A method for manufacturing a portable data carrier by means of a continuous manufacturing method, comprises the steps: providing at least one foil as a rolled good, unrolling at least one first foil, with at least a first foil being coated at least partly with an adhesive on at least one side, with at least the first foil being scored on at least one side along at least one creasing edge, with at least the first foil being folded up in precise fit along at least one creasing edge and bonded, with the foil being folded up in the direction of the side which is coated with adhesive, with the side coated with adhesive being arranged on the opposite side of the foil which has at least one scored creasing edge along which it is folded.

A method for manufacturing a portable data carrier by means of a continuous manufacturing method, comprises the steps: providing at least one foil as a rolled good, unrolling at least one first foil, with at least a first foil being coated at least partly with an adhesive on at least one side, with at least the first foil being scored on at least one side along at least one creasing edge, with at least the first foil being folded up in precise fit along at least one creasing edge and bonded, with the foil being folded up in the direction of the side which is coated with adhesive, with the side coated with adhesive being arranged on the opposite side of the foil which has at least one scored creasing edge along which it is folded.

A transaction card includes an anodized card body having a front and rear face. Various information and security features may be provided on the front face and on the rear face. A magnetic stripe may be provided on the rear face of the anodized card body. The magnetic stripe may be adhered within a slot formed within the rear face of the anodized body. Alternatively, the magnetic stripe may be provided via an overlay that is adhered to the rear face of the anodized body, and the magnetic stripe may be integral with the overlay or adhered to the overlay after the overlay is applied to the anodized card body. The transaction card may also include a hologram. The hologram may be integral with the overlay or may be applied to the overlay that has been arranged on the anodized card body.

A system and method for producing a multi-layered materials sheet that can be separated into a number of payment cards having an embedded metal layer that provides durability and aesthetics at a reduced cost and increased efficiency. During product of the materials sheet, multiple layers are collated and laminated to produce a large materials sheet. The lamination step involves heating and cooling the materials at specific temperatures and pressures for specific time periods. At a registration step, the sheet is automatically milled with alignment holes. During a singulation step, the alignment holes are used to position the sheet on a vacuum table, and vacuum holds the sheet in place while a milling device cuts cards from the sheet.

A system and method for producing a multi-layered materials sheet that can be separated into a number of payment cards having an embedded metal layer that provides durability and aesthetics at a reduced cost and increased efficiency. During product of the materials sheet, multiple layers are collated and laminated to produce a large materials sheet. The lamination step involves heating and cooling the materials at specific temperatures and pressures for specific time periods. At a registration step, the sheet is automatically milled with alignment holes. During a singulation step, the alignment holes are used to position the sheet on a vacuum table, and vacuum holds the sheet in place while a milling device cuts cards from the sheet.

The mechanically stable value or security document 2000 according to the invention comprising an electric circuit 1270 is characterised by the following features: the document is formed of at least three document layers which are arranged in a stack 1700 and which are connected together face-to-face by a joining method, wherein a first document layer is formed by a circuit carrier layer 1200 which supports the electric circuit 1270, at least one second document layer is formed in each case by a compensation layer 1100 which has at least one opening 1120 and/or recess, and at least one third document layer is formed in each case by an outer cover layer 1300. The first 1200, the at least one second 1100, and the at least one third document layer 1300 are formed from a fibre composite material.

The mechanically stable value or security document 2000 according to the invention comprising an electric circuit 1270 is characterised by the following features: the document is formed of at least three document layers which are arranged in a stack 1700 and which are connected together face-to-face by a joining method, wherein a first document layer is formed by a circuit carrier layer 1200 which supports the electric circuit 1270, at least one second document layer is formed in each case by a compensation layer 1100 which has at least one opening 1120 and/or recess, and at least one third document layer is formed in each case by an outer cover layer 1300. The first 1200, the at least one second 1100, and the at least one third document layer 1300 are formed from a fibre composite material.

There is described a method of creating a transparent polymer window (W) with a field of lenses (L) in a security paper substrate (1), the method comprising the steps of (i) providing a security paper substrate (1), (ii) forming an opening (10) into the security paper substrate (1), (iii) laminating a transparent film (5; 5*) onto a first side (I) of the security paper substrate (1) in such a way as to close the opening (10) at one end, and (iv) filling the opening (10) with transparent polymer material (2). In one embodiment, the transparent film (5) comprises a field of lenses (L) and is laminated onto the first side (I) of the security paper substrate (1) in such a way as to form lenses (L) on the first side (I) of the security paper substrate (1) in register with the opening (10). In another embodiment, the field of lenses (L) is replicated into the transparent polymer material (2) applied in the opening (10) in such a way as to form lenses (L) on a second side (II) of the security paper substrate (1), opposite to the first side (I), in register with the opening (10). Also described is a device designed to fill the opening (10) formed into the security paper substrate (1) with the transparent polymer material (2) and a processing machine comprising the same.

There is described a method of creating a transparent polymer window (W) with a field of lenses (L) in a security paper substrate (1), the method comprising the steps of (i) providing a security paper substrate (1), (ii) forming an opening (10) into the security paper substrate (1), (iii) laminating a transparent film (5; 5*) onto a first side (I) of the security paper substrate (1) in such a way as to close the opening (10) at one end, and (iv) filling the opening (10) with transparent polymer material (2). In one embodiment, the transparent film (5) comprises a field of lenses (L) and is laminated onto the first side (I) of the security paper substrate (1) in such a way as to form lenses (L) on the first side (I) of the security paper substrate (1) in register with the opening (10). In another embodiment, the field of lenses (L) is replicated into the transparent polymer material (2) applied in the opening (10) in such a way as to form lenses (L) on a second side (II) of the security paper substrate (1), opposite to the first side (I), in register with the opening (10). Also described is a device designed to fill the opening (10) formed into the security paper substrate (1) with the transparent polymer material (2) and a processing machine comprising the same.

A method for manufacturing a physical security element with a spatially appearing pattern includes a carrier and at least one see-through transparent cover layer. Onto the carrier is applied a design layer deformable under pressure. Either the carrier has a lower dimensional stability under heat than the cover layer, or a cover layer has a lower dimensional stability under heat than the carrier. A see-through transparent structural layer forming the pattern is arranged between carrier and cover layer. The structural layer has a higher dimensional stability under heat than either the carrier or a cover layer. During lamination, the structural layer is pressed into the carrier or into the cover layer, whereby the design layer is deformed under the pattern formed by the structural layer and the structural layer in its edge regions is reshaped in such a way that its surfaces, in cross-section, converge tangentially.