. A
memory smart card stores information in electronic memory circuits,
while a processor smart card can manipulate information stored in
associated memory. Of course a smart card module can include both
processing and memory circuitry. A "contact" smart card
communicates via a physical contact interface. A contact smart card
is typically inserted into a smart card reader, thereby making
physical contact between the interface and the reader. A
"contactless" smart card may have an antenna through which signals
are communicated, as shown in U.S. Pat. No. 6,424,029, which is
herein incorporated by reference. Thus, a contactless smart card
may not need a physical interface. Of course, a smart card can
include both a contact and contactless (e.g., antenna and
supporting circuitry) interface. A smart card may be passive in
that it lacks an internal power source. Power can be supplied
through its interface, which energizes the smart card's internal
circuits. Of course, there are smart cards that may include an
internal power source. Further background for smart cards and smart
card readers can be found, e.g., in U.S. Pat. Nos. 5,721,781,
5,955,961, 6,000,607, 6,047,888, 6,193,163, 6,199,144, 6,202,932,
6,244,514, 6,247,644, 6,257,486, and 6,485,319.
[0005] Smart cards are capable of performing a variety of
functions, including carrying data, manipulation or processing
information and data, controlling access (e.g., by carrying pass
codes, biometric data, passwords, etc.), providing identifying
information, holding biometric data, etc. Of course, this is not an
exhaustive list of possible smart card functionality.
[0006] A conventional smart card manufacturing process provides a
blank card. The blank is drilled, perhaps by a second vendor or
manufacturer. A smart card chip is inserted into a pre-drilled
blank. (U.S. Pat. No. 6,404,643, herein incorporated by reference,
discloses a card with an integrated circuit. The integrated circuit
is attached to a card blank and is bonded by melt flowing adhesive.
The card blank can have a pre-drilled cavity into which the
integrated circuit is placed, or may be the same size and shape as
is the card blank and a space there between is filled with
adhesive.) Often times the chip filled blank is passed to a third
vendor or manufacturer who prints or engraves the chip filled
blank. The printing processes available at this stage are sometimes
limited. In fact, printing is not always possible on both sides of
the card--due to the contact area presented by a smart card module.
Even if a smart card is printed after embedding an integrated
circuit module, the printing may nevertheless be vulnerable to
malicious attacks (e.g., by changing information printed on the
smart card).
[0007] We have found additional limitations that are associated
with conventional smart cards. In the case of contact smart cards,
some of these problems include the smart card module popping off
the card when flexed, flex stresses that damage the smart card
module, and/or the card itself cracking with normal wear and
tear.
[0008] Accordingly, in one embodiment of the present invention, we
provide a contact smart card including a core layer. The core layer
can include a synthetic paper--offering flexibility for the contact
smart, card. Thus, the synthetic paper core may also help to reduce
cracking often seen after normal wear and tear of conventional
smart cards. The core layer is preferably preprinted, perhaps with
personal information, prior to the insertion of a smart card
module. We can print high quality images and text--on both sides of
the document, if needed--since the smart card module is installed
after printing. The print is preferably covered with a laminate to
offer intrusion protection and wear-and-tear protection. A cavity
is formed in the laminated structure and integrated circuitry is
secured in the cavity.
[0009] Some of our smart card processes can also be controlled by
one entity, if desired, such as in a "central" issue (CI) program.
Commercial systems for issuing ID documents are of two main types,
namely so-called "central" issue (CI), and so-called "on-the-spot"
or "over-the-counter" (OTC) issue. Of course, we envision that we
will provide so-called "blank" documents (e.g., document structures
without printing and lamination, or with some pre-printing and/or
some lamination) to over-the-counter (OTC) issuing stations.
[0010] Central issue type ID documents are not immediately provided
to the bearer, but are later issued to the bearer from a central
location. For example, in one type of CI environment, a bearer
reports to a document station where data is collected, the data is
forwarded to a central location where the card is produced, and the
card is forwarded to the bearer, often by mail. Another
illustrative example of a CI assembling process occurs in a setting
where a driver passes a driving test, but then receives her license
in the mail from a CI facility a short time later. Still another
illustrative example of a CI assembling process occurs in a setting
where a driver renews her license by mail or over the Internet,
then receives a drivers license through the mail.
[0011] Centrally issued identification documents can be produced
from digitally stored information and generally comprise a core
material (also referred to as "substrate"), such as paper or
plastic, sandwiched between a plurality of layers of, e.g., clear
plastic laminate, such as polyester or polycarbonate, to protect
printed information (e.g., photographs, text, barcodes, biometric
representations, security features, etc.) from wear, exposure to
the elements and tampering. The materials used in such CI
identification documents can offer the ultimate in durability. In
addition, centrally issued digital identification documents
generally offer a higher level of security than OTC identification
documents because they offer the ability to pre-print the core of
the central issue document with security features such as
"micro-printing", ultra-violet security features, security indicia
and other features currently unique to centrally issued
identification documents. Another security advantage with centrally
issued documents is that the security features and/or secured
materials used to make those features are centrally located,
reducing the chances of loss, misappropriation or theft (as
compared to having secured materials dispersed over a wide number
of "on the spot" locations).
[0012] In addition, a CI assembling process can be more of a bulk
process facility, in which many cards are produced in a centralized
facility, one after another. The CI facility may, for example,
process thousands of cards in a continuous manner. Because the
processing occurs in bulk, CI can have an increase in efficiency as
compared to some OTC processes, especially those OTC processes that
run intermittently. Thus, CI processes can sometimes have a lower
cost per ID document, if a large volume of ID documents is
manufactured.
[0013] In contrast to CI identification documents, over-the-counter
("OTC") identification documents are issued immediately to a bearer
who is present at a document-issuing station. An OTC assembling
process provides an ID document "on-the-spot." (An illustrative
example of an OTC assembling process is a Department of Motor
Vehicles ("DMV") setting where a driver's license is issued to a
person, on the spot, after a successful exam.). In some instances,
the very nature of the OTC assembling process results in small,
sometimes compact, printing and card assemblers for printing the ID
document.
[0014] In identification and security applications, it is often
desirable to increase the functionality of identification
documents. Accordingly, one aspect of the present invention may
provide the look and/or feel of conventional identification
documents while providing smart card functionality. In one
implementation, we combine an image bearing identification card
with smart card functionality. We sometimes refer to these types of
documents as "smart identification documents." In another
implementation, we "upgrade" an identification document that may
have already passed into circulation by providing a smart card
module within a pre-circulated ID document.
[0015] Another aspect of the present invention involves
modification of a synthetic paper core-based identification (ID)
document to provide a smart card that includes integrated circuitry
(e.g., a semiconductor chip and interface), laser, thermal transfer
and/or offset printed images (e.g., including photographic
representations) and/or customized (or personalized) text and
data.
[0016] (In this document, the use of the terms "identification
document" and "ID document" is intended to include at least all
types of ID documents. Note that, for the purposes of this
disclosure, the terms "document," "card," "badge" and
"documentation" are used interchangeably. In addition, ID documents
are broadly defined herein and include (but are not limited to),
documents, magnetic disks, credit cards, bank cards, phone cards,
passports, driver's licenses, network access cards, employee
badges, debit cards, security cards, visas, immigration
documentation, national ID cards, citizenship cards, social
security cards and badges, certificates, identification cards or
documents, voter registration cards, police ID cards, border
crossing cards, security clearance badges and cards, gun permits,
badges, gift certificates or cards, membership cards or badges,
tags, CD's, consumer products, knobs, keyboards, electronic
components, etc., or any other suitable items or articles that may
record information, images, and/or other data, which may be
associated with a function and/or an object or other entity to be
identified.).
[0017] In addition, in this document, "identification" includes
(but is not limited to) information, decoration, and any other
purpose for which an indicia can be placed upon an article in the
article's raw, partially prepared, or final state. Also, instead of
ID documents, our inventive techniques can be employed with product
tags, product packaging, business cards, bags, charts, maps,
labels, etc., etc., particularly those items including an laminate
or over-laminate structure. The term ID document thus is broadly
defined herein to include these tags, labels, packaging, cards,
etc.
[0018] According to another aspect of the present invention, a
smart identification document includes: a core layer including a
first surface and a second surface; a first layer of a
substantially transparent polymer adjacently arranged on the first
surface of the core layer; an aperture; and a module. The aperture
includes a first section disposed in the first polymer layer, the
first section including a ledge in the first polymer layer, and a
second section disposed in at least the core layer. The module
includes electronic circuitry, wherein at least a first portion of
the module is adjacently arranged with the ledge, and at least a
section portion of the module extends into at least some of the
second section of the aperture.
[0019] According to still another aspect of the present invention,
an identification document includes a core layer including a front
side and a back side; printed indicia formed on at least the front
side of the core layer; a first laminate layer secured with an
adhesive to the back side of the core layer; a second laminate
layer secured with an adhesive to the front side of the core layer;
a cavity disposed in the first laminate, the cavity extending
through the first laminate layer, adhesive and into the core layer;
and electronic circuitry disposed in the cavity.
[0020] According to yet another aspect of the invention, a
manufacturing method includes the steps of providing a first
laminate and a second laminate, the first laminate comprising a
front surface and a back surface, and the second laminate
comprising a front surface and a back surface; adjacently arranging
an adhesive with the back surface of the first laminate; adjacently
arranging an adhesive with the back surface of the second laminate;
providing a core having a top surface and a bottom surface;
laminating the first laminate, adhesive, core, adhesive and second
laminate to form a structure; machining a portion of the structure;
and providing an integrated circuitry module in the machined
portion of the structure, the integrated circuitry module providing
at least some smart card functionality.
[0021] Still another aspect of the present invention relates to a
milling tool for milling a polymer and a synthetic paper structure
to receive a smart card module. The tool includes: a fluted shaft
having a first section and a second section; a first cutting edge
having a first bevel disposed on the first section; a second
cutting edge having a second bevel disposed on the second section,
the first and second cutting edges forming a first axis; and
wherein a non-cutting end of the first bevel and a non-cutting end
the second bevel form a second axis which is rotated at a first
angle in a range of 15-60 degrees from the first axis.
[0022] Yet another aspect of the present invention relates to a
method of milling a cavity in an identification document to receive
a smart card module. The identification document includes at least
a laminate layer--document core structure. The method includes
providing a first cut in the laminate layer to create a rough upper
cavity, the rough upper cavity including a first aperture;
providing a second cut to create a lower cavity, the lower cavity
extending through the laminate layer into the document core, the
lower cavity and the rough upper cavity being approximately
centered around a common axis, wherein the aperture of the lower
cavity is relatively smaller than the aperture of the rough upper
cavity resulting in a shelf in the laminate layer; and providing a
third cut around the rough upper cavity to create a finished upper
cavity, the finished upper cavity having an aperture which is
larger than the aperture of the rough upper cavity, the finished
upper cavity being approximately centered around the common
axis.
[0023] Still another aspect of the present invention includes an
identification document including: a first PET (polyethylene
terephthalate) film including a top surface and a bottom surface; a
second PET film including a top surface and a bottom surface; an
image-receiving layer provided on the first PET film top surface;
and an adhesive layer in contact with the first PET film bottom
surface and the second PET film top surface, the adhesive serving
to secure the first PET film and the second PET film to one
another.
[0024] Still another aspect of the present invention provides a
method of making a contactless smart identification document. The
method includes: providing a carrier layer including at least an
antenna and electronic circuitry, wherein the carrier comprises at
least one permeable area; arranging the carrier layer between a
first contact layer and a second contact layer, and then securing
the first contact layer and second contact layer to the carrier
layer through at least one of heat and pressure so that at least a
portion of one of the first contact layer and the second contact
layer migrates into the carrier layer at the one permeable area;
and providing first and second laminate layers over at least the
first and second contact layers, respectively.
[0025] Further aspects, features and advantages of the present
invention will become even more apparent with reference the
following detailed description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is a cross sectional view of an identification
document including a document core.
[0027] FIG. 2A is a cross-sectional view of the FIG. 1 document
including a cavity provided therein to receive a smart card module
(e.g., a contact-type smart card module).
[0028] FIG. 2B is a cross-sectional view of the FIG. 2A document
including adhesive provided on a layer shelf.
[0029] FIG. 2C is a cross-sectional view of the FIG. 2A document
including a smart card module provided in the cavity.
[0030] FIG. 3 is a flow diagram illustrating steps to manufacture,
e.g., a contact-type smart identification document according to one
aspect of the present invention.
[0031] FIG. 4A is a cross-sectional view of the FIG. 1 document
including an upper cavity provided in a laminate layer.
[0032] FIG. 4B is a cross-sectional view of the FIG. 4A document
including a lower cavity extending into a core layer.
[0033] FIG. 4C is a cross-sectional view of the FIG. 4B document
including a finish cut of the upper cavity.
[0034] FIGS. 5A-5F are diagrams illustrating a milling tool
according to one aspect of the present invention.
[0035] FIG. 6 is a cross-sectional view of a contactless smart
identification document according to one implementation.
[0036] FIG. 7 is a cross-sectional view of another implementation
of a contactless smart identification document.
[0037] FIG. 8 is a cross-sectional view of still another
implementation of a contactless smart identification document.
[0038] FIG. 9 is a cross-sectional view of yet another
implementation of a contactless smart identification document.
[0039] FIG. 10 is a top view of a contactless smart identification
document's carrier layer including an antenna and integrated
circuitry according to one aspect of the present invention.
[0040] FIG. 11 is a cross-sectional view of a contactless smart
identification document according to another implementation of the
present invention.
[0041] FIG. 12 is a cross-sectional view of the FIG. 11 contactless
smart identification document including over-laminates.
[0042] FIG. 13 is a cross-sectional view of a finished
over-the-counter identification document (conventional art).
[0043] FIG. 14 is a cross-sectional view of a PET-based
identification document according to one implementation.
[0044] FIG. 15 is cross-sectional view of another PET-based
document according to still another implementation.
[0045] Of course, the drawings are not necessarily presented to
scale, with emphasis rather being placed upon illustrating the
principles of the invention. In the drawings, like reference
numbers indicate like elements.
DETAILED DESCRIPTION OF THE INVENTION
[0046] The Detailed Description is divided into three sections for
the reader's convenience (e.g., "Contact Smart Cards Including a
Document Core," "Contactless Smart Cards Including Multi-layered
Structure," and "Manufacture of PET-Based Identification
Document"). It should be appreciated, however, that elements and
functionality disclosed in one section can be readily combined with
elements and functionality found in another section. Therefore, the
section headings should not be interpreted as limiting the scope of
the present invention.
Section 1: Contact Smart Cards Including a Document Core
[0047] For purposes of illustration, the following section will
generally proceed with reference to contact-type smart cards (which
are sometimes interchangeably referred to as a "contact smart ID
document" or a "smart ID document"). A preferred contact-type smart
ID document includes a multi-layered ID document including a
document core and fused or secured polymer laminates. The
multi-layered ID document is provided with integrated circuitry to
facilitate processing and/or memory storage. It should be
appreciated, however, that the present invention is not so limited.
Indeed, as those skilled in the art will appreciate, the inventive
techniques can be applied to many other structures formed in many
different ways. For example, contactless smart card modules can be
suitably packaged, with such packages being disposed in a cavity
created in a multi-layered document structure.
[0048] FIG. 1 is a cross-sectional view of an identification
document 1 according to one aspect of the present invention. The
identification (ID) document 1 is used as the foundation for a
smart ID document. The ID document 1 preferably includes a core 10,
and a generally transparent laminate 12. The ID document will
typically include a second laminate layer 14. Adhesive 11 and 13 is
preferably used to help adhere the laminate layers 12 and 14 to the
core 10. (Instead of separate adhesive layers 11 and 13, the
laminate 12 may be coated with an adhesive or may include adhesive
materials.) If indicia (e.g., printed text, images, machine
readable code, etc.) is provided on the core or laminate
surface(s), the adhesive 11 and 13 is preferably transparent. A
laminate structure can be cut to meet the dimensions specified for
a particular identification document, if needed.
[0049] Indicia (interchangeably used with "information") can be
provided (e.g., screen printed, offset printed, gravure printed,
thermal transferred, provided via ink or laser jet printing, laser
engraved, etc.) on the front and/or back surface of the core 10 or
laminate 14/adhesive 13 prior to lamination. For example, the
information may include variable information, which is information
that is unique to a cardholder (e.g., name, birth date, age, sex,
weight, address, biometric information, photograph, and/or
signature, etc.). The information may also include so-called
"fixed" information. Fixed information is generally thought of as
that information which remains constant from card to card, such as
issuing agency information, seal, and/or some types of security
designs, etc. Additional information, e.g., optical variable
devices, can be provided on the core 10, adhesive 11 and 13, or
laminate layers 12 and 14. (Reference may be had to assignee's U.S.
patent application Ser. No. 09/969,200, filed Oct. 2, 2001, for
even further information regarding optical variable inks and
devices. This application is herein incorporated by reference.).
Other security features that may be optionally presented on the
smart identification document include, e.g., ghost images,
microprinting, ultraviolet or infrared images, biometric
information, etc. We can optionally provide a print receiver (e.g.,
an image-receiving layer) to help a core or laminate layer better
receive printed or transferred information. (For example, see the
D2T2 receivers discussed in the present patent document and in U.S.
Pat. No. 6,066,594, which patent is herein incorporated by
reference.).
[0050] Printed or engraved information may optionally include a
so-called digital watermark. Digital watermarking is a process for
modifying physical or electronic media to embed machine-readable
indicia (or code) into the media. The media may be modified such
that the embedded code is imperceptible or nearly imperceptible to
the user, yet may be detected through an automated detection
process. In some embodiments, the printed or engraved information
identification document includes two or more digital watermarks. In
other embodiments, a digital watermark is "fragile" in that it is
designed to degrade or be lost upon copying and/or reproducing.
[0051] Digital watermarking systems typically have two primary
components: an encoder that embeds the digital watermark in host
media, and a decoder that detects and reads the embedded digital
watermark from a signal suspected of containing a digital
watermark. The encoder embeds a digital watermark by altering the
host media signal. (E.g., the encoder can make slight alterations
to a graphic, background pattern or photograph that is to be
printed on an identification document. The alterations may be to
pixel values, DCT coefficients corresponding to the host media
signal, transform domain representations of the host media signals,
etc., etc.). The reading component analyzes a suspect signal to
detect whether a digital watermark is present. In applications
where the digital watermark encodes information (e.g., as a payload
or message bits), the reader extracts this information from the
detected digital watermark. The reading component can be hosted on
a wide variety of tethered or wireless reader devices, from
conventional PC-connected cameras and computers to fully mobile
readers with built-in displays, etc. By imaging a watermarked
surface of an identification document, the watermark information
can be read and decoded by a reader.
[0052] Several particular digital watermarking techniques have been
developed. The reader is presumed to be familiar with the
literature in this field. Some techniques for embedding and
detecting imperceptible watermarks in media signals are detailed in
the assignee's co-pending U.S. patent application Ser. No.
09/503,881, U.S. Pat. No. 6,122,403 and PCT patent application
PCT/US02/20832, which are each herein incorporated by
reference.
[0053] (Material types are now provided by way of example only. Of
course, there are many other materials that may be suitably
interchanged with some aspects of the present invention. Returning
to FIG. 1, the core 10 material can include a synthetic such as
TESLIN, other synthetic materials, polymer, composite, and/or
polyolefin, etc. TESLIN is a synthetic paper sold by PPG
Industries, Inc., One PPG Place, Pittsburgh, Pa. 15272 USA. TESLIN
can be provided in sheets, with multiple cores taken from each
TESLIN sheet. The laminate (sometimes called an "over laminate")
may include (but is not limited to) film and sheet products.
Laminates usable with at least some embodiments of the invention
include those which contain substantially transparent polymers
and/or substantially transparent adhesives, or which have
substantially transparent polymers and/or substantially transparent
adhesives as a part of their structure, e.g., as an extruded
feature. In some of the embodiments of the present invention, the
term "laminate" may include both the laminate and adhesive layers
(e.g., layers 12 and 11), e.g., in FIGS. 1-2C. Examples of usable
laminates include at least polyester, polycarbonate, polystyrene,
cellulose ester, polyolefin, polysulfone, or polyamide, etc.
Laminates can be made using either an amorphous or biaxially
oriented polymer as well. A laminate can comprise a plurality of
separate laminate layers, for example a boundary layer and/or a
film layer. Our most preferred laminate, however, is a
polycarbonate. Various lamination processes are disclosed in
assignee's U.S. Pat. Nos. 5,783,024, 6,007,660, 6,066,594, and
6,159,327. Other lamination processes are disclosed, e.g., in U.S.
Pat. Nos. 6,283,188 and 6,003,581. Each of these U.S. patents is
herein incorporated by reference.)
[0054] (The degree of transparency of a laminate can, for example,
be dictated by the information contained on the core layer, the
particular colors and/or security features used, etc. The thickness
of the laminate layers is not critical, although in some
embodiments it may be preferred that the thickness of a laminate
layer be about 1-20 mils (where 1 mil is about 25 .mu.m).
Lamination of any laminate layer(s) to any other layer of material
(e.g., a core layer) can be accomplished using a conventional
lamination process, and such processes are well known to those
skilled in the production of articles such as identification
documents. Of course, the types and structures of the laminates
described herein are provided only by way of example, those skilled
in the art will appreciated that many different types of laminates
are usable in accordance with the invention. The material(s) from
which a laminate is made may be transparent, but need not be.
Laminates also includes security laminates, such as a transparent
laminate material with proprietary security technology features and
processes, which protects documents of value from counterfeiting,
data alteration, photo substitution, duplication (including color
photocopying), and simulation by use of materials and technologies
that are commonly available. Laminates also can include
thermosetting materials, such as epoxy.). Suitable laminate
materials can be readily obtained, e.g., from GE Plastics,
headquartered in Pittsfield, Mass. USA. Laminates can be even
provided in roll form, e.g., 1000 ft/roll (e.g., about 21
cards/ft).)
[0055] (One adhesive material (e.g., layers 11 and 13 in FIG. 1)
can include, e.g., KRTY as provided by Transilwrap, headquartered
in Franklin Park, Ill. 60131 USA. The adhesive may also be provided
as a laminate layer or coated onto the laminate or laminate rolls.
Other adhesives usable in accordance with some embodiments of the
invention include polyester, polyester urethane, polyether
urethane, polyolefin, and/or hot melt or ultraviolet or thermally
cured adhesive, thermoplastics, etc. The multi-layered structure is
formed during a lamination process, in which adjustments to the
processing time, temperature and pressure can be varied to optimize
lamination.)
[0056] Dimensions of an ID document will vary according to
specified design requirements. For example, applicable
International Organization for Standardization (ISO) specifications
for identification documents may specify required dimensions.
Within specified dimensions there is some dimension play. In one
implementation, we provide a core including a 4-20 mil depth,
adhesives with a 2-7 mil depth, and laminate layers ranging from
3-15 mils. Our most preferred implementation provides a 12 mil back
laminate, a 2 mil back adhesive, a 12 mil core, a 2 mil front
adhesive and a 5 mil front laminate.
[0057] In some implementations we provide a matte finish on a top
surface of the back laminate layer. The matte finish helps to feed
the laminate layer if provided in roll form. The matte finish may
also provide a tactile security feature, as an inspector can feel
the texture of the card (e.g., a matted finish) to determine if the
card is legitimate.
[0058] With reference to FIG. 2A, a cavity or well 20 is provided
(e.g., machined, milled, cut or laser etched, etc.) in the FIG. 1
ID document 1. We interchangeably use the terms "cavity" and "well"
in this document. The well 20 provides a housing or receptacle for
a smart card integrated circuit module (hereafter sometimes
referred to a "module" or as "smart card module"). The shape and
dimensions of the well 20 will vary according to the shape and
dimensions of a selected smart card module that is to be inserted
into the well 20. For discussion purposes we have chosen to
illustrate the present invention with respect to the Hitachi AE 45C
smart card chip module, as provided by Hitachi, located in
Maidenhead, Berkshire, UK, and which provides 32K bytes of memory.
A multi-application chip operating system, e.g., MULTOS or any
other suitable chip operating system, can be used to control the
operation of the smart card module. MULTOS can be obtained, e.g.,
through Moasco, Ltd in London, England. (We note that dimensions of
the Hitachi AE 45C module are analogous to the Atmel 1608 Module,
which, like other smart card modules, can be suitably interchanged
with the Hitachi AE 45C module.). Our chip selection will naturally
dictate some of the shapes and dimensions discussed below. It
should be appreciated, however, that the present invention is not
so limited. Indeed, some aspects of the present invention
anticipate the cooperation with may different smart card modules,
and corresponding cavity 20 shapes and depths. For example, in one
implementation, instead of the rectangular shaped cavity 20 as
illustrated in FIG. 2A, we provide an oval shaped cavity. The oval
shaped cavity cooperates, e.g., with an oval shaped smart card
module (e.g., Atmel's model no. AT88SC1608-090T-00--headquartered
in San Jose, Calif. USA). Of course there are many other cavity and
module shapes and sizes that will fall within the scope of the
present invention.
[0059] Returning to FIG. 2A, cavity 20 may include an upper chamber
(or cavity) 20a and a lower chamber (or cavity) 20b. The depth D of
the upper chamber 20a is generally dependent on a corresponding
depth of the smart card module. We have found that it is generally
preferable to seat the smart card module in the cavity 20 so that
the module's interface is about flush with the outer surface of
laminate 12, although the module's contact interface can slightly
protrude above (or below) the laminate 12 surface. This seating
arrangement helps to prevent the smart card module from catching on
objects, which may undesirably unseat the module from the cavity
20. The upper chamber 20a, which is adjacently arranged to the
lower chamber 20b, preferably includes a relatively larger aperture
than that of the lower chamber 20b. The aperture differences
between the lower cavity 20b and the upper cavity 20a result in a
shelf 22. We have found that it is preferable (but not required) to
provide the shelf 22 in the laminate layer 12, while allowing
sufficient laminate shelf depth d, since a smart card module's
adhesion (e.g., via adhesive) to the laminate layer 12 is generally
superior than a module's adhesion (e.g., via adhesive) to adhesive
layer 11 or core layer 10. If the depth d is too small, the shelf
22 may pull up and away from the adhesive 11 and/or core 10 layers.
In some cases we have found that too small of a depth d results in
the shelf 22 and adhesive 11 together pulling up and away from the
core 10. The depth d in our most preferred implementation is about
2 mils. Of course this preferred depth d may vary as structure
layer depths or module dimensions vary.
[0060] If using the ID document 1 as shown in FIG. 1, the lower
cavity 20b preferably extends through, e.g., the laminate 12 and
adhesive 10, and into the core 10. A depth D+ of the lower cavity
20b is generally dependent on the vertical depth of the smart card
module. While not necessary to practice the present invention, we
can provide enough depth D+ so that the bottom of the smart card
module will "float" in the well or otherwise not contact the bottom
B of the well 20 when the ID card is at rest (see FIG. 2C). This
floating arrangement provides somewhat of a cushion for the smart
card module--allowing the card to flex without causing undue stress
on the bottom of the smart card module. (We note that some thought
should be given to the depth D+of a well, since if the well is too
deep, a card assembler risks having the bottom surface of the smart
card module show through the remaining core depth--resulting in
unwanted discoloration when viewed from the front of the card.) In
our most preferred implementation, the D+ depth extends about 10
mils into the core layer. (Of course, this depth can be altered
according to layer dimensions and smart card module used, etc.). In
other implementations, the bottom and/or sides of a smart card
module contact the bottom B and/or or sides, respectively, of the
well 20, perhaps through an adhesive.
[0061] We preferably provide an adhesive to help secure a smart
card module 26 in the cavity 20. There are several options for
providing adhesive. With reference to FIG. 2B, we can provide an
adhesive 24 directly onto shelf 22, e.g., through injection or spot
adhesives. Alternatively, the smart card module can be coated with
an adhesive on a side that is to be adjacently positioned with
shelf 22. (We note that a smart ID document manufacturing method
can be automated. In such cases, the smart card modules can be
provided in roll form, e.g., one reel including about 7,500 chips.
Adhesive (e.g., cyanoacrylate epoxy from Henkel of America, in
Gulph Mills, Pa. USA) or a roll of glue tape (e.g., Tesa HAF 8410
HS or Tesa BDF 8410 from Tesa Tape, Inc. in Charlotte, N.C. USA)
can be applied to the bottom side of the chip roll. Assembling
machines provided by, e.g., Muhlbauer, headquartered in Roding,
Germany, can be used for final assembly. Such an automated process
may proceed by printing a card, laminating, cutting and verifying
dimensions and printed information, and then milling, implanting a
smart card module and then encoding or initializing the smart card
module. Testing can be performed to detect a bad smart card module,
etc.). In an implementation without shelf 22, we coat the sides
and/or bottom of a smart card module with adhesive, and/or provide
adhesive to a cavity and then insert the module.
[0062] A smart ID document results once the integrated circuitry
module is secured in a cavity of an ID document (FIG. 2C). A smart
card module can be optionally programmed to store relevant
information such as information printed on the document, biometric
information, account information, cryptographic hashes or other
algorithmic representation of data, passwords, etc. One programmer
example is a computerized smart card Personalizer, e.g., as
provided by Muhlbauer of Germany, which enters commands or data
into the smart card module. Other programmers are provided, e.g.,
from Hitachi and Atmel, among many others. Information stored in
the smart card circuitry is optionally cross-correlated with
information printed on the smart card. This cross-correlation can
be checked to verify authenticity of the document or stored
information. Or if a digital watermark is provided on the document,
a watermark payload can be cross-correlated with information stored
in the smart card's memory circuitry. A cross-correlation of the
watermark information and the module's stored information can be
analyzed to determine authenticity of the identification
document.
[0063] FIG. 3 is a flow diagram illustrating the steps to
manufacture a contact smart card according to one implementation. A
document core or substrate is provided (step S30). The document
substrate (or sometimes a laminate/adhesive layer) is printed (step
S32), e.g., to include personalized or variable information. If
printing on an inner laminate or adhesive layer, the printing may
be reversed so it appears properly oriented when viewed from the
outer surface of the laminate or adhesive layer. The printing may
also include security patterns and designs, digital watermarks, and
may also include optical variable devices, such as those provided
with optical variable ink. A photograph may be included in the
variable information. Printing options are widespread and may
include, e.g., offset printing, screen printing, laser or ink jet
printing, laser engraving, thermal transfer, etc. An image
receiving layer can also be used, e.g., to better facilitate the
reception of the information. The printed substrate is preferably
laminated (step 34). The lamination process may involve adhesives
or adhesive layers, but the present invention is not so limited.
The laminate structure optionally may be cut to desired
specifications (step not shown), if needed. A cavity or well is
provided in the laminated, printed core (step S36). The cavity can
be machined, milled, drilled, cut, etched (laser or chemical), etc.
The cavity is preferably sized to accommodate a corresponding smart
card module. In some implementations, the cavity extends into the
core. The corresponding smart card module is secured in the cavity
(step S38). While this method is anticipated to be most suited for
contact-type smart card, we anticipate that some contactless-type
smart card modules can be packaged such that they may also be
provided in a cavity, e.g., as created with reference to FIGS.
2A-3.
Milling Operation
EXAMPLE
[0064] FIGS. 4A-4C are cross sectional diagrams illustrating the
methodology behind one milling implementation of the present
invention. A cavity is milled to receive a smart card module. We
note that the illustrated method is but one of many methods that
can be used to mill or machine out a cavity in an ID document.
[0065] We start our milling discussion by returning to FIG. 1. FIG.
1 illustrates a multi-layered identification document including a
core and laminates. We realized that the material used for the
laminate (e.g., polycarbonates) and core (e.g., a synthetic like
TESLIN) was susceptible to tearing or leaving burrs when cut. The
illustrated milling technique (FIGS. 4A-4C) optimizes a milling
operation to eliminate burrs in the multi-material cavity so that a
smart card module can be securely mounted therein.
[0066] A milling (or machining or etching) tool contacts the back
laminate 12 and machines a rough upper cavity 20a (see "Rough Cut"
represented with dotted lines in FIG. 4A). The machining tool then
(preferably after re-centering or realigning according to a
reference or start position, or common axis) contacts the laminate
at the bottom of the rough upper cavity to machine out the lower
cavity 20b (see FIG. 4B). We then pass the machining tool back
through the upper cavity (preferably after re-centering or
realigning according to a reference or start position, or common
axis) to shave or finish the upper cavity (see FIG. 4C). FIG. 4C
illustrate the finish cut in relation to the original rough cut
(dotted lines). An advantage of the finish pass is to clean up any
rough edges or burrs left from the rough cut. The finish pass can
be subtle, e.g., slightly expanding the upper cavity 20a while
cleaning up debris and rough edges. (In our preferred
implementation, the finish pass comprises about a 0.001 mil cut.)
Table 1, below, illustrates software code that can be used to
automate such a milling process. The code is written so as to
operate a Muhlbauer cutting station, e.g., through a user interface
(e.g., a text editor or graphical user interface) such as provided
by Galil Motion Control, Inc. (Muhlbauer is headquartered in
Roding, Germany, while Galil Motion Control, Inc. is headquartered
in Rocklin, Calif. USA.). Of course, the dimensions and
instructions as illustrated in the Table 1 software code can be
changed according to need, card dimensions, module dimensions, card
materials used, cutting station and interface, etc.
TABLE-US-00001 TABLE 1 #F30 ! Program Name ! CRADIUS =1.8 POSX=15.1
!Defines center position for cavity on card ! POSY=23.89 POSZ=0.0
JS #MOVXYZ POSZ=0.18 ! Surface ruff cut - LEAVE .0015'' FOR Finish
cut! POS1Z=0.18 LENGTHX=12.9 ! LEAVE about .010'' FOR CLEAN-UP !
WIDTHY=11.6 ! '' '' ! RADIUS=2.3 JS#RECT ! Milling Instruction !
PR, -6000 ! Re-center over cavity ! BGY AMY POSZ=0.47 ! Lower
Cavity final cut ! POS1Z=0.47 LENGTHX=8.4 WIDTHY=8.7 RADIUS=1.8 JS
#RECT ! Milling Instruction ! PR , -5000 ! Re-center for finish cut
! BGY AMY POSZ=0.21 ! Finish Cut ! POS1Z=0.21 LENGTH=13.4
WIDTHY=12.1 ! RADIUS=2.3 JS #RECT ! Milling Instruction ! POSX=15.1
! Return Tool to a home position ! POSY=23.89 POSZ=0.0 JS #WAITPOS
END
[0067] In an alternative implementation, we make a rough cut for
the lower cavity 20b, and then follow-up with finish cut for the
lower cavity 20b. In other implementations, we make one cut for the
upper cavity 20a, and one cut for the lower cavity 20b. In still
further implementations, we provide a first cavity including the
lower cavity 20b, and then expand the first cavity to include the
final upper cavity 20a. Debris can be evacuated from the cavity 20
through pressurized air or vacuuming, etc.
Milling Tool
EXAMPLE
[0068] FIG. 5A-5D are diagrams of a milling tool that can be used
to mill a cavity in an ID document. It should be appreciated that
this is but one of many tools that can be used to provide a cavity
in an identification document. In some cases, a laser or chemical
process is used to create a cavity. In other implementations,
conventional tools or cutters are used to machine or cut a cavity
in an identification document. It will also be appreciated that
while specific dimensions (in millimeters) are provided in the FIG.
5 representations, the present invention is not so limited. Indeed
the dimensions can be changed in many respects without deviating
from the scope of this aspect of the present invention.
[0069] With reference to FIGS. 5A and 5B, the cutting tool 50
preferably includes a shaft 51 having a first 52 and second 54
section. The shaft 51 can be fluted as shown in the figures. The
first section 52 includes a first cutting edge 52a and the second
section 54 includes a second cutting edge 54a. Each of the cutting
edges 52a and 54a can be off-centered (see OC1 and OC2 in FIG. 5A).
Off-centering the cutting edges helps to provide an aggressive
cutting tool, e.g., by increasing the tool's angle of attack (e.g.,
the angle at which a cutting edge encounters material to cut). A
face (or surface) of each of the first and second cutting edges 52a
and 54a is preferably beveled or tapered. The taper helps to ensure
that the cutting edge is optimally presented to the document
material. While the FIG. 5 representations may suggest a 15-degree
bevel, we anticipate acceptable cuts with a tool including a bevel
in a range of about 5-35 degrees. As shown in FIGS. 5A and 5B, a
relief 56 can be provided for each of the cutting edges. The relief
is another mechanism to help present the cutting edge to the
material in a favorable manner. While the figures suggest a
45-degree relief, we anticipate that a relief in the range of about
30-60 degrees will provide acceptable results.
[0070] One advantage of this type of tool is that its configuration
allows for a carving type cutting motion, in comparison to
conventional tools that provide more of a scrapping or tearing
motion. A carving motion allows for a clean cut, e.g., for shelf
22. A clean shelf allows for a better bonding surface with an
adhesive.
[0071] Other features and advantages of this cutting tool are
readily discernable from further examination of the drawings,
including FIGS. 5C-5F.
Inventive Combinations
[0072] In addition to the inventive aspects detailed above and in
the claims, some of the inventive combinations with respect to
(e.g., contact-type) smart ID documents include the following:
[0073] A. An identification document comprising:
[0074] a core layer including a front side and a back side;
[0075] printed indicia formed on at least the front side of the
core layer;
[0076] a first laminate layer secured with an adhesive to the back
side of the core layer;
[0077] a second laminate layer secured with an adhesive to the
front side of the core layer;
[0078] a cavity disposed in the first laminate, the cavity
extending through the first laminate layer, adhesive and into the
core layer; and
[0079] electronic circuitry disposed in the cavity.
[0080] A1. The identification document of combination A wherein the
cavity comprises an upper cavity and a lower cavity, an aperture of
the upper cavity being relatively larger than an aperture of the
lower cavity so as to result in a shelf, wherein the electronic
circuitry is packaged and a portion of the package is adjacently
arranged on the shelf.
[0081] A2. The identification document of combination A1, wherein a
portion of the package floats in the lower cavity.
[0082] A3. The identification document of combination A1, wherein
the lower cavity includes a floor in the core layer, and wherein a
portion of the package extends into the lower cavity but does not
contact the floor when the identification document is at rest.
[0083] B. A manufacturing method comprising the steps of:
[0084] providing a first laminate and a second laminate, the first
laminate comprising a front surface and a back surface, and the
second laminate comprising a front surface and a back surface;
[0085] adjacently arranging an adhesive with the back surface of
the first laminate;
[0086] adjacently arranging an adhesive with the back surface of
the second laminate;
[0087] providing a core having top surface and a bottom
surface;
[0088] laminating the first laminate, adhesive, core, adhesive and
second laminate to form a structure;
[0089] machining a portion of the structure; and
[0090] providing an integrated circuitry module in the machined
portion of the structure, the integrated circuitry module providing
at least some smart card functionality.
[0091] B1. The method of combination B, further comprising a step
of printing the core prior to said laminating step.
[0092] B2. The method of combination B1, wherein the printing
comprises at least one of a photograph, name, birth date; social
security number, signature and identification number.
[0093] B3. The method of combination B1, wherein the printing
comprises at least one of: offset inks, process inks, thermal
transfer, laser xerography and laser printer toners.
[0094] B4. The method of combination B1, further comprising the
step of cutting the structure into the shape of an identification
card.
[0095] B5. The method of combination B, wherein the core comprises
a sheet of TESLIN.
[0096] B6. The method of combination B, wherein the at least some
smart card functionality comprises at least one of data carrier,
data manipulation, access control, identification verification,
biometric carrier and data processing.
[0097] B7. The method of combination B1, wherein the printing
comprises steganographic indicia.
[0098] B8. The method of combination B7, wherein the steganographic
indicia comprises a digital watermark.
[0099] B9. The method of combination B8, wherein the digital
watermark comprises a fragile watermark.
[0100] B10. The method of combination B8, wherein the integrated
circuitry module comprises information stored therein, and wherein
the information corresponds to the digital watermark for
cross-correlation.
[0101] B11. An identification document made according to any one of
the combinations set forth in B-B10.
[0102] C. A manufacturing method comprising the steps of:
[0103] providing a first laminate and a second laminate, the first
laminate comprising a front surface and a back surface, and the
second laminate comprising a front surface and a back surface;
[0104] providing a core having top surface and a bottom
surface;
[0105] laminating the first laminate, second laminate and core to
form a structure, the structure comprising the back surface of the
first laminate in contact with the top surface of the core and the
back surface of the second laminate in contact with the bottom
surface of the core;
[0106] milling a cavity through the first laminate and into the
core for affixing an integrated circuitry module; and
[0107] providing an integrated circuitry module in the cavity, the
integrated circuitry module providing at least some smart card
functionality.
[0108] C1. The method of combination C, further comprising the step
of printing the core or second laminate prior to said laminating
step.
[0109] C2. The method of combination C, wherein the core comprises
a silica-filled polyolefin.
[0110] C3. The method of combination C, wherein the core comprises
a synthetic paper.
[0111] C4. The method of combination C, wherein each of the first
laminate and second laminate comprise an adhesive layer, the
adhesive layers being arranged between the first laminate and the
core and second laminate and the core, respectively.
[0112] C5. The method of combination C4, wherein the adhesive
comprises a thermoplastic adhesive.
[0113] C6. The method of combination C, wherein at least one of the
first laminate and the second laminate comprises a security
feature.
[0114] C7. An identification document made according to combination
C.
[0115] C8. An identification document made according to combination
C4.
[0116] C9. The method of combination C, wherein said milling step
creates a shelf in the first laminate layer, and wherein said
providing an integrated circuitry module in the cavity step
provides the module to be adjacently arranged on the shelf.
[0117] C10. The method of combination C9, wherein at least a
portion of the module extends into the core layer.
[0118] C11. The method of combination C10, wherein the module
portion that extends into the core layer does not extend to a
bottom of the cavity.
[0119] D. A manufacturing method comprising the steps of:
[0120] providing a first laminate and a second laminate, the first
laminate comprising a front surface and a back surface, and the
second laminate comprising a front surface and a back surface;
[0121] coating the back surface of the first laminate with
adhesive;
[0122] coating the back surface of the second laminate with
adhesive;
[0123] providing a core having top surface and a bottom
surface;
[0124] laminating the first laminate, second laminate and core to
form a structure, the structure comprising the adhesively coated
back surface of the first laminate in contact with the top surface
of the core and the adhesively coated back surface of the second
laminate in contact with the bottom surface of the core;
[0125] machining a portion of the structure; and
[0126] providing an integrated circuitry module in the machined
portion of the structure, the integrated circuitry module providing
at least some smart card functionality.
[0127] D1. A document made according to the method of combination
D.
[0128] E. A manufacturing method comprising the steps of:
[0129] providing a first laminate and a second laminate, the first
laminate comprising a front surface and a back surface, and the
second laminate comprising a front surface and a back surface;
[0130] providing a core having top surface and a bottom
surface;
[0131] laminating the first laminate, second laminate and core to
form a structure, the structure comprising the back surface of the
first laminate in contact with the top surface of the core and the
back surface of the second laminate in contact with the bottom
surface of the core; and
[0132] providing an integrated circuitry module in the structure,
the integrated circuitry module providing at least some smart card
functionality.
[0133] E1. A document made according to the method of combination
E.
[0134] F. A method of milling a cavity in an identification
document to receive a smart card module, the identification
document comprising at least a laminate layer--document core
sandwich structure, said method comprising:
[0135] providing a first cut in the laminate layer to create a
rough upper cavity, the rough upper cavity including a first
aperture;
[0136] providing a second cut to create a lower cavity, the lower
cavity extending through the laminate layer into the document core,
the lower cavity and the rough upper cavity being approximately
centered around a common axis, wherein the aperture of the lower
cavity is relatively smaller than the aperture of the rough upper
cavity resulting in a shelf in the laminate layer; and
[0137] providing a third cut around the rough upper cavity to
create a finished upper cavity, the finished upper cavity having an
aperture which is larger than the aperture of the rough upper
cavity, the finished upper cavity being approximately centered on
the common axis.
[0138] F1. The method of combination F, wherein the laminate layer
comprises an adhesive, so that the sandwich structure comprises a
laminate-adhesive-document core structure.
[0139] F2. The method of combination F1, wherein the shelf is
provided in laminate.
[0140] F3. The method of combination F2, wherein the document
comprises document-holder specific printing thereon.
[0141] F4. The method of combination F, wherein the laminate layer
comprises a polymer and the document core comprises a synthetic
paper.
[0142] F5. The method of combination F4, wherein the synthetic
paper comprises TESLIN.
[0143] F6. An identification document made according to any one of
the methods set forth in combinations F-F5.
[0144] G. A contact smart card comprising:
[0145] a core layer including a top surface and a back surface;
[0146] a first laminate layer adjacently secured to the top surface
core layer;
[0147] a second laminate layer adjacently secured to back surface
of the core layer;
[0148] printed indicia provided either on the top surface of the
core layer or on a surface of the first laminate layer that is to
be secured to the top surface of the core, the indicia comprising
at least some information that is unique to a bearer of the contact
smart card;
[0149] a well disposed in at least the second laminate layer;
and
[0150] an integrated circuitry module provided in the well, the
module including a contact surface.
[0151] G1. The contact smart card of combination G, wherein the
well includes a shelf in the laminate layer and the well extends
into the core layer, and wherein at least a first portion of the
module is adjacently arranged on the shelf and a second portion of
the module extends into the core layer.
[0152] G2. The contact smart card of combination G wherein the
information comprises a photographic representation of the
bearer.
[0153] H. A milling tool for milling a polymer and a synthetic
paper structure for receiving a smart card module comprising:
[0154] a fluted shaft having a first section and a second
section;
[0155] a first cutting edge having a first bevel disposed on the
first section;
[0156] a second cutting edge having a second bevel disposed on the
second section, the first and second cutting edges forming a first
axis; and
[0157] wherein a non-cutting end of the first bevel and a
non-cutting end the second bevel form a second axis which is
rotated at a first angle in a range of 15-60 degrees from the first
axis.
[0158] H1. The milling tool of combination H, wherein the first
bevel is tapered in a range of 5 and 45 degrees.
[0159] H2. The milling tool of combination H, wherein the first
bevel is tapered at an angle of 15 degrees.
[0160] H3. The milling tool of combination H, wherein the second
bevel is tapered in a range of 5 and 45 degrees.
[0161] H4. The milling tool of combination H3, wherein the second
bevel is tapered at an angle of 15 degrees.
[0162] H5. The milling tool of combination H3 wherein the first
angle comprises 45 degrees.
Section 2: Contactless Smart Cards Including Multi-Layered
Structure
[0163] The following section primarily focuses on contactless smart
cards. However, it should be appreciated that our inventive
techniques can be extended to include contact smart card and other
identification documents as well. A contactless smart card can be
generalized as a card including integrated electronic circuitry.
Unlike a contact-type smart card, where the integrated electronic
circuitry communicates via a physical contact interface, a
contactless smart card communicates (e.g., transfers/receives) data
via an antenna or transceiver structure. The antenna (or
transceiver) is connected to the integrated circuitry. A
contactless smart card may include an internal power source to
energize its electronic circuitry. Alternatively, the integrated
circuitry can be energized through electromagnetic energy received
through the antenna (or other transceiver structure). The
integrated circuitry can include data processing circuitry for
processing or manipulating data or software instructions, and/or
memory circuitry for data storage. (Of course, the circuitry can
include other components such as a clock generator, system bus
structure, and buffers, etc., etc.).
[0164] Some contactless smart cards have heretofore been affiliated
with their fair share of problems. One problem is protecting a
contact between the antenna and the integrated circuitry.
Communication ability of a contactless smart card will be lost or
hampered if the contact between an antenna and circuitry is
severed. Protecting this connection becomes a chore, since smart
cards are often subjected to onerous stresses and flexing. An
associated problem with conventional smart cards is longevity. We
have found that conventional contactless smart cards crack,
degrade, and/or fail to operate as anticipated. We overcome some or
all of these drawbacks in one implementation of an inventive
contactless smart card.
[0165] Another implementation of contactless smart cards combines a
contactless smart card with the benefits of an identification
document. Some identification document benefits may include (but
are not limited to): photographic representations, personalized
information, security indicia, over-laminate layers, etc., etc.
[0166] In another implementation of a contactless smart card, we
provide a multi-layered card structure that provides the benefits
of a smart card with the durability and flexibility of a
multi-layer structure. Multi-layers may also provide protection
from unwanted radiation, e.g., ultraviolet radiation, which may
interfere with contactless communication.
[0167] In yet another implementation of a contactless smart card,
we employ a central issue (CI) type issuing model when producing
inventive contactless smart cards. A central issue model allows us
to tightly control the materials and processing of contactless
smart cards.
[0168] These and further features, implementations and advantages
of our contactless smart cards (or "contactless smart ID
documents") will become even more evident with reference to the
following disclosure and corresponding figures.
[0169] One implementation of a multi-layer contactless smart card
60 (or smart ID document) is disclosed with reference to FIG. 6. A
carrier layer 61 is provided. The carrier layer 61 carries or
includes a contactless smart card module, such as an antenna 100
(or transceiver, etc.), and electronic circuitry 102 (see FIG. 10).
The circuitry 102 may include processing and memory circuitry
(e.g., 2K-256K bytes, etc.). In some cases a chip operating system
is employed with the integrated circuitry 102. The antenna
communicates with the circuitry 102 through an interface or contact
104. (Note that there may be more or less contacts as shown in FIG.
10.). Of course, the antenna 100 can include a plurality of
receiving elements (e.g., loops or coils, copper wiring, etc.).
[0170] The carrier 61 is sandwiched between contact layers 62a and
62b. Contact layers 62a and 62b may include, e.g., a polymer,
synthetic, composite, etc., and can include a layered structure
such as a polymer-adhesive layering. The carrier layer 61 is
preferably permeable, e.g., like a mesh or scrim. The carrier layer
61 material can be composed of many different materials including,
e.g., polymers, PET (polyethylene terephthalate), PET fibers,
polycarbonate, polyester, poly-composite, polystyrene, cellulose
ester, polyolefin, polysulfone, poly-bends, composites, etc., etc.
One suitable scrim material that includes contactless smart card
circuitry and transceiver means is provided by Hitachi
Semiconductor (America), Inc., with US headquarters in San Jose,
Calif. (For example, Hitachi can provide a scrim inlay, in sheet
sizes of about 153/4''.times.24'', including 6-by-6 wired antennas
and corresponding integrated circuits, each antenna/circuit/carrier
layer have a dimension of about 45 mm.times.77 mm. When using scrim
sheets, and/or when aligning individual antenna/circuitry, some
care should be given to ensure proper alignment of the carrier
layer 61 (e.g., including the antenna/circuitry) when considering
cutting (e.g., die cutting), preprint information and/or
personalization of a contactless smart identification document. If
using a mesh material, we have found excellent results when using a
mesh weight-per-area ratio in a range of about 5 grams/m.sup.2-20
grams/m.sup.2. Our most preferred mesh includes a ratio of about 10
grams/m.sup.2. In some implementations the antenna 100 and
integrated circuitry 102 are positioned or embedded between two
sheets of carrier (e.g., scrim or mesh) material. Of course, there
are many other acceptable carrier layers and/or contactless smart
card modules that are suitably interchangeable with this aspect of
the present invention such as those provided by Philips and Sony,
among many others.
[0171] A permeable carrier 61 facilitates the migration of contact
layers 62a and 62b into and/or through the carrier layer 61 during
a lamination (e.g., heat and/or pressure) process. The migration of
the contact layers into and/or through the carrier 61 helps to
firmly secure the smart card module, including the contact 104
between the antenna 100 and integrated electronic circuitry
102.
[0172] In an alternative implementation we embed (e.g., through
injection molding, lamination, etc.) a contactless smart card
module in a carrier layer 61. The carrier layer 61 is generally
solid instead of permeable in this implementation. In this
implementation the carrier layer 61 preferably includes a material
that is receptive to lamination or bonding, e.g., a polymer or
adhesive material. In still a further alternative implementation, a
carrier layer 61 comprises a metal or conductive material (e.g.,
copper wiring). The carrier layer 61 itself serves as the antenna
100, which is connected to the electronic circuitry 102 via a
contact 104.
[0173] Regardless of which implementation is employed, contact
layer 62a and/or 62b can receive indicia (or printing) provided
thereon. The printing may include information that is typically
associated with an identification document, such as a photographic
representation of the card bearer, variable information, e.g.,
name, address, sex, height, weight, biometric information,
signature, and/or citizenship, etc., etc. The printing may
optionally include so-called fixed information such as information
pertaining to an issuing authority, security feature (e.g., optical
variable devices, etc.), etc. In other implementations, the indicia
includes a digital watermark. Instead of printing information on
the contact layer 62a or 62b surface, we sometimes print
information on an underside of a laminate/adhesive (e.g., 64a
and/or 64b). If printing on an inner laminate or adhesive layer,
the printing may be reversed so it appears properly oriented when
viewed from an outer surface of the laminate or adhesive layer. In
some implementations, the ink and printing techniques disclosed in
Bentley Bloomberg and Bob Jones' patent application titled "INK
WITH COHESIVE FAILURE AND IDENTIFICATION DOCUMENT INCLUDING SAME,"
filed concurrently herewith (Attorney Docket No. P0714D) will be
used to print a contactless (or contact) smart identification
document. Printing techniques may include offset, gravure, screen,
thermal transfer, ink or laser jet, etc.
[0174] In some implementations of our contactless smart ID
document, we pre-print information onto a layer surface. The
pre-printed information may include variable or fixed
information.
[0175] Generally transparent laminate layers 64a and 64b are
provided over the contact layers 62a and 62b, respectively. The
laminate layers 64a and 64b are secured to the contact layers,
e.g., through a conventional lamination process involving heat
and/or pressure. Laminates like those discussed above in Section 1
can be used here also. Laminate layers 64a and 64b provide some
degree of intrusion protection for information printed on the smart
card, as well as providing additional strength and a moisture
barrier.
[0176] While specific dimensions may be dictated according to
identification document required standards, we note that our
preferred dimensions for the contactless smart identification
document shown in FIG. 7 include: carrier (3-15 mils); contact
layers (3-16 mils); and laminate (2-15 mils). A preferred range of
document depths is between about 27-40 mils, with our most
preferred document depth includes about 30 mils.
[0177] Further implementations and examples of contactless smart
identification documents are discussed with reference to FIGS.
7-12.
[0178] With reference to FIG. 7, contact layers 62a and 62b include
an adhesive (AD)/polymer/adhesive (AD) structure. The adhesive can
be coated or layered on the polymer. The polymer layers (62a and
62b) may be formed from any polymer, for example polyester,
polystyrene, cellulose ester, polyolefin, polysulfone, or
polyimide. Either an amorphous or biaxially oriented polymer may be
used. But we use polycarbonate as our most preferred polymer. The
polymer 62a and 62b can be colored, e.g., white, to help accentuate
indicia provided thereon or on the laminate layers 64a or 64b. (In
some implementations (not shown), we even provide a synthetic with
adhesive layers (e.g., adhesively coated TESLIN), composite,
poly-bend and/or paper--instead of a polymer--as a contact layer
62a and 62b material.). The contact layers 62a and 62b can
optionally include coloration, e.g., white, if desired. The
adhesive layers AD (or coating) help secure the contact layers 62a
and 62b to the carrier layer 61 and to the laminate layers 64a and
64b during a lamination process. In one implementation the adhesive
comprises a co-extruded polyurethane (PU) (e.g., with a soft point
between about 230-290.degree. F.). In another implementation we use
an aliphatic PU-based adhesive, CLA-93A, from Thermedics, Inc. in
Woburn, Mass. Still another suitable adhesive is KRTY as provided
by Transilwrap, headquartered in Franklin Park, Ill. 60131 USA.
Other suitable adhesives may include polyester, polyester urethane,
polyether urethane, polyolefin, poly-composites, thermoplastic
adhesives, and/or a hot melt or ultraviolet or thermally cured
adhesive; of course, an adhesive may be coated, extruded or cast on
to one surface of the polymer layer. The laminate layers 64a and
64b can also include, e.g., a polymer, polycarbonate, polyester,
polyester urethane, poly-composite, polystyrene, polybutylene
terephthalate (PBT), cellulose ester, polyolefin, polysulfone,
polyimide, and/or polybutylene terephthalate (PBT), etc. Here
again, our most preferred laminate layers 64a and 64b each comprise
polycarbonate. Polycarbonate sheets are widely available, e.g.,
from GE Plastics, headquartered in Pittsfield, Mass.
[0179] With reference to FIG. 8, contact layers 62a and 62b
preferably include an Adhesive (AD2)/Polymer/Adhesive (AD1)
structure, while the laminates (64a and 64b) preferably include a
Polymer/Adhesive (AD3) structure. Adhesive 2 is selected so as to
provide a favorable bond with Adhesive 1 and Adhesive 3. Similarly,
Adhesive 1 is selected to favorably bond with adhesive 2 and 3. (In
some cases, Adhesive 2 and Adhesive 3 will comprise the same
adhesive.). Our most preferred implementation employs a
polycarbonate as the polymer and polyurethane as the adhesives. Of
course, other materials as discussed above can be used instead. If
the adhesive layers include polyurethane, and since the foundation
of polyurethane chemistry is generally based on isocyanate, a
variety of monomers and different reactions can be exploited for
synthesis of polymeric materials with desired properties, such as
flexibility, toughness, durability, adhesion, and UV-stability by
other additives. Additional polyurethane compounds need not be
explored herein; rather, one inventive concept is applying
different polyurethane compounds to the various layers to achieve
desired properties.
[0180] With reference to FIG. 9, our contact layers 62a and 62b and
our laminate layers 64a and 64b each comprise a polymer (or
synthetic)/adhesive structure. The adhesive sides (or coating)
contact one another to help form a bond. Our most preferred
implementation employs a polycarbonate as the polymer and a
polyurethane as the adhesive. Of course, other materials as
discussed in this patent document and those known in the art as
suitable equivalents can be used instead.
[0181] With reference to FIG. 11, we provide yet another example of
a contactless smart identification document. We start with scrim
inlay sheets (e.g., with a sheet size of about 153/4''.times.24''
that include about 6.times.6 antenna 100/chip 102 structures, with
each antenna/chip structure having a dimension of about 45
mm.times.77 mm, as can be supplied from HITACHI). Of course the
scrim inlay sheets can be cut or otherwise sized as well. The
antenna/chip structure is preferably disposed between (or embedded)
two scrim layers or sheets to form a scrim core 110.
[0182] The scrim core 110 is preferably sandwiched between contact
layers 112 and 114. Each contact layer 112 and 114 preferably
includes a polycarbonate layer (a) and polyurethane layers (b and
c) (e.g., each layer comprises about 2 mils of polyurethane (e.g.,
CLA93A from Thermedics, Inc.), about 8 mils of white polycarbonate
film (e.g., as supplied by GE Plastics), and about 2 mils of
polyurethane (e.g., CLA93A)). The polyurethane layers (b and c) can
be coated, extruded, sprayed, layered, etc. onto the polycarbonate
layer (a). Some care is given to the alignment of the scrim 110
(e.g., including multiple antenna/chip structures) and contact
layers 112 and 114 to allow for favorable printing and cutting down
stream. In some situations, we can even provide a registration
marker (e.g., printing) on an outer surface of the polycarbonate or
polyurethane to help properly align the contact layers 112 and 114.
In other cases we provide information (e.g., so-called fixed
indicia) on an outer surface of layer 112b and 114c. The
information can be offset printed, xerographically printed, laser
printed, gravure printed, etc., etc.
[0183] Contact layers 112 and 114 are secured to the scrim core
110. For example, we attach the contact layers 112 and 114 through
a lamination process (e.g., a heated surface, roller, or iron
press). The H1 structure shown in FIG. 11 results (i.e., without
the spacing as illustrated). A preferred resulting structure is an
8.5''.times.11'' sheet, including a laminated scrim core
110/contact layer 112 and 114 structure. Of course, other sheet
sizes can be used as well. If using an 8.5''.times.11'' sheet there
are usually about nine antenna/chip structures per sheet. We have
two preferred branches in our process at this point. A first branch
includes cutting (e.g., die cutting) the sheet into blanks after
the H1 structure is assembled. Each blank includes one antenna/chip
structure having a cross-section as shown in FIG. 11. The blanks
can be, e.g., supplied to an over-the-counter issuing station, and
further processed by, for example, printing personal information on
the blank or on an over-laminate and/or programming the on-card
chip.
[0184] The second branch, perhaps better suited for use with a
central-issue model, is discussed with reference to FIG. 12. The H1
structure sheet (e.g., including multiple antenna/chip structures)
is even further protected by providing over-laminate sheets 116a
and 116b (e.g., 7 mil clear polycarbonate, e.g., HP92W supplied
from GE Plastics). In some cases, the over-laminates 116a and 116b
will include an adhesive (not shown) to even further help the
lamination process. The laminate layers 116a and 116b are
preferably personalized prior to lamination. The personalization
may include printing variable information (e.g., photographs, text,
graphics, signatures, etc., etc.) through laser printing (e.g.,
Xerox's DOC12 laser printer), ink jet printing, offset printing,
screen-printing, etc. (We note that the printing of variable
information is preferably reversely printed in the FIG. 12
implementation, since the print is provided on an inner surface of
the laminate layers 116a and/or 116b. Thus, the printed information
appears correctly aligned when viewed from the "view angle" shown
in FIG. 12.).
[0185] The over-laminates 116a and 116b can be secured to the H1
structure through, e.g., lamination. One lamination techniques is a
platen press, which receives the H1 structure and over-laminates
116a and 116b. The platen press includes upper and lower plates
(e.g., Teflon coated metal or glass plates), which press (e.g.,
about 2.5K PSI) the H1 structure and over-laminates 116a and 116b
with heat (e.g., up to about 275.degree. F.) to form the H2
structure (i.e., without the spacing as illustrated). The
lamination time varies between about 3-15 minutes, with an optimal
lamination of about 10 minutes. Of course, other lamination
techniques (e.g., rollers, press, pads, etc.) can be used to secure
the over-laminates 116a and 116b to the H1 structure. The laminated
structure H2 is cut (e.g., die cut) to yield multi-contactless
smart identification documents. Each of these contactless smart
identification document can be programmed as needed (e.g., the
on-board chip 102 can be programmed to include personalized
information such as pass codes, biometric information,
identification information, information corresponding to the
cardholder or to information printed on the identification
document, etc.).
[0186] While specific structures have been discussed with respect
to FIGS. 6-12, we note that many other implementations will fall
within the scope of the present invention. For example, additional
layers (e.g., laminate layers or print layers) can be added to the
illustrated structures. Also, in a few cases, we use a structure
including a contact layer/carrier/contact layer structure, or a
laminate/contact layer/carrier/contact layer structure. In another
implementation, we provide a cavity in an identification document,
and then secure a contactless smart card module in the cavity.
[0187] And while we have described certain materials and dimensions
for our contactless smart identification documents the present
invention should not be limited to such. Indeed, the present
invention includes many more contactless smart identification
documents of different dimensions and materials.
Inventive Combinations
[0188] In addition to the inventive aspects detailed above and in
the claims, some of the inventive combinations with respect to
(e.g., contactless) smart ID documents include the following:
[0189] A. A method of manufacturing a contactless smart card
comprising the steps of:
[0190] providing a first contact layer and a second contact layer,
the first contact layer comprising a front surface and a back
surface, and the second contact layer comprising a front surface
and a back surface;
[0191] providing an adhesive adjacently with at least the back
surface of the first contact layer;
[0192] providing an adhesive adjacently with at least the back
surface of the second contact layer;
[0193] providing a carrier having a top surface and a bottom
surface;
[0194] combining the first contact layer, second contact layer and
carrier to form a multi-layered structure, wherein the carrier
comprises an antenna and electronic circuitry therein.
[0195] A1. The method of combination A, wherein the carrier
comprises scrim and the electronic circuitry provides at least some
smart card functionality.
[0196] A2. The method of combination Al, further comprising the
steps of:
[0197] coating at least the front surface of the first layer;
and
[0198] coating at least the front surface of the second layer.
[0199] A3. The method of combination A2, wherein the coating
comprises polyurethane, and the first and second layers each
comprises polycarbonate.
[0200] A4. The method of combination A3, further comprising the
step of laminating a top laminate and a bottom laminate
respectively so as to be in contact with the front surface of the
first contact layer and the front surface of the second contact
layer.
[0201] A5. The method of combination A1, further comprising the
step of printing at least the first contact layer prior to said
combining step.
[0202] A6. The method of combination A1, further comprising
providing a laminate over at least the first contact layer, wherein
the laminate comprises personalized information thereon, the
information being document-holder specific.
[0203] B. A method of producing smart cards or identification
documents comprising the steps of:
[0204] providing a scrim core comprising electrical circuitry and
an antenna; and
[0205] providing the scrim core between a first layer and a second
layer so that the first layer and second layer migrate into or
through the scrim layer.
[0206] B1. The method of combination B, wherein the first layer and
second layer each comprise polycarbonate.
[0207] B2. The method of claim B1, wherein the first layer contacts
a core top side and the second layer contacts a core bottom side,
wherein the top side layer is coated with a first polyurethane
material and the bottom side second material is coated with a
second polyurethane material.
[0208] B3. The method of any one of claims B, B1 and B2, wherein
the electrical circuitry operates to provide at least some smart
card functionality.
[0209] B4. The method of claim B3, wherein the at least some smart
card functionality comprises at least one of data carrier, data
manipulation, access control, identification verification,
biometric carrier and data processing.
[0210] C. A smart identification document manufactured by the
method in any one of claims A-A6 and B-B4.
[0211] D. A method of making a contactless smart identification
document comprising:
[0212] providing a carrier layer including at least a transceiver
and electronic circuitry, wherein the carrier comprises at least
one permeable area;
[0213] arranging the carrier layer between a first contact layer
and a second contact layer, and then securing the first contact
layer and second contact layer to the carrier layer through at
least one of heat and pressure so that at least a portion of one of
the first contact layer and the second contact layer migrates into
the carrier layer at the one permeable area; and
[0214] providing a first laminate layer over at least the first
contact layer.
[0215] D1. The method of combination D, wherein indicia is provided
on at least one of the first contact layer and the first laminate
layer prior to said providing a first laminate layer step.
[0216] D2. The method of combination D1 further comprising
providing a second laminate layer over the second contact
layer.
[0217] D3. The method of combination D1 wherein the first contact
layer and the first laminate layer each comprise a polymer.
[0218] D4. The method of combination D3, wherein the first contact
layer comprises an adhesive/polymer/adhesive structure.
[0219] D5. The method of combination D4 wherein the second contact
layer comprises an adhesive/polymer/adhesive structure.
[0220] D6. The method of combination D3, wherein the first laminate
comprises a polymer/adhesive structure.
[0221] D7. The method according to any one of combinations D3-D6,
wherein the polymer comprises polycarbonate.
[0222] D8. The method according to combination D7 wherein the
adhesive comprises polyurethane.
[0223] E. A contactless smart identification document
comprising:
[0224] a first contact layer;
[0225] a second contact layer;
[0226] a carrier layer sandwiched in between the first and second
contact layers, the carrier layer including at least a transceiver
and electronic circuitry;
[0227] wherein at least a portion of the first contact layer and
the second contact layer have migrated into the carrier layer, the
migration helping to secure at least a portion of the transceiver
or electronic circuitry to the first and second contact layers;
and
[0228] a first laminate layer covering the first contact layer and
a second laminate layer covering the second contact layer.
[0229] E1. The contactless smart identification document of
combination E wherein the carrier comprises at least one of a scrim
and mesh.
[0230] F. A method of manufacturing a contactless smart card
comprising the steps of
[0231] providing a first layer and a second layer, the first layer
comprising a front surface and a back surface, and the second layer
comprising a front surface and a back surface;
[0232] coating at least the back surface of the first layer with an
adhesive;
[0233] coating at least the back surface of the second layer with
an adhesive;
[0234] providing a core having a top surface and a bottom
surface;
[0235] combining the first layer, second layer and core to form a
core structure, the core structure comprising the coated back
surface of the first layer in contact with the top surface of the
core and the coated back surface of the second layer in contact
with the bottom surface of the core, wherein the core comprises an
antenna and electronic circuitry contained therein.
[0236] G. A method of producing smart identification documents
comprising the steps of:
[0237] providing a scrim core comprising electrical circuitry and
an antenna; and
[0238] providing the scrim core between a first layer and a second
layer.
Section 3: Manufacture of PET-Based Identification Document
[0239] The following section focuses primarily on identification
documents. In particular, we present an incredibly earth-friendly
and easily recycle-able identification document at a relatively low
cost-per card. In one implementation, we provide an identification
document structure including PET (polyethylene terephthalate)
materials. PET material also has good strength and flexibility
(with a low cracking tendency) and high anti-abrasion
properties--while also providing advantageous cost
efficiencies.
[0240] We envision that in some implementations of the present
invention, our inventive a PET-base identification documents will
be used in an over-the-counter (OTC) issuing model. As discussed in
the background section above, over-the-counter ("OTC")
identification documents are generally issued immediately to a
bearer who is present at a document-issuing station. An OTC
assembling process provides an ID document "on-the-spot". (An
illustrative example of an OTC assembling process is a Department
of Motor Vehicles ("DMV") setting where a driver's license is
issued to a person, on the spot, after a successful exam.). In some
instances, the very nature of the OTC assembling process results in
small, sometimes compact, printing and card assemblers for printing
the ID document. Of course, our inventive PET identification
documents can be used in a central issue (CI) model as well.
[0241] One example of an OTC identification document (as disclosed
in our U.S. Pat. No. 6,066,594, and which is herein incorporated by
reference) is shown in FIG. 13. FIG. 13 shows a schematic
cross-section through an over-the-counter identification document
(card). The document comprises a core layer 112 formed of an opaque
white reflective polyolefin (e.g., a TESLIN sheet) and printed on
both surfaces with fixed indicia 114.
[0242] The printed core layer 112 is sandwiched between two polymer
layers 116 formed from an amorphous or biaxially oriented polyester
or other optically clear plastic such as polycarbonate. Each of
these polymer layers 116 is fixedly secured to the core layer 112
by a layer 118 of adhesive. On the opposed side of each polymer
layer 116 from the core 112 is provided an image-receiving layer
120 suited to the acceptance of printed image or portrait or other
variable indicia (indicated schematically at 122) by dye diffusion
thermal transfer methods. The material used to form the
image-receiving layers 120 is chosen so as to be immiscible with
the polymer system of the donor sheet used, in accordance with U.S.
Pat. No. 5,334,573 (which is herein incorporated by reference).
[0243] With reference to FIG. 14, we present an inventive
over-the-counter identification document including PET materials.
In contrast to the FIG. 13 document, the FIG. 14 implementation is
a coreless structure. The document primarily includes two PET
layers (or films). Transilwrap, of Franklin Park, Ill., provides a
suitable polyethylene terephthalate (PET) film under the trade name
"TXP." In some implementations we provide an amorphous PET film or
layer. Of course, there are many other PET films that can be
suitably interchanged with this aspect of present invention. The
two PET layers are combined, e.g., through a conventional
lamination process. As shown in FIG. 12 we can use adhesive layers
(e.g., thermoplastic adhesives--preferably PET-based adhesives) to
help secure the PET layers. The adhesive layers can be coated or
layered with the PET layers. A resulting structure PET structure is
cut into required identification document sized cards, if needed.
(We note that the document's height H can be adjusted according to
required identification document specifications. For example, the
PET layers are preferably between about 5-15 mils and the adhesive
layers are preferably between about 2-10 mils. One implementation
comprises 10 mil PET layers (e.g., Transilwrap's TXP white PET
film) and 5 mil adhesive layers (e.g., Transilwrap's KRTY
(polyolefin)).
[0244] The outer surface of a PET layer preferably receives
information or indicia provided thereon. The PET layer can include
coloration, e.g., white to even better accentuate the indicia. The
information can include, e.g., variable information such as a
cardholder's name, address, photograph, signature, biometric
information, etc. and/or fixed information (e.g., information which
is common to a number of cards, such as the issuing authority,
security features, etc.). The printing may also include a so-called
digital watermark. The watermark may be embedded in a background
tint or pattern, a graphic or photograph, etc. A watermark can also
be embedded through text or font manipulation as well. While we
preferably transfer information to the PET layer through a dye
diffusion thermal transfer--or "D2T2"--process, the PET layer can
also be offset printed, ink or laser jet printed, laser etched,
etc. We provide information on an outer surface of both PET layers
in some implementations. We can also print information in stages.
For example, we can pre-print fixed information on a PET layer or
PET substrate prior to lamination (or after lamination) and before
a second stage printing of variable information. The information
can also include a registration or calibration marker to help align
the identification document in subsequent printing steps.
[0245] The PET layer can be can be adapted to even better receive
printed information. For example, we can provide a receiving-layer
or "image receiving-layer" on an outer surface of a PET film. The
term "image" in this disclosure should be understood to include all
forms of printed and transferred information including images,
graphics, text, machine readable code, and/or designs, etc., etc.
The image-receiving layer (e.g., about a 2-20 micron layer) may be
formed from any material capable of receiving an image, e.g., by
dye diffusion thermal transfer. (In some cases we use Transilwrap's
DITX receiving fluid as an image-receiving layer. In other cases, a
polymer (e.g., PVC) is used to form an image-receiving layer is
first dissolved in an organic solvent, such as methyl ethyl ketone,
dichloromethane or chloroform, and the resultant solution is coated
onto the PET layer using conventional coating apparatus, and the
solvent is then evaporated to form the image-receiving layer.
However, if desired, the receiving layer can be applied to the PET
layer by extrusion casting, or by slot, gravure or other known
coating methods. Of course, other materials and receiving layers,
e.g., such as those disclosed in U.S. Pat. Nos. 5,334,573 and
6,066,594, may be suitable interchanged with this image-receiving
aspect of the present invention.
[0246] It may be advantageous to coat the image-receiving material
at a centralized production facility and then provide resultant
"blank" documents to a plurality of document issue stations (OTC
stations) at which variable data is applied to the image-receiving
layers of the identification documents.
[0247] Following the printing of information on an image-receiving
layer (if provided, otherwise after printing on the PET layer), a
protective layer (not shown) is optionally affixed over at least a
portion of the image-receiving layer. The protective layer serves
to protect the relatively fragile image-receiving layer from
damage, and also prevents bleeding of information (e.g., thermal
transfer dye) from the image-receiving layer. Materials suitable
for forming such protective layers are known to those skilled in
the art of dye diffusion thermal transfer printing and any of the
conventional materials may be used provided that they have
sufficient transparency and sufficient adhesion to the specific
image-receiving layer with which they are in contact and/or block
bleeding of dye from this layer. However, in keeping with the theme
of this aspect of the present invention, we preferably apply a
transparent PET-based protective laminate, if used.
[0248] The protective layer may optionally provide additional
security and/or features for the identification document. For
example, the protective layer may include a low cohesivity
polymeric layer, an optically variable ink, variable information,
an image printed in an ink which is readable in the infra-red or
ultraviolet but is invisible in normal white light, an image
printed in a fluorescent or phosphorescent ink, cohesive failure
ink, or any other available security feature which protects the
document against tampering or counterfeiting, and which does not
compromise the ability of the protective layer to protect the
identification document against wear and the elements.
[0249] With reference to FIG. 15 we provide yet another alternative
implementation of a PET-based identification document. In
particular, we provide a PET substrate, protected by PET protective
laminates. Of course we can use adhesives to help secure the PET
laminates to the PET substrate. The PET substrate is preferably
colored, e.g., a white opaque color. Prior to lamination we provide
information (e.g., variable and/or fixed information) on an outer
surface or surfaces of the PET substrate. The PET substrate (or PET
laminate) can be coated, prior to lamination, with an
image-receiving material as discussed above. The image-receiving
material can be provided between the PET laminate and PET substrate
(e.g., on either or both of these layers). The image-receiving
material can be alternatively (or in addition to) provided on an
outer surface of the PET laminate layer. If information is provided
on an outer-surface of a PET laminate, a thin film protective coat
or layer can be optionally provided over the information for
enhanced protection. A completed structure can be sized according
to need (e.g., height H). Our structure, however, preferably
includes dimensions in the following ranges: PET substrate (5-25
mils); PET laminates (2-15 mils) and adhesive layers, if used (2-8
mils).
[0250] From the foregoing, it will be seen that our PET-based
identification documents provides an over-the-counter
identification document that affords significant improvements in
durability (e.g., flexibility and crack-resistance) and
earth-friendly characteristics (e.g., recycle and low-hazardous
emissions during production) as compared with the other OTC
identification documents. These types of PET-based ID documents can
also be provided at a significantly lower cost than other OTC (and
CI) documents. Our PET-based identification documents can also
provide a durable and secure identification document that is
instantly produced over-the-counter. It should be appreciated that
our PET-base identification document can also include so-called
"blanks," or document structures without printing, or with printing
but prior to personalizing the document.
[0251] While we prefer that our PET identification documents
include all PET materials, it should be appreciated that our
inventive PET-based ID documents need not be limited as necessarily
including all PET. For example, a polymer (but non-PET)
over-laminate may be added, a non-PET adhesive may be used, a
non-PET image receiving layer is employed, etc. And of course the
dyes or inks and other security features will not generally be
PET-based. Such deviations certainly fall within the scope of this
aspect of the present invention.
Inventive Combinations
[0252] In addition to the inventive aspects detailed above and in
the claims, some of the inventive combinations with respect to
PET-based ID documents include the following:
[0253] A. A careless identification document comprising:
[0254] a first PET (polyethylene terephthalate) film including a
top surface and a bottom surface;
[0255] a second PET film including a top surface and a bottom
surface;
[0256] an image-receiving layer provided on the first PET film top
surface; and
[0257] an adhesive layer in contact with the first PET film bottom
surface and the second PET film top surface, the adhesive serving
to secure the first PET film and the second PET film to one
another.
[0258] A1. The document of combination A, wherein the receiving
layer comprises a layer capable of being imaged by dye diffusion
thermal transfer.
[0259] A2. The document of combination A wherein the
image-receiving layer comprises a layer capable of being imaged by
gravure printing.
[0260] A3. The document of combination A, wherein the
image-receiving layer comprises a depth in a range of 2 to 15
microns.
[0261] A4. The document of combination A, wherein the first PET
film and the second PET film each comprises a depth of about 10
mils.
[0262] A5. The document of combination A, wherein the adhesive
layer comprises at least two adhesive layers.
[0263] A6. The document of combination A, wherein the adhesive
comprises PET.
[0264] A7. The document of combination A, wherein indicia is
provided on the image-receiving layer.
[0265] A8. The document of combination A7, wherein a laminate layer
is provided over the indicia on the image-receiving layer.
[0266] A9. The document of combination A7, wherein the indicia is
provided through dye diffusion thermal transfer (D2T2).
[0267] A10. The document of combination A7, wherein the indicia is
provided through gravure printing.
[0268] A11. The document of combination A, further comprising a
second image-receiving layer provided on the second PET film top
surface.
[0269] A12. The document of combination A11, wherein indicia is
provided on the second image-receiving layer.
[0270] A13. The document of combination A12, wherein a laminate
layer is provided over the indicia on the second image-receiving
layer.
[0271] A14. The document of any one of combinations A7 and A13,
wherein the indicia comprises at least one of a digital watermark
and information that is specific to one who will bear the
document.
[0272] A15. The document of combination A, wherein each of the
first and second PET layers comprises white coloration.
[0273] A16. The document of combination A15, wherein each of the
first and second PET layers comprises substantially amorphous
PET.
[0274] B. An identification document comprising:
[0275] a PET (polyethylene terephthalate) core layer comprising a
first surface and a second surface,
[0276] a first layer of a substantially transparent PET fixed to
the first surface of the PET core layer;
[0277] a second layer of a substantially transparent PET fixed to
the second surface of the PET core layer; and
[0278] at least one image-receiving layer capable of being
receiving information, the image-receiving layer being fixed to at
least one of the first transparent PET layer and the first surface
of the PET core layer.
[0279] B1. The document of combination B, wherein the receiving
layer comprises a layer capable of being imaged by dye diffusion
thermal transfer.
[0280] B2. The document of combination B wherein the
image-receiving layer comprises a layer capable of being imaged by
gravure printing.
[0281] C. An identification document comprising:
[0282] a first PET (polyethylene terephthalate) film including a
top surface and a bottom surface;
[0283] a second PET film including a top surface and a bottom
surface; and
[0284] an adhesive layer in contact with the first PET film bottom
surface and the second PET film top surface, the adhesive serving
to secure the first PET film and the second PET film to one
another.
[0285] D. A method of making an identification document comprising
the steps of:
[0286] providing a first PET (polyethylene terephthalate) film
including a top surface and a bottom surface;
[0287] providing a second PET film including a top surface and a
bottom surface;
[0288] providing an image-receiving layer adjacently arranged on
the first PET film top surface; and
[0289] providing an adhesive layer so as to be in contact with the
first PET film bottom surface and the second PET film top surface,
the adhesive serving to secure the first PET film to the second PET
film.
[0290] D. A method of making an identification document comprising
the steps of:
[0291] providing a PET (polyethylene terephthalate) core layer
comprising a first surface and a second surface,
[0292] providing a first layer of a substantially transparent PET
so as to be adjacently arranged with the first surface of the PET
core layer;
[0293] providing a second layer of a substantially transparent PET
so as to be adjacently arranged with the second surface of the PET
core layer; and
[0294] providing at least one image-receiving layer capable of
being receiving information, the image-receiving layer being
adjacently arranged with at least one of the first transparent PET
layer and the first surface of the PET core layer.
Conclusion
[0295] Having described and illustrated the principles of the
technology with reference to specific implementations, it will be
recognized that the technology can be implemented in many other,
different, forms.
[0296] For example, while we have described a contact-type smart
card module as including, e.g., a Hitachi AE 45C module, the
present invention is not so limited. Indeed many other smart card
modules are contemplated, e.g., Atmel's 1608, ModuleEight, and
products from Philips, EVM, etc., etc. Of course other modules can
be used to facilitate similar/additional smart card functionality.
A cavity can be formed to accommodate the various shapes and
dimensions of alternative smart card modules.
[0297] In at least one embodiment (not shown), laminate layers are
formed into a pouch into which the core layer slips. With a pouch,
methods such as heat, pressure, adhesives, and the like, are usable
to bond the core layer to the pouch laminates. Those skilled in the
art will appreciate that many known structures and configurations
for laminating are usable with the invention.
[0298] While we use terms herein like "front" and "back," these
terms are provided primarily for the reader's convenience. For
example, a smart card module can be provided on a "front" side,
instead of a "back" side as discussed in section 1.
[0299] The technology disclosed herein can be used in combination
with other technologies. Examples include the technology detailed
in the following applications, the disclosures of which are
incorporated herein by reference: Ser. No. 09/747,735 (filed Dec.
22, 2000); Ser. No. 09/969,200 (filed Oct. 2, 2001) and U.S.
Provisional Application No. 60/429,115 (filed Nov. 25, 2002). Also,
instead of ID documents, the inventive techniques can be employed
with product tags, product packaging, business cards, smart cards,
bags, charts, maps, labels, etc., etc. The term ID document is
broadly defined herein to include these tags, labels, packaging,
cards, etc.
[0300] While many features and aspects of the present invention
have been disclosed herein, it will be appreciated that not all
aspects and features need be incorporated into each of the
following claims.
[0301] To provide a comprehensive disclosure without unduly
lengthening the specification, applicants herein incorporate by
reference each of the patent documents referenced above.
[0302] The particular combinations of elements and features in the
above-detailed embodiments are exemplary only; the interchanging
and substitution of these teachings with other teachings in this
and the incorporated-by-reference patent documents are also
expressly contemplated.
[0303] The technology disclosed herein can be used in combination
with other technologies. For example, instead of traditional smart
cards, the inventive techniques can be employed with identification
documents, drivers' licenses, passports, product tags, product
packaging, business cards, bags, charts, maps, labels, etc. The
terms "smart card" and "smart ID document" are broadly defined
herein to include such licenses, passports, tags, labels,
packaging, cards, etc.
[0304] It should be appreciated that while specific dimensions and
components have been presented herein (including the drawings), the
present invention is not limited to such dimensions and specific
components. Indeed, many of the document dimensions, materials,
printing techniques and smart card circuitry can be interchanged
without deviating from the scope of the present invention.
[0305] In view of the wide variety of embodiments to which the
principles and features discussed above can be applied, it should
be apparent that the detailed embodiments are illustrative only and
should not be taken as limiting the scope of the invention. Rather,
we claim as our invention all such modifications as may come within
the scope and spirit of the following claims and equivalents
thereof.
* * * * *