Multiply polymer composite device with enclosed components, method for producing multiply polymer composite devices with enclosed components and device for producing multiply polymer composite devices with enclosed components

Abstract

A polymer composite device comprises a first thermoplastic covering layer of a polymer material with a first softening temperature and a second thermoplastic covering layer of a polymer material with a second softening temperature. The polymer composite device also comprises a carrier layer, which is arranged between the first covering layer and the second covering layer. An inner layer, which comprises at least a first thermoplastic inner layer ply of a polymer material with a third softening temperature, is arranged between the first covering layer and the second covering layer. The inner layer at least partially surrounds the carrier layer in a material-bonding manner. The third softening temperature is lower than the first softening temperature and lower than the second softening temperature.

Claims

1. A polymer composite device in card form, comprising: a first thermoplastic covering layer of a polymer material with a first softening temperature, a second thermoplastic covering layer of a polymer material with a second softening temperature, a carrier layer which is arranged between the first covering layer and the second covering layer, an inner layer which is formed of at least a first thermoplastic inner layer ply of a polymer material with a third softening temperature and is arranged between the first covering layer and the second covering layer, wherein the inner layer at least partially surrounds the carrier layer in a material-bonding manner, the third softening temperature is lower than the first softening temperature and lower than the second softening temperature.

2. The polymer composite device as claimed in claim 1, further comprising: at least one display device, wherein the at least one display device is arranged between the first covering layer and the second covering layer, in particular on the carrier layer, the first covering layer and/or the second covering layer include, in particular in the region of the display device, at least one partially transparent portion, so that at least part of the at least one display device is optically recognizable/readable for an observer and/or an electronic reader, and/or the first inner layer ply is at least partially transparent at least in the region of the display device.

3. The polymer composite device as claimed in claim 2, further comprising: a first, in particular rechargeable, battery, and a first overheat protection which in particular comprises a polymer material whose softening temperature is higher than the third softening temperature, and/or a second overheat protection which in particular comprises a polymer material whose softening temperature is higher than the third softening temperature, wherein the first overheat protection is arranged between the display device and/or the first battery and the first covering layer, in particular lying against a surface of the display device and/or of the first battery that faces towards the first covering layer, and/or the second overheat protection is arranged between the display device and/or the first battery and the second covering layer, in particular lying against a surface of the display device and/or of the first battery that faces towards the second covering layer.

4. The polymer composite device as claimed in claim 3, further comprising: a second, in particular rechargeable, battery, and/or electronic components, in particular semiconductor components, arranged in particular on the carrier layer, which form an electronic circuit, and/or at least one fingerprint sensor which is arranged and configured to detect and/or to store a fingerprint, and/or at least one induction coil which is electrically conductively connected to the first and/or the second battery, and/or at least two connection contacts which are electrically conductively connected to the first and/or the second battery, wherein the first and/or second battery can be charged by an electric current which is brought about by applying a voltage to the connection contacts and/or by inductive energy transfer to the induction coil.

5. The polymer composite device as claimed in claim 4, further comprising: at least one on/off button which is preferably surrounded by an in particular annular spacer element, wherein the at least one on/off button and/or the spacer element is/are arranged between the first covering layer and the second covering layer, in particular on the carrier layer, and/or the on/off button is configured for starting and/or ending operation of the electronic circuit and/or of the display device, and/or the spacer element protrudes beyond the on/off button in the direction from the second covering layer to the first covering layer or in the direction from the first covering layer to the second covering layer.

6. The polymer composite device as claimed in claim 4, further comprising: an optical sensor which is arranged and configured to detect an optically recognizable symbol, in particular a QR code, wherein the optical sensor and/or the electronic circuit is/are arranged and configured to compare the detected optically recognizable symbols with stored information and/or to electronically process them, and/or the optical sensor and/or the electronic circuit is/are arranged and configured to transmit the detected optically recognizable symbols and/or information determined on the basis of the detected optically recognizable symbols to the display device, and/or the optical sensor is positioned on the side of the carrier layer that faces away from the display device.

7. The polymer composite device as claimed in claim 1, wherein the inner layer further comprises: a second thermoplastic, in particular transparent, inner layer ply, wherein the softening temperature of the second thermoplastic inner layer ply is the same as or lower than the third softening temperature, and/or a third thermoplastic, in particular transparent, inner layer ply, wherein the softening temperature of the third thermoplastic inner layer ply is the same as or lower than the third softening temperature, and/or a fourth thermoplastic, in particular transparent, inner layer ply, wherein the softening temperature of the fourth thermoplastic inner layer ply is the same as or lower than the third softening temperature, and/or a fifth thermoplastic, in particular transparent, inner layer ply, wherein the softening temperature of the fifth thermoplastic inner layer ply is the same as or lower than the third softening temperature, and/or a sixth thermoplastic, in particular transparent, inner layer ply, wherein the softening temperature of the sixth thermoplastic inner layer ply is the same as or lower than the third softening temperature.

8. A laminating device suitable for producing the polymer composite device as claimed in claim 1, comprising: at least a first thermal press which comprises a first heatable pressing plate and a second heatable pressing plate which are oriented parallel to one another and together define an interior space, a first laminating plate which lies against the surface of the first pressing plate that faces towards the second pressing plate, a second laminating plate which lies against the surface of the second pressing plate that faces towards the first pressing plate, a first insulating inlay which lies against the surface of the first laminating plate that faces towards the second pressing plate, and a second insulating inlay which lies against the surface of the second laminating plate that faces towards the first pressing plate, wherein at least the first pressing plate is displaceable in the direction towards the second pressing plate in a manner effective for pressing, so that the first insulating inlay and the second insulating inlay can be brought into contact with a workpiece arranged in the interior space, the first laminating plate can be heated by heating the first pressing plate, and the second laminating plate can be heated by heating the second pressing plate, and the first insulating inlay can be heated in a time-delayed manner by heating the first laminating plate, and the second insulating inlay can be heated in a time-delayed manner by heating the second laminating plate.

9. The laminating device as claimed in claim 8, wherein the first thermal press further comprises: a first heating device for heating the first pressing plate, and/or a second heating device for heating the second pressing plate, and/or a first cooling device for cooling the first pressing plate, and/or a second cooling device for cooling the second pressing plate.

10. The laminating device as claimed in claim 8, further comprising: a transport device which is configured and arranged to convey the workpiece to be manufactured into the interior space of the thermal press, and/or to convey the workpiece out of the interior space of the thermal press.

11. The laminating device as claimed in claim 10, wherein the transport device is further configured and arranged: to move the workpiece to be manufactured in a conveying direction, and/or to be movable in a lowering direction which is orthogonal to the conveying direction.

12. A method for producing a polymer composite device in card form, comprising the steps: providing a first thermoplastic covering layer of a polymer material with a first softening temperature, providing a second thermoplastic covering layer of a polymer material with a second softening temperature, providing a carrier layer, providing an inner layer which is formed of at least a first thermoplastic inner layer ply of a polymer material with a third softening temperature, wherein the third softening temperature is lower than the first softening temperature and lower than the second softening temperature, arranging the carrier layer and the inner layer between the first covering layer and the second covering layer, wherein the inner layer at least partially surrounds the carrier layer, exerting a pressing force on at least one of the covering layers, so that the first covering layer and the second covering layer are pressed at least partially into contact with the inner layer, heating the covering and carrier layers pressed into contact to a manufacturing temperature, wherein the manufacturing temperature is at least equal to the third softening temperature, the manufacturing temperature is lower than the first softening temperature, and the manufacturing temperature is lower than the second softening temperature.

13. The method for producing a polymer composite device as claimed in claim 12, further comprising at least one of the steps: arranging a display device and/or a first battery between the first covering layer and the second covering layer, in particular on the carrier layer, arranging the first overheat protection between the display device and/or the first battery and the first covering layer, in particular lying against a surface of the display device and/or of the first battery that faces towards the first covering layer, arranging the second overheat protection between the display device and/or the first battery and the second covering layer, in particular lying against a surface of the display device and/or of the first battery that faces towards the second covering layer, cooling the layers to a temperature which is lower than the third softening temperature, and releasing the pressing force.

14. The method for producing a polymer composite device as claimed in claim 12, wherein prior to the method steps, electronic components, in particular semiconductor components, are arranged on the carrier layer, in particular by a printing process.

15. The method for producing a polymer composite device as claimed in claim 12, wherein heating of the layers pressed into contact is ended after a predetermined period of time, preferably of 60 seconds, particularly preferably of 30 seconds.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further features, properties, advantages and possible modifications will become clear for a person skilled in the art from the following description, in which reference is made to the accompanying drawings. In the drawings, all the features which are described and/or depicted show the subject-matter disclosed herein on their own or in any desired combination. The dimensions and proportions of the components shown in the figures are not to scale.

(2) FIG. 1 shows, schematically, a polymer composite device with enclosed components.

(3) FIG. 2 shows, schematically, a polymer composite device with enclosed components in a laminating device.

(4) FIG. 3, 4 show, schematically, a laminating device with a transport device.

(5) FIG. 5 shows a program flow chart of an authentication process.

DETAILED DESCRIPTION OF THE EMBODIMENTS

(6) Comparable components and features, or components and features which are the same and have the same effect, are in each case provided with the same reference numerals in the figures. In some cases, for reasons of clarity, reference numerals have also been omitted from some features and components in the figures, such features and components already being provided with reference numerals in other figures. The components and features which are not described again in relation to the further figures are similar in form and function to the corresponding components and features according to the other figures.

(7) FIG. 1 shows a polymer composite device 100 having a first covering layer 110 and having a second covering layer 120. The first covering layer 110 and the second covering layer 120 are manufactured from a thermoplastic polymer material, in particular from polycarbonate. In the exemplary embodiment shown, the first covering layer 110 and the second covering layer 120 are manufactured from the same thermoplastic polymer material, but this is not the case in all the embodiments according to the invention.

(8) The first covering layer 110 and the second covering layer 120 each form the outermost layers of the polymer composite device 100. Between the first covering layer 110 and the second covering layer 120 there are arranged a carrier layer 130 and an inner layer 140.

(9) On the carrier layer 130 there is arranged a plurality of electronic components 133. There are further arranged on the carrier layer 130 a fingerprint sensor 134, a first rechargeable battery 131 and a display device. The display device is arranged and configured to display optically recognizable symbols. The carrier layer, in conjunction with the components arranged thereon, has a profile, uneven in cross-section, with raised elements. In other variants (not shown), the carrier layer 130 can comprise, for example, a second battery, an optical sensor, an on/off button and an induction coil and/or connection contacts for the first and/or second battery.

(10) In the exemplary embodiment shown in FIG. 1, the inner layer 140 comprises six inner layer plies 141, 142, 143, 144, 145 and 146. In the exemplary embodiment shown, the six inner layer plies are manufactured from the same thermoplastic transparent polymer material, but this is not the case in all the embodiments according to the invention. The inner layer plies 141, 142, 143, 144, 145 and 146 can consist, for example, of an in particular uniform PET, PETG, ABS or PVC material.

(11) The inner layer 140 partially surrounds the carrier layer 130 and the components arranged thereon. To that end, recesses are arranged in the first, second, third, fourth and fifth inner layer ply, which recesses are suitable for receiving the carrier layer and the components arranged on the carrier layer. In other embodiments (not shown) with only a few raised components, the implementation of recesses in one or more inner layer plies can be omitted completely.

(12) The first covering layer 110 has a transparent and scratch-resistant portion 111 which, from the perspective of an observer of the polymer composite device 100, is arranged above the display device. The transparent portion 111 is likewise manufactured from a thermoplastic polymer material/polycarbonate. In the embodiment shown here, the portion 111 is a separate piece of film of polymer material which is inserted into the first covering layer 110. However, this is not the case in all the embodiments. The first covering layer 110 further has an opening in the region of the fingerprint sensor 134, so that the fingerprint sensor 134 is not covered by the first covering layer 110.

(13) The fingerprint sensor 134 shown is suitable for detecting and storing the fingerprint of a user. The fingerprint sensor 134, like the electronic components 133, is supplied with electrical energy from the first battery 131.

(14) The first thermoplastic covering layer 110 having the transparent portion 111 has a softening temperature T1. The second covering layer 120 has a softening temperature T2. In the exemplary embodiment shown, the softening temperatures T1 and T2 are identical, but this is not the case in all the embodiments according to the invention.

(15) The inner layer 140, which comprises the six inner layer plies 141, 142, 143, 144, 145 and 146, has a uniform softening temperature T3. In other embodiments, the inner layer can comprise a plurality of inner layer plies wherein the individual inner layer plies can have different softening temperatures from one another.

(16) The softening temperature T3 is lower than the softening temperature T1 or T2. For example, the softening temperature T3 can have a value of 140 degrees Celsius. The softening temperatures T1 and T2 can, for example, each have a value of between 160 and 220 degrees Celsius.

(17) If the polymer composite device 100 is heated above the softening temperature T3, the inner layer 140 softens or liquefies, wherein the first and the second covering layer 110, 120 remain dimensionally stable at least until the polymer composite device 100 is heated to the temperature T1 or T2. As a result, a flat surface of the polymer composite device 100 is obtained, even during heating of the polymer composite device 100 above the softening temperature T3.

(18) If, in addition to heating of the polymer composite device 100, a pressing force is exerted on the first and/or the second covering layer 110, 120, the inner layer 140 molds around/flows around/encloses the carrier layer 130 and the elements arranged thereon in a material-bonding manner, so that no voids remain inside the polymer composite device 100.

(19) The embodiment shown in FIG. 1 of the polymer composite device 100 additionally comprises a first overheat protection 137 and a second overheat protection 138, which are manufactured from a transparent polymer material. The softening temperatures of the first and of the second overheat protection 137, 138 are higher than the temperature T3. During heating of the polymer composite device 100 above the softening temperature T3, both the first and the second overheat protection 137, 138 remain dimensionally stable. The first overheat protection 137 is arranged on the surface of the first battery 131 and of the display device that faces towards the first covering layer 110. The second overheat protection 138 is arranged on the surface of the first battery 131 and of the display device that faces towards the second covering layer 120.

(20) During heating of the polymer composite device 100, the first overheat protection 137 and the second overheat protection 138 protect temperature-sensitive electronic components of the polymer composite device 100 by absorbing part of the supplied heat and delaying heating of the components.

(21) An advantage of the polymer composite device 100 is that no additional filling or adhesive material has to be introduced into the polymer composite device in order to fix the carrier layer which is uneven in cross-section. As a result, temperature management during manufacture is considerably simplified, so that the total manufacturing time can also be reduced. Temperature- and/or pressure-sensitive electronic components in particular are thereby protected. The temperature-sensitive components nearest to the two covering layers are additionally protected by the use of an overheat protection.

(22) FIG. 2 shows, schematically, a thermal press 210 which is suitable for heating a polymer composite device 100 and applying a pressing force thereto. The thermal press 210 comprises a first pressing plate 211 and a second pressing plate 212. The first pressing plate 211 and the second pressing plate 212 are oriented parallel to one another and together define an interior space. A first laminating plate 221 lies against the surface of the first pressing plate 211 that faces towards the second pressing plate 212. A second laminating plate 222 lies against the surface of the second pressing plate 212 that faces towards the first pressing plate 211.

(23) In the exemplary embodiment shown in FIG. 2, an insulating inlay in the form of a first Teflon film 231 lies against the surface of the first laminating plate 221 that faces towards the second pressing plate 212. An insulating inlay in the form of a second Teflon film 232 lies against the surface of the second laminating plate 222 that faces towards the first pressing plate 211.

(24) The insulating inlays assist with uniform heat transfer to the polymer composite device to be heated, and thus contribute towards obtaining the flat surfaces of the polymer composite device during exertion of the pressing force.

(25) The polymer composite device 100 to be manufactured is arranged between the first and the second Teflon films 231, 232.

(26) In the exemplary embodiment shown in FIG. 2, the first pressing plate 211 is arranged and configured to exert a pressing force on the polymer composite device 100 by being displaced in the direction towards the second pressing plate 212 in a manner effective for pressing.

(27) Both the first and the second pressing plate 211, 212 are configured and arranged to be warmed/heated by a heating device (not shown). The heat supplied to the pressing plates 211, 212 is first transferred to the laminating plates 221, 222. The laminating plates 221, 222 warm the first and second Teflon film 222, 232, respectively, wherein the Teflon films delay the transmission of the heat to the polymer composite device 100 arranged in the thermal press. When the delay has passed, the heat is transmitted to the polymer composite device 100 with a uniformly increasing temperature.

(28) The thermal press 210 is configured and arranged to heat the polymer composite device 100 to a manufacturing temperature TF, wherein the manufacturing temperature TF is higher than the softening temperature T3 and lower than the softening temperature T1 or T2. The thermal press 210 is configured and arranged to exert a pressing force on the polymer composite device 100 at the same time as it heats the polymer composite device 100.

(29) The thermal press 210 is further configured and arranged to end heating of the layers pressed into contact after a predetermined period of time, preferably of 60 seconds, particularly preferably of 30 seconds.

(30) FIG. 3 and FIG. 4 show a laminating device 200, which comprises a first thermal press 210 and a second thermal press 240 as well as a transport device 400. The second thermal press 240 corresponds in construction to the thermal press 210 shown in FIG. 2. The second thermal press 240 is further arranged and configured to cool a polymer composite device 100 by means of a cooling device (not shown) and at the same time to exert a pressing force on the polymer composite device 100.

(31) Optionally, a vacuum can be generated in the region of the first and/or second thermal press, in particular in the interior space of the first and/or second thermal press, during heating and/or cooling of the polymer composite device.

(32) A transport device 400 conveys a plurality of polymer composite devices in succession into the interior spaces of the thermal presses 210, 240 or out of the interior spaces of the thermal presses. The polymer composite devices are thereby each in an arrangement of two laminating plates and two Teflon films. The arrangements correspond in each case to the arrangement shown in FIG. 1.

(33) The transport device 400 comprises two revolving belts 410, 420, which in particular are movable independently of one another, which are suitable for moving the polymer composite device, or the arrangements, in a conveying direction X. The revolving belts 410, 420 are guided via the drive rollers 430. The revolving belts 410, 420 are configured and arranged to be lowered into depressions 213, 214 provided therefor before or during the displacement, in a manner effective for pressing, of the first pressing plates of the thermal presses 210, 240.

(34) In other words, the revolving belts 410, 420 are movable in a direction Y, which extends substantially orthogonally to the conveying direction X. The revolving belts 410, 420 can be positioned into the depressions 213, 214 of the thermal presses 210, 240.

(35) If the revolving belts 410, 420 are lowered, the conveyed arrangements, in which the polymer composite devices to be manufactured are received, lose direct contact with the revolving belts and lie against a surface of the respective thermal press. The revolving belts 410, 420 are further configured and arranged to be moved out of the depressions 213, 214, after a pressing force has been released, so that contact between the revolving belts and the polymer composite devices is re-established and successive conveying in the conveying direction X can be continued.

(36) Lowering of the revolving belts 410, 420 can be effected, for example, by lowering the drive rollers 430.

(37) In a further development (not shown), the first and/or the second thermal press can each have its own transport device, each of which has its own drive. The transport devices can interengage in a transfer region. In particular, parallel revolving belts of the transport devices can be at different distances from one another, so that interengagement of the transport devices is made possible. Operation of the transport devices independently of one another is possible.

(38) FIG. 5 shows, schematically, the execution of an authentication process which can be carried out, for example, by means of a polymer composite device.

(39) The authentication method is suitable, for example, for enabling user-individual control authorizations of a data processing device, in particular within the context of banking transactions.

(40) Firstly, there are to be provided for this purpose a data processing device, for example a home computer, a PC tablet or other mobile terminal, and a suitable application program product which controls the data processing device according to the process steps described hereinbelow.

(41) The data processing device to be provided comprises a display device, for example a home computer flat screen. Furthermore, the data processing device to be provided is electronically connected to a central controller, for example a bank server, so that the data processing device and the central controller are able to exchange information. In a variant, the exchange of information can take place wirelessly.

(42) S01: The data processing device with the application program product is started up. This can be carried out in particular by a user.

(43) S02: In order to obtain access to user-specific information, for example to account data or personal data, a user of the data processing device authenticates himself with a first authentication code. This first authentication code is preferably known only to the user himself or to a specific group of people and in particular allows user-specific information to be viewed and predetermined control authorizations to be enabled. The first authentication code can in particular be a multi-digit decimal number, for example a PIN (personal identification number).

(44) S03: Predetermined control authorizations which are accessible only to the user or a specific group of people, for example financial transactions, require a second authentication with a second user-individual authentication code. A higher degree of security/integrity of the controls authorized by the user is thus ensured.

(45) In the case of an attempt to access the predetermined control authorizations, the central controller connected to the data processing device determines a QR code (quick response code) on the basis of the first authentication code already been inputted and with time information.

(46) The construction and representation of QR codes are known as prior art and are not described in greater detail here. Alternatively, other optically recognizable symbols can also be used.

(47) The determined QR code is displayed by the display device of the data processing device which is connected to the central controller.

(48) The QR code contains the second authentication code in an encrypted form, so that access to the second authentication code, in addition to requiring conversion of the QR code into binary data information, also requires decryption. The second authentication code can in particular be a multi-digit decimal number, for example a so-called TAN (transaction number).

(49) S04: For reading the QR code and for decrypting the second authentication code, an identification means that is independent of the data processing device is necessary. In the process described here, this identification means is an identification card having an optical sensor, which is suitable in particular for detecting QR codes, a fingerprint sensor, an electronic circuit, which is adapted for executing a decrypting function, and a card display device, which is suitable for displaying the second authentication code. The identification card is a polymer composite device.

(50) The identification card is started up by the user by means of an on/off button. If the on/off button is not operated again by the user for a predetermined period of time, for example 10 minutes, the identification card switches into a standby mode in order to save energy, in which in particular the card display device, the optical sensor and the fingerprint sensor are deactivated.

(51) S05: The user places a finger on the fingerprint sensor of the identification card, and the fingerprint sensor detects a fingerprint of the user. Detection of the fingerprint makes it difficult for unauthorized third parties to misuse the identification card.

(52) S06: The identification card compares the detected fingerprint of the user with stored fingerprint information of an identification card holder. If the fingerprint information matches, the optical sensor and a decrypting function of the identification card are activated. If the fingerprint information does not match, the optical sensor and the decrypting function are not activated.

(53) S07: For converting the QR code into binary data information and for decrypting the binary data information, the identification card is positioned at the display device of the data processing device, so that the activated optical sensor detects the QR code.

(54) S08: The electronic circuit of the identification card decrypts the detected information and determines the second authentication code. Furthermore, the second authentication code is displayed/outputted by the card display device.

(55) S09: The user inputs the displayed second authentication code into the data processing device.

(56) After the second authentication code has been inputted into the data processing device, the user-individual control authorization is enabled.

(57) If the second authentication code inputted is incorrect, the user is denied the control authorization. It is possible to carry out the authentication process or individual steps of the authentication process again. In a further development (not shown), after repeated incorrect inputting of the first or the second authentication code, predetermined control authorizations are blocked by the data processing device and it is not possible to repeat the authentication process.

(58) It should be noted that, although numerical ranges and numerical values have been disclosed herein, all numerical values between the disclosed values and any numerical sub-range within the mentioned ranges are likewise to be regarded as disclosed.

(59) The above-described variants of the device and the structural and operational aspects thereof serve merely for better understanding of their structure, functioning and properties; they do not limit the disclosure, for example, to the exemplary embodiments. The figures are partly schematic, important properties and effects in some cases being shown on a significantly enlarged scale in order to clarify the functions, active principles, technical configurations and features. Any mode of functioning, any principle, any technical configuration and any feature that is/are disclosed in the figures or in the text can be combined freely and arbitrarily with all the claims, any feature in the text and in the other figures, other modes of functioning, principles, technical configurations and features which are contained in this disclosure or follow therefrom, so that all conceivable combinations are to be assigned to the described procedure. Combinations between all the individual implementations in the text, that is to say in every section of the description, in the claims, and also combinations between different variants in the text, in the claims and in the figures, are also included. The claims also do not limit the disclosure and thus the possible combinations of all the indicated features with one another. All the disclosed features are explicitly also disclosed herein individually and in combination with all the other features.