WO1991008911A1

WO1991008911A1 - Method and apparatus for applying materials to a substrate

Info

Publication number: WO1991008911A1
Application number: PCT/GB1990/001930
Authority: WO
Inventors: Richard Smith; Glenn Dimmock
Original assignee: Oakwood Design
Priority date: 1989-12-11
Filing date: 1990-12-11
Publication date: 1991-06-27
Also published as: GB2241200A; GB8927926D0; GB9026833D0; AU6963091A; GB2241200B

Abstract

A method and apparatus for forming an article including a substrate layer (2), an outer layer (3) overlaying the substrate layer (2), the outer layer (3) having at least one predetermined area/region thereof covered by a further layer (8/9) of material(s) (usually different from that of the outer layer), in which method all of said materials (8, 9) are simultaneously applied to the outer layer (3). Following such application the substrate (2), the outer layer (3) and said material(s) (8, 9) are simultaneously so treated that in the finished article (6) the substrate, the outer layer and material(s) are integrally bonded together in such manner that the outer surface(s) of said material(s) does/do not protrude above the adjacent surface of the outer layer.

Description

METHOD AND APPARATUS FOR APPLYING MATERIALS TO A

SUBSTRATE

FIELD OF THE INVENTION

This invention relates to the application of material onto a predetermined area of a substrate.

In particular the present invention is concerned with the laying of thin materials such as the magnetic tape and signature panels which are applied to a substrate to provide so-called identification cards, bank cards or the like.

BACKGROUND OF THE INVENTION

The use of identification cards incorporating at least one area or region of a magnetisable material for the purposes of being encoded with identificatory alphanumeric information, and a further area/region upon which an authorised intended user needs to sign in order to validate the card for use for the purposes for which the card has been issued to such user, has been expanding day by day and now such cards are used by a vast number of organisations for a multitude of purposes and reasons.

Perhaps one of the best known uses for such identification cards are as the so-called credit/charge cards now used world wide as a means.for enabling a user to obtain services without the need to tender cash for the purposes of the transaction involved; as a means for establishing the identity of a person at the point of using a cheque to obtain goods/service in commercial and like transactions. Further uses include identification means whereby the user can gain access to premises on presentation of the card either to a person controlling admission or by means of apparatus provided for reading the encoded 5 alphamumeric data encoded on the magnetisable material the latter usually being in the form of a strip on the card.

Further uses include prepayment cards which are purchased by the user for subsequent use in paying for a particular Λ Q function such as use of a telephone.

In the manufacture of such cards which are as is well known relatively flexible and thin having a thickness of, for example, 0,3mm or 0,4mm it is known to use a laminated construction for the card involving a central η5 substrate layer whose outer faces are overlaid with clear plastics material. As a result of the lamination process used to weld the layers together to form a finished card, the completed card has highly finished smooth outer surfaces which are required to be resistive

2_Q to everyday wear and tear such as the card would receive on being frequently handled, for example, by being inserted and removed from a card case or by being passed across the face of a magnetic read head for the reading of the encoded data during the intended use of the card.

25 Generally speaking, as mentioned above, every card is provided with at least one magnetisable material area/region and at least one area/region upon which the intended user needs to write/sign his name or to provide some other specified information in order to validate the

30 card for its intended use. In practice, the physical characteristics of the materials required for satisfying the functions of the two different types of area are essentialy totally different from each other in terms of the handling properties.

These wide differences in handling properties, in practice, lead to considerable difficulties and problems in, not only the production of such cards at the production rates necessary to meet with the ever increasing demand for cards, but also in the construction and utilisation of machinery for producing the cards.

In the production of identification cards it is known to ^aPPly t^ne magnetisable material strips and write-on material strips upon the laminated card and to then hot stamp these magnetisable strips onto the card to secure the strips in the required positions. With this arrangement after attachment the strips remain proud of the surface of the substrate in the finished card. In addition, careful examination of the thus produced card indicates that the outer surface of the magnetisable material is not usually truly flat in that this outer surface can be slightly concave so that the longitudinal edges thereof stand proud of the central longitudinal region. This leads to excessive wear of the magnetisable strip during use.

Following this stage the user write-on area(s)s/regions(s) is/are applied by means of an appropriate process i.e., by means of adhesive. As before the write-on areas/regions remain proud of the outer surface of the substrate.

It has been found that these known arrangments inherently involve certain disadvantage.

A first is that the known methods of manufacture involve a large number of separate unrelated stages in the proαucrxon of cards.

Secondly, since the magnetisable area(s)/region(s) is/are proud of the surrounding substrate excessive wear on magnetic read heads is likely to occur.

A further disadvantage is that when the write-on area remains proud of the surrounding surface of the card it is possible to remove the write-on areas with an authorised user's signature and to replace them with unsigned areas thereby making it possible for fraudulent signatures to be applied to such cards whereby unauthorised persons can make use of the cards with impunity and with little chance of being detected.

OBJECTS OF THE INVENTION

It is an object of the present invention to reduce the number of separate manufacturing stages required to produce articles including a substrate having at least first and second predetemined area(s)/region(s) thereof respectively covered by first and second materials (usually different) .

STATEMENTS OF THE INVENTION

Broadly, according to a first aspect of the invention there is provided a method of forming an article including a substrate layer, an outer layer overlaying the substrate layer, the outer layer having at least one predetermined area/region thereof covered by a further layer of material(s) (usually different from that of the outer layer), in which method following such application of the layers to the substrate, the outer layer and said material(s) are simultaneously so treated that in the finished card the substrate, the outer layer and raaterial(s) are integrally bonded together in such manner that the outer surface(s) of said material(s) does/do not protrude above the adjacent surface of the outer layer.

Broadly, according to a second aspect of the invention there is provided a method of forming an identity or like card, including a substrate layer, an outer layer overlaying the substrate layer, the outer layer having at least one predetermined area/region thereof covered by a further layer of material(s) (usually different from that of the outer layer), in which method all of said materials are simultaneously applied to the outer layer, and in which following such application the substrate, the outer layer and said material(s) are simultaneously so treated that in the finished card the substrate, the outer layer and material(s) are integrally bonded together in such manner that the outer surface(s) of said material(s) does/do not protrude above the adjacent surface of the outer layer.

In the case of a card a first of said materials is a magnetisable material; and a second material is one upon which it is possible to write with a writing implement,

Preferably the substrate has associated therewith two outer layers, one to each side thereof.

Preferably, the substrate, outer layer(s), and material(s) are heat laminated together.

Preferably, also the outer surfaces' of said material(s) is/are flush with the adjacent surface of the associated outer layer.

Preferably, the laminating is effected by a combined heating/pressure regime sufficient to cause the outer layer(s) to adhere to the central substrate, to cause the materials applied thereto to adhere to the resulting assembly/sandwich, and to render the outermost surfaces of the applied materials flush with the adjacent outer surface of thus laminated assembly /sandwich.

A further aspect of the invention provides an identity card or the like including on one surface thereof a magnetisable area/region and an area/region of a material upon which it is possible to write with a writing implement, both said areas/regions being such that the outer surfaces of both said areas/regions do not protrude above the adjacent surface of the card.

For a better understanding of the invention and to show how to carry the same into effect reference will now be made to the accompanying drawings in which:

Figure 1 is a very schematic exploded diagram illustrating a first stage in the formation of an identity card from an assembly of a substate layer and outer layers;

Figure 1A illustrates schematically a non-exploded edge on view of the assembled layers of Figure 1 ;

Figure 2 very schematically illustrates a subsequent stage in the formation of an identity card;

Figure 2A very schematically illustrates a variation of the stage shown in Figure 2;

Figure 3 very schematically illustrates in cross-section the formation of an identity card in accordance with the concepts of the invention, Figures 4A to 4D illustrate schmatically stages in the production of an identity card in accordance with the proposals of the invention; and

Figure 5 illustates in more detail apparatus for carrying out the method of the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings and more particularly to Figure 1 , which schematicaly illustrates the formation of an assembly or sandwich 1 including an inner substrate layer of card or plastics material 2; and two outer layers 3,4 of clear plastics material i.e., PVC, one to each surface of the substrate sheet 2, of plastics material. In thr arrangement shown the layers 2,3 and 4 comprise rectangular sheets. In practice, the overall size of the thus formed assembly 1 is of such dimensions as to be divisible into a number of individual identity cards at the end of the raaufacturing process to be discussed. It is a conventional practice in the production of identity cards to preprint information on the substrate sheet 2 such as the identity of the card issuing body and such like. Such pre-printing can be on one or both sides of the substrate sheet 2. The printing is such as to leave a usually rectangular grid of strip-like spaces 5, the so-called gutter strips which effectively define rectangular areas 6 which will provide the individual cards and which are utilised to assist in production alignments as will be discussed hereinafter.

In a particular example, the printing can be such as to provide for eight rows of, for instance, five card areas 6. It will be appreciated that the numbers of rows and columns will be according to requirements and can vary. For example, if desired, the width of the substrate sheet 2 and the outer sheets 3 and 4 can be such as to provide for a single row.

Once the three sheets 2,3 and 4 have been correctly stacked and positioned relative to each other i.e., collated, they are clamped together along one end thereof, usually an end 7 extending transverse to the direction of the eight rows, to maintain the required inter-relationship.

Once this condition has been attained the next stage of the production of the cards is simultaneously to lay at specified spacing one from the other a series of strips 8 of magnetisable material i.e., magnetisable tape and a corresponding number of strips 9 of user write-on paper onto one of the outer sheets i.e., the sheet 3. Usually, the strips are arranged in side-by-side spaced apart pairs on the same side of the substrate assembly/sandwich. If desired, however, more than one strip of any type of material may be used. Figure 2 very schematically illustrates a part of the assembly with a few of the side-by-side strips 8 and 9 positioned on the card.

Both the strips 8 and 9 are locally attached by a hot press operation which joins the strips to the assembly/sandwich only at locations in the gutter areas 5 between the intended individual card areas 6. This ensures that the strips are maintained in their correct positions lengthwise of the sheets.

With the arrangement of Figure 2 both the magnetic strip and the write-on strip extend for the full length of the finished card. For certain applications there is a requirement that, for example, the write-on strip should not extend the full width of the card but should extend only over a central length of the card. In other words the write-on strips can be regarded as forming 'islands' symmetrically located lengthwise of the card. Figure 2A very schematically illustrates such anarrangement of 'islands' 9A. It will be appreciated that the hot sealing arrangements will be suitably modified to effect he attachment of the ends of the 'islands' and the picking-up of the leading end of the write-on strip material each time a new 'island' length has been cut from the supply thereof.

In practice, it is of great importance to be able to reduce the number of handling operations involved in the production of the identity cards. In this connection it will be appreciated tht each time a part completed assembly is moved from machine to machine or otherwise caused to pass through a machine in order to effect successive manufacturing stages there is a risk of damage to the strip materials, and particularly the magnetic strip in view of its being of a very small thickness dimension.

Consequently, the arrangements provided for laying the magnetisable and paper strips are such that the strips irrespective of their number or mutual arrangements are simultaneously laid thereby reducing handling of the assembly/sandwich during the strip laying process.

After the strip laying has been completed the assembly/sandwich plus the strips laid thereupon are subjected to a laminating operation involving a hot pressing operation in which the temperature, pressure and time duration conditions are such that both types of strip material are effectively pushed into the outer surface of the assembly/sandwich outer sheet 3 against which they were laid to such extent that the outermost surface of the laid strips are flush with the surface of the associated outer sheet 3 of the assembly/sandwich. In otherwords, except for the outer surfaces of the two types of strip material the strips are effectively encapsulated by the associated outer sheet 3 of the aforesaid assembly/sandwich .

This condition is shown in Figure 3.

Furthermore, the combined heating and application of pressure to the plastics outer sheets of the assembly/sandwich layers has the effect of causing the outer sheets 3,4 firmly to adhere to the central sheet 2 by reason of the plastics material being effectively forced into surface interstices of the surface of the central sheet 2. This arrangment leads to a very firm bond without the need for an adhesive interface.

At the completion of the laminating operation the individual cards are cut from the laminated assembly/sandwich.

It will thus be seen that by means of a single laminating hot pressing operation the lamination of the card forming assembly/sandwich has been achieved together with the simultaneous bonding of the two types of material in strip form into a countersunk relationship to the remainder of the card structure.

Thus, the method of the invention provides a card structure in which, since the user writing strip is countersunk, it cannot be readily removed and replaced without making it clearly obvious that the card has been tampered with. Referring now to Figures 4A to 4D, these Figures very schematically illustrate the essential features of apparatus for the laying the strips 8 and 9 of the magnetisable material and the write-on material onto a substrate assembly.

In the process under discussion the magnetisable material is provided in tape form which includes a layer of magnetic oxide 10 spread upon a carrier tape of plastics material and coated with an anti-scuff coating 11.

One such magnetic material being marketed by Thorn EMI under the Registered Trade Mark 'Watermark Magnetics'.

Arrangements are provided for peeling the magnetic oxide layer and its anti-scuff coating away from the carrier tape immediately prior to the magnetisable material being applied to the aforementioned assembly/sandwich. Since this feature does not form part of the present invention and as apparatus for effecting such separation has been marketed by the Applicants a detailed description of such operation is not thought necessary.

Returning now to Figure 4A the apparatus indicated therein includes a support table 12 with location pins or the like (not shown) for receiving, and collating the sheets 2,3 and 4 for forming the assembly/sandwich 1 of Figure 1. At one end of the table 12 there is provided a unit 13 for bonding the leading edge 7 of the sheets of the assembly/sandwich. It will be understood that the sandwich can be formed from separate lengths/sheets of material as has been discussed or by continuous feed from supply rolls (not shown) of the substate forming material ^and the outer sheet forming material. It will be understood, that when separate sheets are used the leading edges of each group of three sheets need to be bonded, whereas such bonding is only required at the leading ends in the case of roll feed at the commencement of feed from the rolls.

The apparatus includes a support frame or the like (not shown in Figures 4A-4D) for mounting a series of reels 14 of the paper strip material for forming the strips 8 and a further series of reels 15 of the magnetisable material strip 9. In practice, there will be one reel of strip material for each line of strip material to be laid on the assembly/sandwich.

Thus, if the assembly/sandwich is large enough to provide ten rows of cards 6 there will be ten pairs of the reels of strip material as is shown in Figure 5.

The strip materials from the reels 14,15 are fed by way of guides 16 to a strip material laying head 17 which is arranged to be traversable lengthwise of the assembly/sandwich.

This travelling head 17 also incorporates a plurality of spot welding heads 18 (Figure 4B) one for each strip being laid.

In addition, the travelling head 17 incorporates arrangements 19 for separating the magnetisable oxide material 10 from its carrier tape 20, the thus separated carrier tapes 20 being automatically wound onto carrier tape pick-up reels 21.

Finally, the travelling head includes strip material cutter means 22 adapted for cutting the laid strips 8,9 from the supply reels 14,15 when the travelling head has completed a traverse, and for gripping the new free ends of the strips from the supply reels so that on return of the travelling head 17 to its initial position the strips have been positioned ready for the repeat of the operations above mentioned. It will be appreciated that when write-on strip 'islands' 9A are required the cutter means 22 associated with the write-on strips 9 will be actuated as and when required to cut the 'islands' 9A to the required lengths.

Similarly, the associated spot welding units will be operated to attach the ends of the 'island' forming strips in place during the traverse of the head 17 lengthwise of the plastics sheets.

Since the construction and modes of operation of tape laying heads are known in the art a detailed description thereof is not thought necessary.

The Figures 4A to 4C illustrate stages in the laying and spot welding of the strips, whilst Figure 4D illustrates the return of the travelling head 17 back to- its start position.

Figure 5 illustrates in very broad outline a practical layout of a machine for carrying out the various procedural steps shown in the previous Figures when handling separate sheets 2,3 and 4.

Components already mentioned have been identified by reference numerals used in relation to previous Figures.

In addition to the components already discussed the apparatus of Figure 5 includes a framework 25 for mounting the reels 14,15, and 21. The Figure also shows the assembly/sandwich table formation in greater detail in that a left hand section 26 is. used for assembling the layers 2,3 and 4 and means are provided for transferring the assembly/sandwich into cooperation with the means 13 for clamping the assembly/sandwich end 7. The table also incorporates a storage portion 27 for receiving an assembly/sandwich following the application of the strips 8 and 9.

In the embodiment shown the travelling head arrangements are enclosed in a transparent housing 28.

In cases where a continuous feed of the substrate and the outer layers is required the above discussed arrsngement can be provided with a support frame for the supply rolls of the substrate and outer layers. In addition, a cutting arrangement will be provided for cutting away lengths of the assembled substrate and outer sheets after the the strips 8 and 9 have been laid in the required positions, for transfer to a laminating apparatus (not shown) .

Claims

1. A method of forming an article including a substrate layer, an outer layer overlaying the substrate layer, the outer layer having at least one predetermined area/region thereof covered by a further layer of material(s), in which method following such application of the material(s) the substrate, the outer layer and said material(s) are simultaneously so treated that in the finished card, the substrate, the outer layer and material(s) are integrally bonded together in such manner that the outer surface(s) of said material(s) does/do not protrude above the adjacent surface of the outer layer.

2. A method of forming an identity or like card, including a substrate layer, an outer layer overlaying the substrate layer, the outer layer having at least one predetermined area/region thereof covered by a further layer of material(s), in which method all of said materials are simultaneously applied to the outer layer and in which following such application the substrate, the outer layer and said material(s) are simultaneously so treated that in the finished card the substrate, the outer layer and raaterial(s) are integrally bonded together in such manner that the outer surface(s) of said material(s) does/do not protrude above the adjacent surface of the outer layer.

3. A method as claimed in claim 3, and characterised in that a first of said materials is a magnetisable material; and a second material is one upon which it is possible to write with a writing implement,

4. A method as claimed in claim 1,2 or 3, and characterised in that the substrate has associated therewith two outer layers, one to each side thereof.

5. A method as claimed in claim 1,2,3 or 4, and characterised in that the substrate, outer layer(s), and material(s) are heat laminated together.

6. A method as claimed in any of claims 1 to 5, and characterised in that outer surfaces of said material(s) is/are flush with the adjacent surface of the associated outer layer.

7. A method as claimed in claim 5, and characterised in that the laminating is effected by a combined heating/pressure regime sufficient to cause the outer layer(s) to adhere to the central substrate, to cause the materials applied thereto to adhere to the resulting assembly/sandwich, and to render the outermost surfaces of the applied materials flush with the adjacent outer surface of thus laminated assembl/sandwich.

8. An identity card or the like including on one surface thereof a magetisable area/region and an area/region of a material upon which it is possible to write with a writing implement, both said areas/regions being such that the outer surfaces thereof do not protrude above the adjacent surface of the card.

9. An identity card as claimed in claim 8, and characterised in that the card is of a laminated construction including a sandwich/assembly of a central substrate layer, outer layers of clear plastics material, a magnetisable area/region and an area/region of material upon which it is possible to write with writing implement, the laminating being such that the outer surfaces of said regions do not protrude outwardl of the said adjacent regions of the associated oute layer.

10. Apparatus for forming an indentity car characterised by means for simultaneously applying to th surface of an assembly/sandwich of a substrate layer and an outer layer at -least one strip of magnetisabl material and at least one strip of a material upon whic it is possible to write with a writing implement; mean for anchoring the strips in position prior to lamination operation.