# US 10,864,668 B2 · Coextruded foil composite material and its use in card bodies

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- Number: US 10,864,668 B2
- Document ID: US10864668B2
- Status: Granted
- Kind: B2
- Application number: 13/579,635
- Filed: 2011-02-23
- Published: 2012-12-27
- Granted: 2020-12-15
- Earliest claimed: 2010-02-25
- Assignees: Giesecke+Devrient Mobile Security GmbH
- Applicants: Josef Riedl; Cordula Regensburger; Andreas Braun
- Inventors: Josef Riedl; Cordula Regensburger; Andreas Braun
- Web page: https://patentgrep.com/patent/US10864668B2

## CPC

- B29C 48/21: the layers being joined at their surfaces
- B29C 48/08: flexible, e.g. films
- B32B 7/023: Optical properties
- B32B 7/10: at least one layer having inter-reactive properties
- B32B 27/08: of synthetic resin
- B32B 27/18: characterised by the use of special additives
- B32B 27/285: {comprising polyethers}
- B32B 27/36: comprising polyesters
- B32B 37/04: characterised by the partial melting of at least one layer
- B42D 25/00: Information-bearing cards or sheet-like structures characterised by identification or security features; Manufacture thereof (printing processes to produce identification or security features B41M3/14)
- B42D 25/305: Associated digital information (record carriers for use with machines and with at least a part designed to carry digital markings G06K19/00)
- B42D 25/36: comprising special materials
- B42D 25/45: Associating two or more layers
- B42D 25/455: using heat
- B42D 25/46: using pressure
- B29C 48/307: {specially adapted for bringing together components, e.g. melts within the die}
- B29K 2067/00: Use of polyesters {or derivatives thereof}, as moulding material
- B29K 2067/003: {PET, i.e. poylethylene terephthalate}
- B29K 2105/0026: {Flame proofing or flame retarding agents}
- B29K 2105/0032: {Pigments, colouring agents or opacifiyng agents}
- B29K 2105/0044: {Stabilisers, e.g. against oxydation, light or heat}
- B29K 2105/005: {Heat sensitisers or absorbers}
- B29K 2105/16: Fillers
- B29K 2995/0046: Elastic
- B29L 2007/008: {Wide strips, e.g. films, webs}
- B29L 2009/00: Layered products
- B32B 2274/00: Thermoplastic elastomer material
- B32B 2307/41: Opaque
- B32B 2307/412: Transparent
- B32B 2307/50: having particular mechanical properties
- B32B 2307/536: Hardness
- B32B 2307/54: Yield strength; Tensile strength
- B32B 2307/546: Flexural strength; Flexion stiffness
- B32B 2307/714: Inert, i.e. inert to chemical degradation, corrosion
- B32B 2307/732: Dimensional properties
- B32B 2307/734: Dimensional stability
- B32B 2307/75: Printability
- B32B 2425/00: Cards, e.g. identity cards, credit cards
- B32B 2429/00: Carriers for sound or information
- B42D 2033/30
- Y10T 156/10: Methods of surface bonding and/or assembly therefor
- Y10T 428/31786: Of polyester [e.g., alkyd, etc.]
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B42D: BOOKS; BOOK COVERS; LOOSE LEAVES; PRINTED MATTER CHARACTERISED BY IDENTIFICATION OR SECURITY FEATURES; PRINTED MATTER OF SPECIAL FORMAT OR STYLE NOT OTHERWISE PROVIDED FOR; DEVICES FOR USE THEREWITH AND NOT OTHERWISE PROVIDED FOR; MOVABLE-STRIP WRITING OR READING APPARATUS
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A composite film material usable in a data carrier card body includes a first outer plastic layer, an inner plastic layer and a second outer plastic layer, all the layers together forming a co-extruded composite. The plastic material of the first outer layer is a polyethylene terephthalate glycol copolymer (PETG) or contains a PETG, the plastic material of the inner layer is a thermoplastic copolyester elastomer (TPC) or contains a TPC, and the plastic material of the second outer layer is a PETG or contains a PETG.

## Claims

### Claim 1

A foil composite material for a card body of a portable data carrier, the foil composite material comprising:
an inner layer formed between a first outer layer and a second outer layer, wherein
the first outer layer, the inner layer, and the second outer layer jointly form a coextruded composite,
within the coextruded composite, the first outer layer is in direct contact with a first surface of the inner layer, and the second outer layer is in direct contact with a second surface of the inner layer, the second surface of the inner layer being opposite from the first surface of the inner layer,
the first outer layer includes at least a first partial layer and a second partial layer, the second partial layer being between the first partial layer and the inner layer, the first partial layer containing 95 wt. % or more polyethylene terephthalate glycol copolymer (PETG),
the inner layer consists essentially of 100% of a single thermoplastic copolyester elastomer (TPC) material or consists essentially of a plurality of inner plastic layers, each of the plurality of inner plastic layers consisting essentially of a same thermoplastic copolyester elastomer (TPC), and
the second outer layer comprises polyethylene terephthalate glycol copolymer (PETG),
wherein the first outer layer, the inner layer, and the second outer layer jointly form a coextruded composite formed by the materials of each of the first outer layer, the inner layer, and the second outer layer are coextruded by being merged into said coextruded composite before leaving an extruder nozzle, and
wherein the inner layer constitutes 60 to 80% of a total thickness of the foil composite material,
wherein a thickness of each of the first outer layer and the second outer layer is in the range of 10 μm to 70 μm, and
wherein the first partial layer and the second partial layer of the first outer layer include a mixture of PETG and TPC and the content of TCP is higher in the second partial layer than in the first partial layer and the content of PETG is higher in the first partial layer than in the second partial layer.

### Claim 2 (depends on 1)

The foil composite material according to claim 1, wherein the first layer of the first outer layer contains an antiblocking agent in the range of up to and including 5 wt. %.

### Claim 3 (depends on 1)

The foil composite material according to claim 1, wherein the first outer layer further includes a second layer, the second layer of the first outer layer being an interior layer formed closer to the inner layer than the first layer of the first outer layer is to the inner layer.

### Claim 4 (depends on 1)

The foil composite material according to claim 1, wherein the inner layer comprises an interior layer formed between a first exterior layer and a second exterior layer.

### Claim 5 (depends on 1)

The foil composite material according to claim 1, wherein one or more of the first outer layer, the inner layer, and the second outer layer contains one or more additives selected from the group consisting of fillers, color pigments, oxidation stabilizers, UV stabilizers, laser additives, flame retardants, and optical brighteners.

### Claim 6 (depends on 1)

The foil composite material according to claim 1, wherein the foil composite has a thickness between 50 μm and 350 μm.

### Claim 7 (depends on 1)

The foil composite material according to claim 1, wherein the thermoplastic copolyester elastomer is a copolyester elastomer of polyether.

### Claim 8 (depends on 1)

The foil composite material according to claim 1, wherein the thermoplastic copolyester elastomer has a Shore D hardness of 33 to 55.

### Claim 9 (depends on 1)

The foil composite material according to claim 1, wherein the thermoplastic copolyester elastomer has an elongation at break greater than 300%.

### Claim 10 (depends on 1)

The foil composite material according to claim 1, wherein the thermoplastic copolyester elastomer has a melting viscosity (MFI) of 7 to 11cm3/10 min.

### Claim 11 (depends on 1)

The foil composite material according to claim 1, having a mutual adhesive strength of the layers of at least 30 N/cm.

### Claim 12 (depends on 1)

The foil composite material according to claim 1, wherein the first layer of the first outer layer contains 96 wt. % polyethylene terephthalate glycol copolymer (PETG).

### Claim 13 (depends on 1)

The foil composite material according to claim 1, wherein the first outer layer further includes a second layer that contains 100 wt. % polyethylene terephthalate glycol copolymer (PETG).

### Claim 14 (depends on 13)

The foil composite material according to claim 13, wherein the second layer of the first outer layer is an interior layer formed closer to the inner layer than the first layer of the first outer layer is to the inner layer.

### Claim 15 (depends on 14)

The foil composite material according to claim 14, wherein the second outer layer further includes a second layer that contains 100 wt. % polyethylene terephthalate glycol copolymer (PETG).

### Claim 16 (depends on 1)

The foil composite material according to claim 1, wherein the second outer layer includes a first layer that contains 95 wt. % or more polyethylene terephthalate glycol copolymer (PETG).

### Claim 17 (depends on 16)

The foil composite material according to claim 16, wherein the first layer of the second outer layer contains an antiblocking agent in the range of up to and including 5 wt. %.

### Claim 18 (depends on 16)

The foil composite material according to claim 16, wherein the second outer layer further includes a second layer, the second layer of the second outer layer being an interior layer formed closer to the inner layer than the first layer of the second outer layer is to the inner layer.

### Claim 19

A data card body of a portable data carrier comprising:
a card core including at least one core layer,
a first cover layer covering a first surface of the card core, and
a second cover layer covering a second surface of the card core,
wherein at least one of the first cover layer or the second cover layer or at least one intermediate layer comprises a foil composite material, the foil composite material including
an inner layer formed between a first outer layer and a second outer layer, wherein the first outer layer, the inner layer, and the second outer layer jointly form a coextruded composite,
within the coextruded composite, the first outer layer is in direct contact with a first surface of the inner layer, and the second outer layer is in direct contact with a second surface of the inner layer, the second surface of the inner layer being opposite from the first surface of the inner layer,
the first outer layer includes at least a first partial layer and a second partial layer, the second partial layer being between the first partial layer and the inner layer, the first layer containing 95 wt. % or more polyethylene terephthalate glycol copolymer (PETG),
the inner layer consists essentially of 100% of a single thermoplastic copolyester elastomer (TPC) material or consists essentially of a plurality of inner plastic layers, each of the plurality of inner plastic layers consisting essentially of a same thermoplastic copolyester elastomer (TPC), and
the second outer layer comprises polyethylene terephthalate glycol copolymer (PETG),
wherein the first outer layer, the inner layer, and the second outer layer jointly form a coextruded composite formed by the materials of each of the first outer layer, the inner layer, and the second outer layer are coextruded by being merged into said coextruded composite before leaving an extruder nozzle,
wherein the inner layer constitutes 60 to 80% of a total thickness of the foil composite material
wherein a thickness of each of the first outer layer and the second outer layer is in the range of 10 μm to 70 μm, and
wherein the first partial layer and the second partial layer of the first outer layer include a mixture of PETG and TPC and the content of TCP is higher in the second partial layer than in the first partial layer and the content of PETG is higher in the first partial layer than in the second partial layer.