Abstract:
An apparatus that stores and synchronizes printed forms that are being transferred between a high speed forms printer and a mechanism for attaching plastic cards to the forms. The apparatus is also able to buffer the forms that are in progress in the printer should the card processing system need to be shut down or paused. The apparatus creates a shingled stack of forms, with the bottommost form in the stack being fed to the attaching mechanism as needed.

Description:
FIELD OF THE INVENTION 
     The invention relates to card processing systems which process data bearing plastic cards, such as credit cards, driver&#39;s licenses, identification cards and the like. More particularly, the invention relates to an apparatus for use in a card processing system in which the apparatus is adapted to handle printed forms to which data bearing plastic cards are eventually attached. 
     BACKGROUND OF THE INVENTION 
     Card processing systems currently in use include apparatus for performing processing operations on the plastic cards, such as printing, embossing, laminating and the like. Many of these card processing systems are formed as modular systems composed of a plurality of separate modules, each of which is designed to perform a particular processing function or functions. The modules can be taken out of, or inserted into, the system so that the system can be adapted to the changing needs of the user. An example of a modular card processing system is the Maxsys system and the 9000 system, each of which is produced by DataCard Corporation of Minnetonka, Minn. 
     Card processing systems also often include apparatus for producing and processing printed forms or sheets to which the plastic cards are subsequently attached for sending to customers. The printed forms are typically produced in a high speed printer. Each printed form contains, for example, personal information thereon related to a particular customer. Each printed form is then matched with the corresponding plastic card(s) for the customer downstream of the printer. 
     The form printing operation can often occur at a faster rate than the card personalization operation, which means that the forms will not be completed at the same time as the card(s) to be attached thereto. Therefore, the forms must be handled while waiting for the card(s) to be finished. 
     In addition, on certain occasions, a card processing system can develop a fault in one or more of its modules which requires that the system be paused or stopped to correct the problem. If this occurs, card processing stops. This can create difficulties in matching the correct printed form with the correct card(s). In the past, if the system has been paused, the forms that are in progress in the printer have often been thrown away because the sheets that are in progress in the printer cannot be stopped. Since each printed form contains personal information for a particular customer which must be mated downstream of the printer with the appropriate plastic card, it is difficult to reprint each of the customer specific printed forms and match the reprinted forms with the appropriate plastic card. 
     One way to eliminate the need to dispose of forms, and to handle forms while they wait for card personalization to be complete, is to utilize a buffer between the printer and the mechanism that mates the cards and forms. A buffer is designed to hold the forms that were in progress in the printer when the system is paused, and to handle forms while the card(s) to be attached thereto are completed. The buffer holds the printed forms until the system is restarted and the card(s) is ready to be attached, at which point the correct form can then be matched with its correct card(s). An example of a buffer is disclosed in U.S. Pat. No. 6,042,528. 
     An additional problem that is presented when matching printed forms with data bearing cards is that the size of the paper used to print the forms may vary depending upon the requirements of the intended customer. For example, some customers may want Letter sized forms, while others may want A4 sized forms. Therefore, if a buffer is used, it needs to be designed to accommodate the differing paper sizes that are often used for forms. 
     SUMMARY OF THE INVENTION 
     The invention relates to a method and apparatus used with a card processing system that produces data bearing plastic cards. The apparatus stores and synchronizes printed sheets that are being transferred between a high speed forms printer and a mechanism for attaching the plastic cards to the forms. The apparatus is also able to buffer the sheets that are in progress in the printer should the card processing system need to be shut down or paused. 
     In one aspect of the invention, a method of storing and synchronizing forms being transferred between a forms printer and a device for attaching personalized cards to the forms is provided. The method comprises providing a forms buffer apparatus between the printer and the attaching device, discharging forms from the printer into the forms buffer apparatus, stacking the forms in the forms buffer apparatus so that a leading edge of each form is set back from the leading edge of the form immediately beneath it thereby creating a shingled stack, moving the shingled stack toward an output to discharge the lowermost form from the shingled stack, and moving the shingled stack back to a home position to permit reception of another form onto the top of the shingled stack. 
     In another aspect of the invention, an apparatus for storing and synchronizing forms that are transferred between a forms printer and a device for attaching personalized cards to the forms is provided. The apparatus comprises an input configured to permit reception of forms from the forms printer, an output through which forms are discharged to the device for attaching personalized cards, and a stack area between the input and output that is configured and arranged to contain a stack of forms. A first mechanism is configured and arranged to transport forms from the input to the stack area, and a second mechanism at the stack area is configured and arranged to transport the stack of forms toward and away from the output. 
     One advantage of the apparatus and method of the invention is that it can operate at high speeds. For example, the apparatus and method can operate at up to 3000 forms per hour, which is fast enough to work with DataCard Corporation&#39;s Maxsys System. In addition, the apparatus can work with a wide range of printers and card processing systems, as well as accommodate a wide range of operating speeds. Further, the apparatus can operate over a wide range of paper parameters, including various paper sizes, moisture contents, paper weights and paper types. The apparatus is also simple in construction and has few parts that require maintenance. 
     For a better understanding of the invention, its advantages and objects obtained by its use, reference should be made to the drawings which form a further part hereof, and to the accompanying description, in which there is described a preferred embodiment of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic depiction of a modular card processing system employing the apparatus of the invention. 
         FIG. 2  is a perspective view of the apparatus of the invention. 
         FIG. 3  is a perspective view of the apparatus with the top plate of the guide path removed. 
         FIG. 4  is a schematic depiction of the shingled stack of forms and the recessed area of the stack area. 
         FIG. 5  is a perspective view of the apparatus viewed from an opposite end of the apparatus. 
         FIG. 6  is a top view of the apparatus. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The invention relates to card processing systems which process data bearing plastic cards, such as credit cards, driver&#39;s licenses, identification cards and the like. With reference to  FIG. 1 , a card processing system  10  is illustrated. The system  10  includes a card personalization system  12  which is capable of personalizing plastic cards with data specific to the intended card holder, as well as perform other processing operations on the cards. Examples of card personalization and processing that can occur includes magnetic stripe programming, integrated circuit chip programming, embossing, monochromatic printing, multicolor printing, laser engraving, card cleaning, and top coat application. Other personalization and processing operations known to those of skill in the art having read this specification are possible. The system  12  is preferably a modular card personalization system, for example the Maxsys system available from DataCard Corporation of Minnetonka, Minn., or the system disclosed in U.S. Pat. No. 5,266,781. 
     Properly personalized cards produced by the system  12  are then output to a sticker module  14  which applies an adhesive material to the cards so that the cards can be attached to forms for mailing to the intended card holders. The adhesive material that is applied can be in the form of at least one sticker that is applied to the backside of the cards. Alternatively, the adhesive material can be a suitable glue. Adhesive materials that would be suitable for affixing plastic cards to forms would be known to those of skill in the art having read this specification. 
     After the adhesive material is applied, the cards are then transported to an affix module  16  at which the cards are affixed to forms for subsequent mailing. The affix module  16  also receives printed forms from a printer  18 . The printer  18  prints cardholder specific data and other data onto paper sheets to produce forms for mailing to intended cardholders. The printer  18  is preferably a high-speed printer, and can be configured to perform black-and-white printing or color printing. An example of a suitable printer for use with the invention is the Hitachi DDP 70 printer, available from Hitachi America, Ltd. The forms are preferably either Letter sized (i.e. 216 mm×279 mm) or A4 sized (i.e. 210 mm×297 mm), although other paper sizes could be used. 
     The affix module  16  receives both cards and printed forms, and affixes one or more cards to the appropriate form for that card. An example of a suitable affix module for use with the invention is the Ultraform Card Affixer available from DataCard Corporation of Minnetonka, Minn. 
     The forms with the cards attached are then transported to a folding module  20  which folds the forms for mailing. An example of a suitable folding module for use with the invention is the Ultraform Folder available from DataCard Corporation of Minnetonka, Minn. 
     The folded forms are then transported to an envelope module  22  which takes the folded forms and inserts them into an envelope for mailing. An example of a suitable envelope module for use with the invention is the PFE Automailer 3 Envelope Inserter available from PFE International Ltd. of Essex, England. 
     Disposed between the printer  18  and the affix module  16  is a buffer apparatus  24  according to the invention. The apparatus  24  is configured to synchronize forms being transferred between the printer  18  and the affixer  16  so that the proper form arrives at the affix-module at the correct time to be matched with the proper card(s) for that form. 
     The apparatus  24  is also configured to store forms that are in progress within the printer  18  in the event that the card personalization system  12 , or any other module of the system  10 , develops an error that requires the card personalization system  12  to be shut down. If the system  12  is shut down, further card personalization stops until the system is again restarted. The apparatus  24  maintains the order of the forms so that when the system  12  is restarted, the forms can be fed to the affix module  16  in proper order so that the proper form can be matched with the proper card(s). Preferably, there are never more than six forms in the printer  18  and buffer apparatus  24  at any one time. As a result, at most six forms will collect in the apparatus  24 . 
     The apparatus  24  is preferably in the form of a module. The use of modular components in the system  10  permits rearrangement and reconfiguration of the system  10 , as well as making replacement of a defective module easier. 
     Turning now to  FIGS. 2–6 , details of the buffer apparatus  24  are illustrated. The apparatus  24  includes a support frame  26  that supports the various components of the apparatus  24 . In use, the support frame  26  is preferably mounted within a housing (not shown) which defines the exterior appearance of the apparatus  24 . The specific construction of the support frame  26  can vary, as long as it is able to perform its function of supporting the components of the apparatus  24 . 
     A forms input  28  is defined adjacent an end of the apparatus  24 . The input  28  is configured to permit reception of forms from the printer  18  after the forms have been printed. A form  30  is illustrated in  FIGS. 3 and 6  about to enter the apparatus  24  through the input  28 . The input  28  is arranged so that the forms enter the apparatus  24  side edge first. Alternatively, the input could be arranged at the end  29  of the apparatus  24  with the forms entering leading edge first. 
     With reference to  FIGS. 2 ,  3  and  5 , the input  28  comprises upper and lower guide plates  32 ,  34  that define an inlet throat  36  for receiving the forms. The plates  32 ,  34  cooperate with the upstream printer  18  to ensure that the forms enter the throat  36 . The input  28  further includes entry roller pairs  38   a ,  38   b  which take each form and drive the form, side edge first, further into the apparatus  24 . Each roller pair  38   a ,  38   b  comprises a pair of upper and lower rollers (only the upper rollers are visible in the figures) which define a roller nip therebetween. The rollers are preferably constantly driven through a suitable drive mechanism by a drive motor (not shown), for example an AC induction motor. A suitable mechanism for driving the rollers would be known to a person of skill in the art having read this specification. 
     A paper guide  40  is also provided at the input  28  for controlling the input of forms into the apparatus. The paper guide  40 , which comprises a part of the forms input  28 , guides each form to a position above a stack of forms in the apparatus  24  where the form is then deflected by a top guide path plate  50  (to be later described) down onto the top of the stack. 
     A plurality of flipper plates  42  are attached to an actuating shaft  44 , as best seen in  FIGS. 2 and 5 . The shaft  44  is connected to and actuated by an actuator  46  (shown in dashed lines in  FIG. 2 ), for example a rotary actuator. The actuator  46  mounts to a plate  47 . The shaft  44  is actuatable by the actuator  46  between a position shown in  FIG. 2  where the plates  42  are disposed at an angle to a vertical axis, and a position (not shown) where the plates  42  are disposed generally vertically. When the plates  42  are at an angle, the form is moved from the printer to the top of the stack of forms. After the form is on the stack, the plates  42  are rotated to the vertical position behind the form to push the form against a first edge guide  56  (to be later described) The plates  42  stay vertical until the form has been pushed under the rollers  86  (to be later described). Once this occurs, the plates  42  are then actuated back to the angled position for the next form. In addition, at the vertical position, the plates  42  define a portion of one side of a form guide path through the apparatus. 
     In use, the plates  42  are disposed behind a shield  48  which is connected to a top guide path plate  50 , as shown in  FIGS. 2 and 5 . The shield  48  provides a handle for the plate  50  to facilitate removal of the plate  50 . With reference to  FIGS. 3–5 , positioned opposite the top plate  50  and spaced therefrom is a bottom guide path plate  52 . The top and bottom plates  50 ,  52  define therebetween a space  54  through which the forms travel through the apparatus  24 . The forms enter the space  54  through the input  28  and the throat  36 . In addition, a first edge guide  56  guides one edge of the forms, while a second edge guide  58 , positioned opposite the edge guide  56 , together with the flipper plates  42 , guide the second edge of the forms. 
     The first edge guide  56  is preferably mounted to permit it to be adjusted toward and away from the second edge guide  58 , as shown by the arrows in  FIG. 2 . In this way, the apparatus  24  can accommodate different paper sizes. With reference to  FIG. 6 , the edge guide  56  includes two sets of adjustment holes  60   a ,  60   b  which provide a guide to the user for adjusting the edge guide to the proper paper size requirements. For example, the sets of holes  60   a ,  60   b  can include holes  61   a ,  61   b  for adjusting the edge guide  56  to accommodate A4 sized forms, and holes for adjusting the edge guide  56  to accommodate Letter sized forms. In  FIGS. 2 ,  3 ,  5  and  6 , adjustment screws  62   a ,  62   b  are shown disposed within the holes for Letter sized forms. To adjust for A4 sized paper, the screws  62   a ,  62   b  are removed, and the edge guide  56  is moved inward toward the second edge guide  58  until the holes  61   a ,  61   b  align with corresponding threaded holes (not shown) provided in the plate  64 . Once aligned, the screws  62   a ,  62   b  are inserted into the holes  61   a ,  61   b  and the holes in the plate  64  to lock the edge guide  56  in position. The adjustment back to the Letter size position occurs in a similar manner. Other holes for accommodating other form sizes, such as Legal size, can also be provided. 
     Turning now to  FIGS. 3 and 6 , the plates  50 ,  52  define a forms input area  70  at which each form that is input initially is disposed. The form is then transported downstream to a stack area  72  where a shingled stack of forms is created. The stack of forms is in a rear or home position when the form enters the input area  70  from the printer. Therefore, the form is placed on top of a stack at that time. A mechanism is provided to move the form from the input area  70  to the stack area  72  and position the form on the stack so that the form has the correct spacing relative to the forms beneath it. 
     At the input area  70 , a roller mechanism  74  is provided. The roller mechanism  74  comprises a driven roller  75  (shown in  FIG. 5 ) that extends upwardly through a space provided in the bottom plate  52  to engage the bottom of the form, and disposed opposite thereto an idler roller  76  that extends downwardly through a space  78  provided in the top plate  50  to engage the top of the form. The driven roller  75  is driven by a motor, for example an AC induction motor which can be the same motor used to drive the roller pairs  38   a ,  38   b  or a different motor. 
     The idler roller  76  is mounted so as to be movable toward and away from the driven roller  75 . When the idler roller  76  is away from the driven roller  75 , a form can enter the input area  70 . After a form has entered the area  70 , the idler roller  76  is actuated toward the driven roller  75  to engage the top of the form. This permits the form to be driven toward the stack area  72 . The idler roller  76  is actuated up and down by an actuator  80 , such as a rotary actuator. 
     A roller mechanism  82  is also provided at the stack area  72 . The roller mechanism  82  is designed to engage the stack of forms at the stack area  72  and move the stack toward and away from the affix module  16 . The roller mechanisms  74  and  82  are spaced apart a distance such that the roller mechanism  74  engages only a single form for driving each form to the stack area  72  and into engagement with the roller mechanism  82 , while the stack of forms at the stack area  72  is engaged only by the roller mechanism  82 . For Letter and A4 sized forms, a suitable distance between the nip of each roller mechanism  74 ,  82  is about 10.875 inches. 
     The roller mechanism  82  comprises a pair of spaced driven rollers  84  (one roller  84  is visible in  FIG. 3 ), and idler rollers  86  opposite the driven rollers  84 . As shown in  FIG. 3 , the rollers  84  extend upwardly through spaces  88  provided in the bottom plate  52  to engage the bottom of the lowermost form in the stack of forms, while the idler rollers  86  extend downwardly through spaces  90  provided in the top plate  50  to engage the top of the uppermost form in the stack. 
     The rollers  84  are driven both forwardly and in reverse by a suitable drive motor (not shown), for example a stepper motor. The idler rollers  86  are connected to a pivot arm  92  which is mounted on a pivot shaft  94 . A spring (not shown) biases the pivot arm  92  downward, thereby biasing the idler rollers  86  toward the rollers  84 . 
     The top and bottom plates  50 ,  52  also define an output  100  therebetween through which each form is discharged to the affix module  16 . Each form is output individually to the affix module as a result of the roller mechanism  82  driving the stack of forms toward the output  100 . As the roller mechanism  82  drives the stack of forms toward the output  100 , the bottommost form in the stack is driven into the nip of exit rollers. The exit rollers take the bottom form and transport the form a short distance further to ensure that the form is out of the nip of the roller mechanism  82 . The exit rollers then transport the form for affixing the card(s) thereon. As shown schematically in  FIGS. 5 and 6 , it is preferred that the exit rollers  104  be part of the affix module  16 . One or more additional sets of exit rollers could be provided in the module  16  for accepting forms. 
     The distance between the nip of the roller mechanism  82  and the nip of the exit rollers  104  is chosen to permit the above operation. For Letter and A4 sized forms, a suitable distance between the nip of the roller mechanism  82  and the exit rollers  104  is about 10.875 inches. For other form sizes, this distance would change. 
       FIG. 4  schematically depicts the stack area  72  with a stack of forms  110  formed between the plates  50 ,  52 . The spacing between the forms and the rollers, and between the forms and the plates  50 ,  52  are exaggerated for purposes of this description, it being understood that the bottommost form rests on the plate  52  and there is minimal spacing between the uppermost form and the plate  50 . In addition, although space is shown between each form, it is to be understood that in use, the forms will be stacked on top of each other with effectively no space therebetween. 
     In the stack  110 , the forms are disposed in a shingled manner, so that the leading edge of each form (except for the bottommost form) is set back from the leading edge of the form immediately beneath it. The setback distance d is the same for each form, with the distance varying depending upon the number of forms that are to be stacked. The distance d is preferably between about 0.65 to about 1.3 inches. In the preferred embodiment, the stack  110  contains a maximum of six sheets, in which case the distance d is about 1.3 inches. However, the stack can accommodate up to twelve forms, in which case the distance d will be about 0.65 inches. A person of ordinary skill in the art have read this specification would understand that other set-back distances could be used. 
     The apparatus  24  operates as follows. The one roller mechanism  82  controls the stack of forms  110  as it moves back and forth away from and toward the output  100 . As a new form enters the input  28  from the printer, it is placed on top of the stack  110  in a shingled manner. Each new form enters the input area  70  at a point above the stack and is directed down onto the stack by the top plate  50 . When a new form enters the input area  70 , the stack is at its home position. As a result, the new form is placed on top of the stack before the new form is moved into the nip of the rollers  84 ,  86  by a mechanism comprising the roller pairs  38   a ,  38   b  and the roller mechanism  74 . When the new form reaches the rollers  84 ,  86 , the stepper motor starts and moves the entire stack a short distance downstream toward the output  100  to make the stack ready to accept a new form. This movement also establishes the set back distance for a new form that is later added to the top of the stack. Assuming a set back distance d of about 1.3 inches, the top form is placed on the stack about 1.3 inches to the left (when viewing  FIG. 4 ) of the sheet below it. 
     To deliver a form to the affix module  16 , the stack  110  is moved by the roller mechanism  82  to the right (when viewing  FIG. 4 ) an amount to place the bottom form into the nip of the rollers  104 . Due to the set back distance d, only the bottommost form enters the nip of the rollers  104 . The leading edge of the bottommost form is grabbed by the rollers  104  which move the bottommost form, for example, about one more inch to the right (when viewing  FIG. 4 ) to ensure that the bottommost sheet is out of the nip of the roller mechanism  82 . The rollers  104  are now free to deliver the form to the affix module  16  for affixing the card(s) thereto. 
     After the bottommost form is delivered, the stack  110  is moved back to the home position (shown in  FIG. 4 ) to receive the next form. When a request for a new form is received, an entry photocell (not shown) at the input  28  determines whether a new form is coming in. If a new form is entering the apparatus, the stack  110  is not moved toward the output  100  until the new form is placed on top of the stack  110 . 
     As a new form exits the printer  18 , it covers the entry photocell and the roller pairs  38   a ,  38   b  and the driven roller of the roller mechanism  74  are actuated. The new form is then placed on top of the stack  110 . A photocell in the input area  70  senses the new form and activates the flipper plates  42  to the vertical position. This forces the form against the edge guide  56 . The idler roller  76  is then actuated downward toward the driven roller for moving the form toward the stack area  72  and into the nip of the roller mechanism  82 . The roller mechanism  82  then moves the new form and the stack  110  to the right about 1.3 inches (assuming a maximum of six sheets in the stack) so that when another form is added on top of the stack, the correct set back results. 
     As each new form is added to the top of the stack, the stack moves about 1.3 inches (assuming a maximum of six sheets in the stack) toward the output  100 . Each request for a form from the affix module  16  moves the bottom form to the output, and each new form that enters the apparatus moves the stack  110  about 1.3 inches toward the output  100  (assuming a maximum of six sheets in the stack). These two operations occur asynchronously, and never at the same time. If a form is entering the apparatus  24 , the stack waits for the form to be added to the top of the stack. 
     Once the bottom form is picked up by the rollers  104 , the stack of forms must be permitted to move back to the home position without interfering with the picked-up bottom form now if the module  16 . To accomplish this, the bottom plate  52  at the stack area  72  includes a recessed area  120  adjacent to and downstream from the roller mechanism  82 . Once the bottom form is engaged by the rollers  104  and pulled into the module  16  about 1.0 inch, the rear edge of the bottom form drops into the recessed area  120 . This takes the rear edge of the form out of the way before the form is taken completely into the affix module  16 . This is important when there is one form on the stack and a new form enters the buffer and moves forward. Without the recessed area  120 , as the new form moves forward it could hit the rear edge of the form that just entered the affix module  16 . 
     As stated above, in the preferred embodiment, there are never more than six forms in the printer and buffer apparatus at any one time. As a result, when a form exits the apparatus, data is sent to the printer for a new form to be printed. If there is no request for a new form from the affix module  16 , six forms will stack in the buffer apparatus  24 . However, there could be less than six forms in the apparatus  24  when the system  12  stops, in which case the remaining forms in progress in the printer will finish printing and then be stacked in the apparatus  24  waiting for restart. 
     The apparatus  24  is capable of handling up to 3000 forms or more per hour. Further, the apparatus is capable of handling 24 to 42 pound bond paper. 
     The above specification, examples and date provide a complete description of the invention. Many embodiments of the invention, not explicitly described herein, can be made without departing from the spirit and scope of the invention.