DESC:
TITLE: METHOD OF MANUFACTURING A HIGH SECURITY FILM BY IN REGISTRATION PROCESS.
FIELD OF THE INVENTION:
The present invention relates to high security film. More particularly the present invention relates to method of manufacturing high security film by in registration process, wherein said high security film may be used in several validation or security applications.
BACKGROUND OF THE INVENTION:
Conventionally, in the known prior art high security film are manufacturing by laminating Roll A to Roll B, wherein said Roll A is manufactured by taking a readily available metalized carrier film, such as MET-PET having a thickness of higher micron, wherein the metalized PET is coated with black resist at discreet location by any means of printing method. Further the metalized PET under goes demetalization step, to form patters such as indicia. The indicia formed during the demetalization step may include any type of texts, graphics or images or a combination thereof. Further magnetic elements are printed over the indicia, to enhance the complexicity of Roll A. The detection of the magnetic elements can be done using magnetic reader and are not visible to the naked eyes.
Similarly, Roll B is manufactured by taking a readily available dimensionally stable carrier film, such as a PET having a thickness of higher micron, wherein the PET is coated with a layer of liquid crystal. Once both the respective Rolls are manufactured, the face side of Roll B comprising the liquid crstal layer is laminated to the face side of Roll A comprising the magnetic elements, with the help of an adhesive.
The drawback of the prior art is that the person skilled in the art has never attempted to manufacture Roll B, wherein the UV curable magnetic elements are printed on the face side of Roll B thus balancing the load of transfer of security feature (especially of magnetic element suck as magnetic ink) on both the Roll’s in balanced proportion. Another drawback associated with the above method of manufacturing is contamination that may occur due to coating of plurality of magnetic layer over the substrate/film. Further the attempt of printing UV curable magnetic elements by printing has never been attempted by the person skilled in the art. Further in register lamination comprising magnetic elements as security feature has never been attempted by the person skilled in the art.
The present invention attempts to provides a solution to over come the drawback mentioned in the prior art.
OBJECT OF THE INVENTION:
The primary object of the present invention is to provide a novel method of manufacturing high security film by in registration process, wherein said high security film may be used in several validation or security applications.
Another object of the present invention is to provide a method of manufacturing high security film that involves in registration lamination process so that it results in precise alignment and placement of the security elements, such as magnetic elements.
Yet another object of the present invention is to print UV curable magnetic elements by printing that has never been attempted by the person skilled in the art.
Yet another object of the present invention is to provide a method of manufacturing high security film, wherein contamination due to layering of plurality of magnetic ink can be eliminated.
Yet another object of the present invention is to print magnetic elements on the face side of Roll B thereby balancing the load of transfer of security feature on both the Roll’s in balanced proportion.
Yet another object of the present invention is to provide one or more security features that are incorporated with one or more indicia including letters, optionally graphics, printing UV curable magnets.Yet another object of the present invention is to provide a method of manufacturing high security film that may be inserted into high security paper such as a bank note paper and the like during the paper making process.
BRIEF DESCRIPTION OF THE INVENTION:
The nature and scope of the present invention will be better understood from the accompanying drawings, which are by way of illustration of a preferred embodiment and not by way of any sort of limitation.
Fig. 1 illustrates a method of manufacturing Roll A as described in the present invention.
Fig. 2 illustrates a method of manufacturing Roll B as described in the present invention.
Fig. 3 illustrates a method of manufacturing Roll C as described in the present invention.
Fig. 4 illustrates a method of manufacturing high security film by in registration process incorporated with high corecivity and low corecivity magnetic elements.
DETAILED DESCRIPTION OF THE INVENTION:
The following detailed description illustrates the invention by way of example and not by way of limitation. The description enables one skilled in the art to make and use the present disclosure, and describes several embodiments, adaptations, variations, alternatives, and uses of the present disclosure, including what is presently believed to be the best mode of carrying out the present disclosure.
Carrier Film: means a film, like but not limited to, PET film, PP film, PC film and like; Metallized PET are Film made from Polyethylene terephthalate resin ranging particularly from 4 microns to 25 microns.

Opaque Printing: is defined to cover, any kind of metallic, non-metallic, carbon ink based, titanium oxide based inks etc. The opacity and dark properties of printing ink is of relevance, while the minerals or metals or other inorganic materials used to make ink, is not a limiting factor. Preferably, dark black background is found to be showing the best colour shift properties.

Liquid Crystal polymer: Means liquid crystal polymers, that can be chiral, nematic/cholesteric or combination thereof and has a specific wavelength.

Adhesive: PSA (pressure sensitive adhesives) or non PSA and may be a formulation of resins, one or more like, Polyvinyl alcohol, polymides derivatives or other polymers, which include acrylics, nylons, UV curable Acrylates, polyurethanes or combination thereof.

Tie II Coat: means flash cured tie coat that is defined as an adhesive between layers of PET films and LC or layers of LC orcoated films or any kind of coatings. This tie coat may have characteristics like that of PSA (pressure sensitive adhesives) or non PSA and may be a formulation of resins, one or more like, Polyvinyl alcohol, polymides derivatives or other polymers, which include acrylics, nylons, UV curable Acrylates, polyurethanes or combination thereof. The curing process may be done by using hot air or LED or UV.

Registered lamination /In-Register lamination: refers to a precise lamination process where layers of materials (such as plastic films or paper) are aligned and laminated together in such a way that specific graphics, patterns, or text elements on the different layers line up exactly. This is crucial for designs that need to maintain accurate alignment between layers, such as in packaging, labels, or security documents.
For example, in packaging, if there’s a logo or text on both an inner and outer layer of material, registered lamination ensures that they are perfectly aligned when the package is viewed.
Key aspects of registered lamination include:
1.Precision: The alignment of graphics or design elements is highly accurate, preventing any misalignment that could affect the appearance or functionality of the product.
2.Application: It is commonly used in high-quality printed materials, such as packaging, where aesthetics and functionality are important.
3.Complexity: It requires more sophisticated machinery and careful production control compared to general lamination processes.The present invention discloses a method of manufacturing high security film that may be inserted into high security paper such as a bank note paper and the like during the paper making process.
More particularly the present invention discloses a method of manufacturing high security film by in registration process, wherein said high security film may be used in several validation or security applications. The invention discloses a method of manufacturing high security film thatinvolves in registration lamination process so that it results in precise alignment and placement of the security elements.
Further the present invention discloses printing magnetic elements that has never been attempted by the person skilled in the art. The present invention discloses printing magnetic elements on the face side of Roll B thereby balancing the load of transfer of security feature on both the Roll’s in balanced proportion. Additionally, the present invention provides a method of manufacturing high security film, wherein contamination due to layering of plurality of magnetic ink can be eliminated.
The invention further provides a novel method of producing a high security film using an in-register process, wherein one or more security features are incorporated on one or more indicia including letters, optionally graphics, printing magnets during such a production process.
During print production, registration it is a very important factor. If the placement of inks such as magnetic inks is out of register, even slightly, images and text can appear fuzzy and blurred, or exhibit a halo effect.
Needless to say, precise registration is a prerequisite for high-quality printing. Achieving the proper registration requires careful set-up and calibration of the printing equipment, as well as frequent monitoring during the production process.
The present invention attempts to provide a novel method of manufacturing high security film by in registration process, wherein said high security film may be used in several validation or security applications.
Fig. 1 illustrates a method of manufacturing Roll A (100), wherein a readily available dimensionally stable metalized carrier film, such as metalized PET (101) having a thickness of 4-25 micron is selected. The metalized PET (101) is coated with dark resist (102). Further the metalized PET coated with dark resist under goes demetalization step to form patters such as indicia (103). The indicia formed during the demetalization step may includes any type of texts, graphics or images or a combination thereof.
The metallised film formed may be selected from PET film, PP film, PC film and like, more preferably the metallisedfilm is made of PET ranging from 4-25microns. The said PET film is either coated with black/opaque masking coat, wherein the PET film is coated with any kind of metallic, non-metallic, carbon ink based, titanium oxide based inks etc to form a metallised PET film. Optionally, metallised PET available in the market can also be obtained to form the metallised PET film. Preferably, dark background is found to be showing the best color shift properties. Optionally the metallised PET film may be further ink coated withdark resist, preferably with black resist at discreet location. The metallised PET film when coated with dark resist at discreet locationfurther under goes demetallizing to form pattern such as INDCIA or demetalized in selected/desired/discreet areas as per required through the known process, so as form clear demetallized zone of transparent text/indicia over the metalized PETfilm.
Fig. 2 illustrates a method of manufacturing Roll B (200), wherein a readily available dimensionally stable carrier film, such as PET (201) having a thickness of 5 -25micron is selected. Further the PET is coated with a layer of polymer such as liquid crystal (202) having a thickness of 2 to 4 micron. The face side of the liquid crystal layer (202) is laminated with a dimensionally stable carrier film, such as the PET (203) having a thickness of 4 -6 micron. The Roll B formed is turned upside down such that the PET (201) having a thickness of 5 - 25 micron becomes the face side and the PET (203) having a thickness of 4 -6 micron becomes the obverse side of Roll B. Further, the PET (201) having a thickness of 5- 25 micron is peeled off, to expose the polymeric side of the liquid crystal layer. Further magnetic elements (204) are printed, at discreet location over the liquid crystal layer of Roll B; wherein the magnetic elements (204) may be U.V curable;
During printing of magnetic elements (204), it is very important that the magnetic elements (204) are printed at discreet location over the liquid crystal layer. The technical advancement of printing the magentic elements (204) over the liquid crystal layer is precise printing. Further the drawback such as contamination due to layering of plurality of magnetic ink can be eliminated with precise printing.
Suprisingly, the technical advancement of the present invention also encompasses the fact that plurality of magentic elements (204) say for example in the form of magnetic ink or ink with variable composition, magnetic ink with high corecivity, low corecivity or combination thereof, can be printed over the liquid crystal layer in a hassle free manner. While manufacturing Roll B (200), the step of printing magnetic elements (204) shows numerous advantages over the commercially known method.
A dimensionally stable carrier film, which is made of Polyethylene terephthalate (PET) ranging from 5- 25microns is taken. The said clear PET is selected of a specific micron which can be reused for a plurality of times. The carrier PET is coated with liquid crystal polymers, that can be chiral, nematic/cholesteric or combination thereof and has a specific wavelength; wherein the said liquid crystal polymers forms an LC layer on the dimensionally stable PET by casting/coating/printing having a thickness of 2 to 4 micron.The aforementioned assembly as disclosed in Fig.2, formed with LC film is laminated with another PETfilm, having a micron ranging from 4 –6 microns. The Roll B formed is turned upside down such that the PET having a thickness of 5 - 25 micron becomes the face side and the PET having a thickness of 4 –6 micron becomes the obverse side of Roll B. Once the assembly is turned up side down, the PET film having micron of higher thickness forms the face side and the PET film having micron of lower thickness becomes the obverse side of Roll B. Further, the PET having a thickness of 5 – 25 micron is peeled off, to expose the polymeric side of the liquid crystal layer. Further the exposed side of the liquid crystal layer is printed with magnetic ink at predefined locations to enable machine readable magnetic properties.
Fig. 3 illustrates a method of manufacturing Roll C (300), wherein Roll B (200) islaminated to Roll A (100) by in registration lamination process with the help of adhesive, such that the face side of the indicia (103) formed during the demetalization step in Roll A is laminated to the face side of the magnetic elements (204) of Roll B by in registration lamination process so that it results in precision alignment and placement of the security elements. Further once the Roll is formed both surface of Roll C is coated with anti-sebum/anti scratch coat on the face as well as the obverse side of Roll C. Optionally the obverse side of Roll C may be coated with UV Fluorescence, and heat seal laqueron both side.
Liquid Crystal Film, being one of the key component is responsible for discreet colour shift values, and is essentially clear at first instance, with a mild hue of colours, created by reflection of random light, at random angles, but when laminated to a Metalized, or de-metalized and/or opaque coated and/or opaque ink printed on a PET film, forms a colour shift effect of pre-defined colour values.
Adhesive is coated by means of Tie Coat process, wherein adhesive is applied between layers of PET films and LC or layers of LC Or coated films or any kind of coatings. The adhesive coated by the tie coat process may have characteristics like that of PSA (pressure sensitive adhesives) or non PSA and may be a formulation of resins, one or more like, Polyvinyl alcohol, polymides derivatives or other polymers, which include acrylics, nylons, UV curable Acrylates, polyurethanes or combination thereof. Further the curing process may be done by using hot air or LED or UV.

Another embodiment of the present invention discloses a method of coating magnetic element having high corecivity and low corecivity at discreet location over the liquid crystal layer by inregister process as disclosed in Fig. 4 of the present invention, wherein , the exposed side of liquid crystal layer is coated with plurality of magnetic feature. The magnetic feature coated may comprise of magnetic slurry coated in the form of magnetic strip, may be coated with magnet of Hi coercivity, may be coated with magnet of Lo coercivity or may be coated with combination of Lo and Hi coercivity, wherein the magnetic area coated will have different coercivity values and whose residual magnetism is identical or different; the difference in coercivity and the identical or different residual magnetism are aimed at generating different codes. In particular, the magnetic areas are provided by means of magnetic inks whose coercivity is different such that it may be a mix of high coercivity and low coercivity. Furtherthe magnetic ink, used for printing one dimensional, two dimensional or three dimensional barcodes, enables non-contact reading, through the paper fibers or camouflaged over/under print. Additionally, these readings can be achieved in miliseconds.
Fig. 4 illustrates method of manufacturing high security film by in registration process incorporated with high co and low co magnetic elements.
Roll A comprises of a readily available dimensionally stable metalized carrier film, such as metalized PET (101) having a thickness of 4 -25 micron is selected. The metalized PET (101) is coated with magnetic slurry in the form of magnetic strip (206) at discreet locations, or may be coated with magnet of Hi coercivity, may be coated with magnet of Lo coercivity or may be coated with combination of Lo and Hi coercivity at discreet locations, wherein the magnetic area coated will have different coercivity values and whose residual magnetism is identical or different.
Roll B is manufactured as disclosed in Fig. 2, wherein the step of printing magnetic element over the liquid crystal layer (202) is replaced by coating magnetic slurry in the form of magnetic strip (205) at discreet locationsover the liquid crystal layer (202). Further the magnetic strip (205) may be in the form of magnet of Hi coercivity, may be in the form of magnet of Lo coercivity or may be coated with combination of Lo and Hi coercivity at discreet locations, wherein the magnetic area coated will have different coercivity values and whose residual magnetism is identical or different.
Roll C is formed by in register lamination of Roll B to Roll A, such that the magnetic strip (205) coated at discreet location on Roll B, aligned as desired to magnetic strip (206) coated at discreet location on Roll A, as disclosed in Fig. 4 of the present invention.
This embodiment or assembly as disclosed in Roll C demonstrates that plurality of magnetic element of different coercivity may be coated or stacked over each other, without any fear of contamination. This process of precises alignment of different magnetic elements is obtained with in register laminating, that aids in precise alignment of all the components while manufacturing the complex security film.The present invention discloses a method of manufacturing high security film by in registration process, wherein said high security film may be used in several validation or security applications. The invention discloses a method of manufacturing high security film thatinvolves in registration lamination process so that it results in precise alignment and placement of the security elements.Further the present invention discloses printing UV curable magnetic elements by printing that has never been attempted by the person skilled in the art. The present invention discloses printing UV curable magnetic elements on the face side of Roll B thereby balancing the load of transfer of security feature on both the Roll’s in balanced proportion.Additionally, the present invention provides a method of manufacturing high security film, wherein contamination due to layering of plurality of magnetic ink can be eliminated.
The advantage of printing the magnetic element over PET film of Roll B and further laminating the Roll B over Roll A by in register lamination process, results in precision alignment and placement of the security elements. Further the impression of the security elements or security inks occurs in the precise position as intended, thus reducing the occurrence of counterfeiting of several validation or security applications.
Further the security elements are evenly distributed in a balanced manner in both the Rolls, such that the physical characteristic of each layer of security elements are retained without any distortion.

,CLAIMS:WE CLAIM:
1. A method of manufacturing a high security film comprises the steps of;
- manufacturing Roll A (100); wherein a dimensionally stable metalized carrier film (101) is coated with dark resist (102), wherein the metalized PET coated with dark resist under goes demetalization step to form patters such as indicia (103); to form Roll A;
- manufacturing Roll B (200); wherein a dimensionally stable carrier film, such as PET (201) having a thickness of higher micron is coated with a liquid crystal layer(202); wherein the face side of the liquid crystal layer (202) is laminated with a dimensionally stable carrier film having a thickness of lower micron; to form a Roll B;
- turning the Roll B formed upside down such that the PET (201) having a thickness of higher micron becomes the face side and the PET (203) having a thickness of lower micron becomes the obverse side of Roll B;
- peeling the PET (201) having a thickness of higher micron, to expose the polymeric side of the liquid crystal layer of Roll B;
- printing magnetic elements (204) at discreet/desired location over the liquid crystal layer of Roll B; wherein the magnetic elements (204) may be U.V curable;
-laminating Roll B (200) to Roll A (100) by in registration process with the help of adhesive, such that the face side of the indicia (103) formed during the demetalization step in Roll A is laminated to the face side of the magnetic elements (204) of Roll B by in registration process so that it results in precision alignment and placement of the security elements; to form Roll C;
2. The method of manufacturing a high security film as claimed in claim 1 comprises the steps of :
- manufacturing Roll A (100); wherein a dimensionally stable metalized carrier film (101) is coated/printed with magnetic strip (206) at discreet location; to form Roll A;
- manufacturing Roll B (200); wherein a dimensionally stable carrier film, such as PET (201) having a thickness of higher micron is coated with a liquid crystal layer (202); wherein the face side of the liquid crystal layer (202) is laminated with a dimensionally stable carrier film having a thickness of lower micron; to form a Roll B;
- turning the Roll B formed upside down such that the PET (201) having a thickness of higher micron becomes the face side and the PET (203) having a thickness of lower micron becomes the obverse side of Roll B;
- peeling the PET (201) having a thickness of higher micron, to expose the polymeric side of the liquid crystal layer of Roll B;
- coating/printing magnetic strip (205) by printing, at discreet location over the liquid crystal layer of Roll B;
-laminating Roll B (200) to Roll A (100) by in registration process with the help of adhesive, such that the face side of the magnetic strip (206) in Roll A is laminated to the face side of the magnetic strip (205) of Roll B by in registration process so that it results in precision alignment and placement of the security elements; to form Roll C;
3. The method of manufacturing a high security film as claimed in claim 2, wherein, the exposed side of liquid crystal layer (202) is coated with plurality of magnetic feature, wherein the magnetic feature coated may comprise of magnetic slurry coated in the form of magnetic strip, and may be coated with magnet of Hi coercivity, may be coated with magnet of Lo coercivity or may be coated with combination of Lo and Hi coercivity, wherein the magnetic area coated will have different coercivity values and whose residual magnetism is identical or different.
4. The method of manufacturing a high security film as claimed in claim 1,metallised film formed may be selected from PET film, PP film, PC film and like, more preferably the metallised film is made of PET ranging from 4-25 microns
5. The method of manufacturing a high security film as claimed in claim 1, wherein the PET film is either coated with black/opaque masking coat, wherein the PET film is coated with any kind of metallic, non-metallic, carbon ink based, titanium oxide based inks etc to form a metallised PET film.
6. The method of manufacturing a high security film as claimed in claim 1, wherein dimensionally stable carrier film, such as PET (201) having a thickness of 5 -25 micron is selected.
7. The method of manufacturing a high security film as claimed in claim 1, wherein the PET is coated with a layer of polymer such as liquid crystal (202) having a thickness of 2 to 4 micron.
8. The method of manufacturing a high security film as claimed in claim 1, wherein the face side of the liquid crystal layer (202) is top sealed with a dimensionally stable carrier film, such as the PET (203) having a thickness of 4 -6 micron.
9. The method of manufacturing a high security film as claimed in claim 1, wherein the PET (203) is coated with liquid crystal polymers, that can be chiral, nematic/cholesteric or combination thereof and has a specific wavelength.
10. The method of manufacturing a high security film as claimed in claim 1, wherein optionally the obverse side of Roll C may be coated with UV Fluorescence, and heat seal laquer on both side.
Dated this day on 7th October of 2024

RANJIT BHATTACHARYA
IN/PA - 1626
(Authorized Patent Agent for the Applicant)