Highly flexible foil composite material and its use in card bodies

1. A method for manufacturing a foil composite material comprising a coextrusion of at least one first outer layer plastic material, at least one second outer layer plastic material, and at least one inner layer plastic material, the method comprising the steps:

coextruding and merging each of the plastic materials so as to form the foil composite material to include

an inner plastic layer formed between a first outer plastic layer and a second outer plastic layer,

the first outer plastic layer being in direct contact with a first surface of the inner plastic layer, and

the second outer plastic layer being in direct contact with a second surface of the inner plastic layer, the first surface of the inner plastic layer being opposite from the second surface of the inner plastic layer;

wherein

the at least one first outer layer plastic material comprises a thermoplastic polymer or a mixture of thermoplastic polymers,

the at least one second outer layer plastic material comprises a thermoplastic polymer or a mixture of thermoplastic polymers, and

the at least one inner layer plastic material comprises a mixture of at least one thermoplastic elastomer and at least one thermoplastic polymer, and

wherein the inner plastic layer includes an interior plastic layer, a first exterior plastic layer, and a second exterior plastic layer, the interior plastic layer being formed between and in contact with each of the first exterior plastic layer and the second exterior plastic layer,

wherein the foil composite material is opaque, and

wherein

each of the first outer plastic layer and the second outer plastic layer are 0% thermoplastic elastomer, 85% to 95% thermoplastic polymer, and 15% to 5% filler

each of the first exterior plastic layer and the second exterior plastic layer are 20% to 50% thermoplastic elastomer, 75% to 35% thermoplastic polymer, and 5% to 15% filler, and

the interior plastic layer is 50% to 70% thermoplastic elastomer, 45% to 15% thermoplastic polymer, and 5% to 15% filler.

2. The method according to claim 1 , wherein

the first outer plastic layer and the second outer plastic layer are extruded at a nozzle temperature of 200 to 280° C., the first exterior plastic layer and the second exterior plastic layer are extruded at a nozzle temperature of 200 to 270° C., and the interior inner plastic layer is extruded at a nozzle temperature of 190 to 270° C.

3. A method for manufacturing a card body configured as a portable data carrier, the method comprising:

forming a plurality of plastic layers to include a card core and at least two cover layers, the card core being made of at least one inner core layer, the card core being formed between the at least two cover layers, a first cover layer being in direct contact with a first surface of the card core and a second cover layer being in direct contact with a second surface of the card core,

wherein, in the step of forming the plurality of plastic layers,

the plastic layers are laminated to each other in one work operation or in several work operations, and

the card core, the first cover layer, or the second cover layer includes a foil composite material that comprises a coextrusion of at least one first outer layer plastic material, at least one second outer layer plastic material, and at least one inner layer plastic material,

the foil composite material being formed by

coextruding and merging the at least one first outer layer plastic material, the at least one second outer layer plastic material, and the at least one inner layer plastic material such that the foil composite material includes

an inner plastic layer formed between a first outer plastic layer and a second outer plastic layer,

the first outer plastic layer being in direct contact with a first surface of the inner plastic layer, and

the second outer plastic layer being in direct contact with a second surface of the inner plastic layer, the first surface of the inner plastic layer being opposite from the second surface of the inner plastic layer,

wherein the at least one first outer layer plastic material comprises a thermoplastic polymer or a mixture of thermoplastic polymers,

the at least one second outer layer plastic material comprises a thermoplastic polymer or a mixture of thermoplastic polymers, and

the at least one inner layer plastic material comprises a mixture of at least one thermoplastic elastomer and at least one thermoplastic polymer,

wherein the foil composite material is opaque, and

wherein

each of the first outer plastic layer and the second outer plastic layer are 0% thermoplastic elastomer, 85% to 95% thermoplastic polymer, and 15% to 5% filler,

each of the first exterior plastic layer and the second exterior plastic layer are 20% to 50% thermoplastic elastomer, 75% to 35% thermoplastic polymer, and 5% to 15% filler, and

the interior plastic layer is 50% to 70% thermoplastic elastomer, 45% to 15% thermoplastic polymer, and 5% to 15% filler.

4. The method according to claim 3 , wherein the plastic layers are laminated to each other at a temperature of between 120° C. and 200° C.

5. The method according to claim 1 , wherein

the first exterior plastic layer is adjacent to the first outer layer plastic material, the first exterior plastic layer includes a first thermoplastic polymer, and the first thermoplastic polymer of the first exterior plastic layer is the same as the thermoplastic polymer of the first outer layer plastic material, and

the second exterior plastic layer is adjacent to the second outer layer plastic material, the second exterior plastic layer includes a second thermoplastic polymer, and the second thermoplastic polymer of the second exterior plastic layer is the same as the thermoplastic polymer of the second outer layer plastic material.

6. The method according to claim 1 , wherein the interior plastic layer, the first exterior plastic layer, and the second exterior plastic layer include a same thermoplastic elastomer.

7. The method according to claim 5 , wherein the first exterior plastic layer includes the first thermoplastic polymer and the second exterior plastic layer includes the second thermoplastic polymer, and the mixture of at least one thermoplastic elastomer and at least one thermoplastic polymer of the interior plastic layer includes the first thermoplastic polymer and the second thermoplastic polymer.

8. The method according to claim 1 , wherein

the interior plastic layer is thicker than the first exterior plastic layer, and

the interior plastic layer is thicker than the second exterior plastic layer.

9. The method according to claim 1 , wherein the inner layer plastic material comprises a first interior plastic layer and a second interior plastic layer, and

the first interior plastic layer is comprised of a first percentage of thermoplastic elastomer, and the second interior plastic layer is comprised of a second percentage of thermoplastic elastomer, and

when the first interior plastic layer is a more interior layer than the second interior plastic layer, the first percentage of thermoplastic elastomer is greater than or equal to the second percentage of thermoplastic elastomer.

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

11. The method according to claim 1 , wherein the foil composite material has a total thickness between 80 μm and 130 μm.

12. The method according to claim 1 , wherein the foil composite material has a total thickness between 150 μm and 350 μm.

13. The method according to claim 1 , wherein a total thickness of the first outer layer plastic material is 10% to 30% of a total thickness of the foil composite material, a total thickness of the second outer layer plastic material is 10% to 30% of the total thickness of the foil composite material, and a total thickness of the inner layer plastic material is 80% to 40% of the total thickness of the foil composite material.

14. The method according to claim 1 , wherein

a total thickness of the first outer layer plastic material is 10% of a total thickness of the foil composite material,

a total thickness of the second outer layer plastic material is 10% of the total thickness of the foil composite material,

a total thickness of the first exterior plastic layer is 20% of the total thickness of the foil composite material,

a total thickness of the second exterior plastic layer is 20% of the total thickness of the foil composite material, or

a total thickness of the interior plastic layer is 40% of the total thickness of the foil composite material.

15. The method according to claim 1 , wherein the interior plastic layer is comprised of a first percentage of thermoplastic elastomer, the first exterior layer is comprised of a second percentage of thermoplastic elastomer, and the second exterior layer is comprised of a third percentage of thermoplastic elastomer, and

the first percentage of thermoplastic elastomer is greater than or equal to the second percentage of thermoplastic elastomer, and

the first percentage of thermoplastic elastomer is greater than or equal to the third percentage of thermoplastic elastomer.