Abstract:
Document personalization machines with a mechanism designed to operate as an in-line document puncher/voider. The document personalization machine includes a document personalization mechanism that performs a personalization operation on the document, a document transport mechanism that transports the document along a document path through the document personalization machine and a document punch mechanism that creates a punch hole on the document. The document can be, for example, a card such as a financial (e.g. credit and debit) card, drivers&#39; license, and a national identification document, or another documents such as a passport. A punched hole can, for example, indicate that the document is void, destroy a magnetic stripe, integrated circuit chip or other information storage medium on the document, or provide access for a lanyard, a key ring and the like.

Description:
FIELD 
       [0001]    This disclosure relates to document personalization machines, particularly personalization machines that perform one or more personalization operations on a document, such as a credit card, driver&#39;s license, identification card, passport and the like. More particularly, this disclosure relates to the personalization operation of an in-line document puncher/voider within a document personalization machine. 
       BACKGROUND 
       [0002]    The use of personalization machines for personalization of documents is known. In such equipment, a document to be personalized is input into the personalization machine, one or more personalization operations are performed on the input document, and the document is then output from the personalization machine. The personalization operations performed on the document by known personalization machines include one or more of printing, laminating, laser engraving, magnetic stripe encoding, programming of a chip embedded in the document, and the like. 
         [0003]    The personalization machine is often configured in the form of a unit that can perform one or more document personalization operations within a single housing. Commercial examples of document personalization machines include the SP55 Card Printer and the SP75 Card Printer each of which is available from DataCard Corporation of Minneapolis, Minn. Examples of personalization machines that perform printing are disclosed in U.S. Pat. Nos. 5,426,283; 5,762,431; 5,886,726; 6,315,283; 6,431,537; and 6,536,758. Of these, U.S. Pat. No. 5,426,283 describes a unit that performs chip programming in addition to printing. 
         [0004]    It is often necessary to punch a hole in a personalized document to permit connection of a lanyard, key ring, etc. A hole can also be used to indicate that the document is void and thereby prevent issue or use of the document. A hole can also be used to destroy all or a portion of an information containing portion of a document, such as a magnetic stripe or an integrated circuit chip on a card, thereby preventing access to information stored in those areas. 
         [0005]    Prior solutions to creating a punch hole in a personalized document such as a card include hand held punchers, hand actuated table top punchers, and electric punch machines. These prior punch devices are separate from the personalization machine and are typically used after the document has been personalized and discharged from the personalization machine. This means that the punch device takes up separate working space near the machine. In addition, the punch device can be easily removed from the working space, making the punch device unavailable when needed. 
         [0006]    There is a need for a document personalization machine that can perform traditional personalization operations, such as printing, as well as inline document punching/voiding. 
       SUMMARY 
       [0007]    A document personalization machine that is capable of performing one or more traditional personalization operations, for example printing, laminating or magnetic stripe programming, on a document, as well as punching a hole or multiple holes of any shape and in any location on the document. The hole can be used to indicate that the document is void, to destroy a magnetic stripe, integrated circuit chip or other information storage medium on a document, or provide access for a lanyard, a key ring and the like. 
         [0008]    Embodiments of a document personalization machine with a mechanism designed to operate as an in-line document puncher/voider are shown in the attached drawings. The document personalization machine includes a machine housing and an input whereby a document enters the document personalization machine. Within the machine is a document personalization mechanism that can perform a personalization operation on the document, a document transport mechanism that can transport the document along a transport path through the document personalization machine and a document punch mechanism that can create a punch hole of any size and in any location, including the perimeter edges, on the document. 
         [0009]    The document punch mechanism can be a dead-end document punch mechanism where it is located at the end of a transport path. The document punch mechanism can also be a pass through document punch mechanism where it is located at any intermediate location along a transport path. 
         [0010]    The document punch mechanism is configured to create one or more punch holes of different shapes, types and sizes and upon any location of a document including a document&#39;s perimeter edges. A punch hole can include, but is not limited to, an indentation, perforation, void, notch, serration or the like on a document. However, the punch mechanism does not destroy the document, thereby permitting later inventory tracking procedures to take place and permitting investigation as to why a document needed to be voided in the case of a voided card. 
         [0011]    The dead-end document punch mechanism is designed as a modular assembly in which the entire mechanism is insertable and removable as a single unit into and from a document personalization machine, and all elements necessary for the operation of the mechanism, except for electrical power and command signals, are integrated into the mechanism. In addition, the mechanism is integrated into the document personalization machine using a fastenerless assembly in which no screws, bolts, or rivets are used to connect the mechanism to the machine. 
         [0012]    Further, the housing of the document personalization machine can also comprise a cover that can be opened to provide access to the interior of the machine and a removable waste bin positioned near the document punch mechanism. The waste bin stores remnants punched from documents. 
     
    
     
       DRAWINGS 
         [0013]      FIG. 1  is a perspective view of one embodiment of a document personalization machine with a single document personalization level employing a dead-end document punch mechanism. 
           [0014]      FIG. 2A  is perspective view of the dead-end document punch mechanism. 
           [0015]      FIG. 2B  is an enlarged view of a punch arm of the dead-end document punch mechanism. 
           [0016]      FIG. 3  is a perspective view of another embodiment of a document personalization machine having two vertically separate document personalization levels employing a pass-through document punch mechanism. 
           [0017]      FIG. 4  is a perspective view of the pass-through document punch mechanism. 
           [0018]      FIG. 5A  is another perspective view of the pass-through document punch mechanism. 
           [0019]      FIG. 5B  is an enlarged view of a punch arm of the pass-through document punch mechanism. 
       
    
    
     DETAILED DESCRIPTION 
       [0020]    This disclosure relates to mechanisms for an in-line document puncher/voider within a document personalization machine. The documents can be cards, such as financial (e.g. credit and debit) cards, drivers&#39; licenses, and national identification documents, or other documents such as passports. To facilitate the description, the description will hereinafter refer to the document as a card, and the personalization machine as a card personalization machine. It is to be realized that the document is not limited to cards and can be any document on which a personalization operation is performed. 
         [0021]    The card personalization machine described herein is configured to perform one or more traditional personalization operations on a card. Traditional personalization operations that can be performed on the card include one or more of at least the following exemplary personalization operations: multi-color printing, monochromatic printing, laminating, document cleaning, magnetic stripe encoding, laser printing, embedded computer chip programming, card de-bowing, indent printing and embossing. Other card personalization operations would be encompassed by the concepts described herein as well. The card personalization machine will be described herein as including printing and a document punch mechanism. However, other traditional personalization operations can be implemented with or replace printing. 
         [0022]    The document punch mechanism is configured to create one or more punch holes of different shapes, types and sizes and at any location on a card including a card&#39;s perimeter edges. A punch hole can include, but is not limited to, an indentation, perforation, void, notch, serration or the like on a card. 
         [0023]    Two separate embodiments are described in detail below. The first embodiment describes a card personalization machine wherein a card punch mechanism is located at the end of a transport path. This type of card punch mechanism is hereinafter referred to as a dead-end card punch mechanism. The second embodiment describes a card personalization machine wherein the card punch mechanism is located along a transport path such that the transport path is on each side of the card punch mechanism allowing the card to pass through the card punch mechanism. This type of card punch mechanism is hereinafter referred to as a pass-through card punch mechanism. 
       Dead-End Card Punch Mechanism 
       [0024]    With reference to  FIG. 1 , a card personalization machine  1  with a single card personalization level employing a dead-end card punch mechanism  5  is illustrated. The card personalization machine  1  includes a housing  2  having an input/output mechanism  3  in the form of a combined input/output hopper which can store a plurality of cards waiting to be personalized, and which stores cards discharged from the housing  2 . A personalization mechanism integrated within the housing  2  includes a card personalization mechanism  4 , for example a printing mechanism. In addition, a card punch mechanism  5  is provided along a single personalization level. A card transport mechanism  6  is provided for transporting a card through the housing  2  and to and from the personalization mechanism  4  and the card punch mechanism  5 . 
         [0025]    Further information on housings, input/output mechanisms and card transport mechanisms in card personalization machines can be found in U.S. Pat. Nos. 5,762,431 and 5,886,726 and U.S. Patent Application Publication No. US 2005-0104281A1. 
         [0026]    For convenience in describing the figure, the end of the machine  1  where the input/output mechanism  3  is located will be described as being at a front end region  7  of the housing  2  while the opposite end of the housing  2  will be referred to as a back end region  8 . 
         [0027]    In operation of the personalization machine  1 , a card is fed from the input/output mechanism  3  into the housing  2 . As an alternative to having the input/output mechanism  3 , the machine housing  2  can have a slot whereby a user manually feeds a card into the machine housing  2 . 
         [0028]    Once a card enters the housing  2 , the card transport mechanism  6  transports the card through the interior of the housing  2 . The transport mechanism  6  moves the card along a transport path  9  using a series of rotating nip rollers or other transport mechanisms known in the art. The card transport mechanism  6  is configured such that a card entering from the input/output mechanism  3  travels along the transport path  9  from the front end region  7  of the housing  2  toward the back end region  8 . 
         [0029]    The card transport mechanism  6  first transports the card from the input/output mechanism  3  to the personalization mechanism  4 . The personalization mechanism  4  performs a desired personalization operation on the card. The desired personalization can include one or more of printing, embossing, laminating, laser engraving, magnetic stripe encoding, programming of a chip embedded in the card, and the like. The card transport mechanism  6  then transports the card from the personalization mechanism  4  to the card punch mechanism  5 , if necessary, to form a punch hole in the card. 
         [0030]    As shown in  FIG. 1 , the card punch mechanism  5  is located at the back end region  8  of the housing  2 . Punching of the card by the dead-end card punch mechanism  5  can be the last operation performed by the machine  1  prior to discharging the card, or the punching can occur prior to additional personalization. After personalization and punching of the card are complete, the card transport mechanism  6  transports the card back along the card path  9  to the input/output mechanism  3 . 
         [0031]    In the illustrated embodiment, cards are transported through the machine  1  in a generally horizontal orientation. However in other embodiments, the cards may be transported in a generally vertical orientation. 
         [0032]    With respect to  FIGS. 2A and 2B  details of the dead-end card punch mechanism  5  are shown. The dead-end card punch mechanism  5  is illustrated as a modular assembly in which the entire mechanism  5  is insertable and removable as a single unit into and from the personalization machine  1 , and all elements necessary for the operation of the mechanism  5 , except for electrical power and command signals, are integrated into the mechanism  5 . In addition, the mechanism  5  is also a fastenerless assembly. By fastenerless, Applicants mean that no screws, bolts, or rivets are used to connect the mechanism  5  to the card personalization machine  1 . The modular construction, along with the lack of fasteners, facilitates assembly of the mechanism  5  into the machine  1 , thereby reducing assembly costs. An example of a fastenerless connection within a card personalization machine is described in U.S. Patent Application Publication No. US 2005-0104281A1. 
         [0033]    As shown in  FIG. 2A , the mechanism  5  includes a fixed chassis that is formed by a side plate  11 , a back plate  13  and a spring plate  38  positioned generally behind the back plate  13 . The spring plate  38  has two lower spring arms  37   a ,  37   b  (see  FIG. 1  as well) that extend forward generally horizontally on either side of the back plate  13 . 
         [0034]    The mechanism  5  also includes a movable punch arm  12  and a waste bin  15 . The punch arm  12  has an upper horizontal member  11  and two vertical members  14   a ,  14   b  that extend downward on either side of the horizontal member  10 . Near the bottom of both the vertical members  14   a ,  14   b  of the punch arm  12  is a non-circular slot  33   a ,  33   b . The punch arm  12  also includes a generally vertical back member  35  that has two upper spring arms  36   a ,  36   b  that extend backward generally horizontally on each side of the back plate  13 . Attached to the bottom of each of the upper spring arms  36   a ,  36   b  is a spring  34   a ,  34   b  respectively. Attached to the bottom of each of the springs  34   a ,  34   b  (spring  34   b  is shown in  FIG. 1 ) are the lower spring arms  37   a, b  of the spring plate  38 . 
         [0035]    The upper region of the punch arm  12  is shown in more detail in  FIG. 2B . The upper horizontal member  10  comprises a replaceable punch set  16  made up of one or more punches  18   a ,  18   b  mounted into mounting positions  17   a ,  17   b  and  17   c  which permit mounting of punches of various shapes, type and sizes. In the illustrated embodiment the punch arm  12  comprises mounting positions for three punches, however the punch set  16  uses only the two punches  18   a ,  18   b . In other embodiments the punch arm  12  can include more or less punch mounting positions where a punch set  16  can be positioned, and can include more or less punches. 
         [0036]    The back plate  13  is a generally vertical surface that includes an opening  19  at the bottom of which is a horizontal card path surface  20 , perpendicular to the vertical surface of the back plate  13  and extends underneath the punch arm  12 , The opening  19  and the card path surface  20  of the back plate  13  allow a card to travel beneath the punch arm  12  to be punched. The card path surface  20  of the back plate  13  comprises a replaceable die set  21  with one or more dies (not shown) that correspond to the mounting positions  17   a ,  17   b  and  17   c  of the punch arm  12  and the punches  18   a ,  18   b  of the punch set  16 . 
         [0037]    In use, the die set  21  retains remnants of the cards that are punched by the punches. After a number of cards have been punched, lower ones of the remnants retained in the die set  21  will be pushed by newly added remnants through the die set  21  and below the card path surface  20  and into the waste bin  15 . The replaceable punch set  16  and the replaceable die set  21  allows the punch hole(s) to be positioned at any location, including the perimeter edges, on the card along an axis perpendicular to the direction of the transport path  9  (shown in  FIG. 1 ). 
         [0038]    Beneath the card path surface  20  of the back plate  13  is a remnant or chad ramp  22  that extends downward at an angle towards the waste bin  15 , as shown in  FIG. 2A . The ramp  22  allows remnants of the cards removed by the card punch mechanism  5  to slide downwards and into the waste bin  15 . The waste bin  15  is preferably removable to allow the user to remove the bin and empty the bin of the remnants of the punched cards from the interior of the housing  2 . The waste bin  15  can be connected to a removable cover on the housing  2  whereby removal of the cover simultaneously removes the waste bin. Alternatively, the housing  2  can include a movable cover that is moved aside to provide access to the waste bin which is then removed. 
         [0039]    The punch arm  12  is driven by a drive train that includes an electric motor  27 , for example a DC motor, that is mounted to the side plate  11 . The motor  27  drives a pinion  28  that is rotatably affixed to the other side of the side plate  11 . A gear  29  is also rotatably affixed to the side plate  11  and is engaged with the pinion  28 . A smaller gear  30  is mounted onto the gear  29  and is engaged with a gear  31 . The gear  31  is mounted on a cam  32  which eccentrically engages at each end within the slots  33   a ,  33   b  formed in the members  14   a ,  14   b.    
         [0040]    During a rotation of the gear  31 , the eccentric cam  32  engaged within the slots  33   a ,  33   b  drives the punch arm  12  and the punches connected thereto downward. As the gear  31  continues to rotate, the punch arm  12  is lifted upward via the upward bias of the springs  34   a ,  34   b  acting on the punch arm  12 . 
         [0041]    In use, a sensor (not shown) detects when a card enters the card punch mechanism  5 . Once the card is positioned in the mechanism  5 , the motor  27  is electrically energized and the cam  32  is rotated. The cam  32  drives the punch arm  12  downward, driving the punches into the card to create the hole(s). Thereafter, the punch arm  12  is driven vertically upward back to its original position by the springs  34   a ,  34   b . The card is then sent back along the transport path  9  toward the front end  7  of the machine  1 . 
         [0042]    Returning to  FIG. 2A , the mechanism  5  includes a pair of hooks  22   a ,  22   b  and a pair of resilient attachment arms  23   a ,  23   b  that are integral with the back plate  13 . As shown in  FIG. 1 , the hooks  22   a ,  22   b  are designed to hang on a top shaft  24  within the machine  1  and the resilient attachment arms  23   a ,  23   b  are designed to snap onto a bottom shaft  26 . The hooks  22   a ,  22   b  and the attachment arms  23   a ,  23   b  form a fastenerless mechanism for detachably connecting the mechanism  5  to the remainder of the machine  1 . 
       Pass-Through Card Punch Mechanism 
       [0043]    With reference to  FIG. 3 , a card personalization machine  40  with two vertically separate card transport paths  50   a ,  50   b  employing a pass-through card punch mechanism  46  is illustrated. The card personalization machine  40  includes a housing  41  having an input/output mechanism  42  in the form of a combined input/output hopper which can store a plurality of cards waiting to be personalized, and which stores cards discharged from the housing  41 . A waste bin handle  47  is attached to the housing  41  and allows user access to a waste bin  67  of the card punch mechanism  46 . Personalization mechanisms integrated within the housing  41  include one or more card personalization mechanism  44   a ,  44   b , for example a printing mechanism and a laminating mechanism separated along two personalization levels. A card transport mechanism  43  is provided for transporting a card through the housing  41  and to the one or more personalization mechanism  44   a ,  44   b  and the card punch mechanism  46 . 
         [0044]    Further information on a card personalization machine with vertically separate transport paths without a card punch mechanism can be found in U.S. Patent Application Publication No. US 2006-0175395 A1 which is incorporated herein by reference in its entirety. 
         [0045]    For convenience in describing the figure, the end of the machine  40  where the input/output mechanism  42  is located will be described as being at a front end region  48  of the housing  41  while the opposite end of housing  41  will be referred to as a back end region  49 . 
         [0046]    In operation of the personalization machine  40 , a card is fed from the input/output mechanism  42  into the housing  41 . As an alternative to having the input/output mechanism  42 , the machine housing  41  can have a slot whereby a user manually feeds a card into the machine housing  41 . 
         [0047]    Once a card enters the housing  41 , the card transport mechanism  43  transports the card through the interior of the housing  41 . The transport mechanism  43  moves the card along a first and second card transport path  50   a ,  50   b  using a series of rotating nip rollers or other transport mechanisms known in the art. The card transport mechanism  43  is configured such that a card entering from the input/output mechanism  42  travels along the first transport path  50   a  from the front end region  48  of the housing  41  toward the back end region  49 . Once the card reaches the back end region  49 , the card is then sent down to the second transport path  50   b , vertically below the first transport path  50   a , for transport from the back end region  49  of the housing  41  to the front end region  48 . 
         [0048]    The card transport mechanism  43  first transports the card from the input/output mechanism  42  to the first personalization mechanism  44   a . The first personalization mechanism  44   a  performs a desired personalization operation on the card. The desired personalization can include one or more of printing, embossing, laminating, laser engraving, magnetic stripe encoding, programming of a chip embedded in the document and the like. The card transport mechanism  43  then transports the card from the first personalization mechanism  44   a  toward the back end region, and down to the card punch mechanism  46  which forms a punch hole in the card. 
         [0049]    As shown in  FIG. 3 , the card punch mechanism  46  is located at the back end region  49  of the housing  42  along the second transport path  50   b . After punching (if necessary) of the card is complete, the card transport mechanism  43  then transports the card to the second personalization mechanism  44   b . The second personalization mechanism  44   b  performs a desired personalization operation on the card. The desired personalization can include one or more of printing, embossing, laminating, laser engraving, magnetic stripe encoding, programming of a chip embedded in the document and the like. The card transport mechanism  43  then transports the card along the second card transport path  50   b  to the input/output mechanism  42 . 
         [0050]    In the illustrated embodiment, cards are transported through the machine  40  in a generally horizontal orientation. However in other embodiments, the cards may be transported in a generally vertical orientation. 
         [0051]    With respect to  FIGS. 4 ,  5 A and  5 B details of the pass-through card punch mechanism  46  are shown. As shown in  FIG. 4 , the mechanism  46  includes a chassis  51  fixed within the machine housing  41 . The chassis  51  is formed by a first side plate  52 , a second side plate  53  and a back plate  54 . The mechanism  46  also includes a movable punch arm  55  and a fixed card path structure  79 . The punch arm  55  has an upper horizontal member  56  and two vertical members  57   a ,  57   b  that extend downward on either side of the horizontal member  56 . Near the middle of each vertical member  57   a ,  57   b  is a slot  75   a  and  75   b . In addition, near the bottom of the vertical member  57   a  is a slot  74 . 
         [0052]    The upper member  56  of the punch arm  55  and the fixed card path structure  79  are shown in more detail in  FIG. 5B . The fixed card path structure  79  is generally positioned underneath the upper member  56  and has an opening  61  at the bottom of which is a horizontal card path surface  62 . The top of the fixed card path structure  79  includes holes  60   a ,  60   b  and  60   c  extending therethrough that receive punches of various shapes, type and sizes. A replaceable punch set  58  made up of one or more punches  59   a  is fixed to the upper member  56  of the punch arm  55  with the punches extending downward into and through the holes  60   a ,  60   b ,  60   c . In the illustrated embodiment the card path structure  79  includes holes to receive three punches; however the punch set  58  is illustrated as including only one punch  59   a . In other embodiments, a larger or smaller number of holes and punches can be used. 
         [0053]    A card travels through the opening  61  of the card path structure  79  beneath the punch arm  55  to be punched. The card path surface  62  includes a replaceable die set  63  with one or more dies  65   a ,  65   b ,  65   c  that correspond in shape to the punches  59   a  of the punch set  58 . In use, the die set  63  retains remnants of the cards that are punched by the punches. After a number of cards have been punched, lower ones of the remnants retained in the die set  63  will be pushed by newly added remnants through the die set  63  and below the card path surface  62  for collection by the waste bin. The replaceable punch set  58  and the replaceable die set  63  allows the punch holes(s) to be positioned at any location, including the perimeter edges, on the card along an axis perpendicular to the direction of the second transport path  50   b.    
         [0054]    Beneath the card path surface  62  of the card path structure  79  is a remnant or chad ramp  66  that extends downward at an angle towards the waste bin  67  as shown in  FIG. 5A . The waste bin  67  is integrally formed with the waste bin handle  47  which is accessible from the exterior of the housing  41  to allow a user to remove the waste bin  67  and remove remnants that are punched from the cards. 
         [0055]    The punch arm  55  is driven by a drive train that includes an electric motor  68 , for example a DC motor, that is mounted to the inside plate  69 . The motor  68  drives a pinion  70  that is rotatably affixed to the other side of the inside plate  69  on one side. A gear  71  is engaged with the pinion  70  and is fixed to a smaller gear  72 . The gear  72  is mounted to an axle  73  that extends through the slot  74  and is supported by the second side plate  53 . The slot  74  allows the punch arm  55  to move up and down relative to the axle  73 . 
         [0056]    In addition, the gear  72  is engaged with a gear  76 . The gear  76  is mounted on a cam  77  which eccentrically engages within the slot  75   a . The opposite end of the cam is engaged in a similar slot (not shown) formed in the member  57   b , similar to the embodiment shown in  FIG. 1 . The cam  77  extends through a sleeve  80  extending between a plate  82  and the plate  69 . 
         [0057]    During a rotation of the gear  76 , the eccentric cam  77  engaged within the slot  75   a  (and the non-illustrated slot) drives the punch arm  55  and the punches connected thereto downward in order to punch a card. As the gear  76  continues to rotate, the punch arm  55  is lifted upward by the cams  77  and the punch operation is complete. 
         [0058]    In use, a sensor (not shown) detects when a card enters the card punch mechanism  46 . Once the card is positioned in the mechanism  46 , the motor  68  is electrically energized to actuate the punch arm  55  to punch the card. After punching, the card is sent along the transport path  50   b  toward the front end  48  of the machine  40  for personalization by the personalization mechanism. 
         [0059]    Although the dead-end punch mechanism has been described and illustrated as being used on a single-level card personalization machine, it is to be realized that the dead-end punch mechanism could be used on a multi-level card personalization machine like in  FIG. 3 . In addition, the pass-through card punch mechanism could be used on a single level card personalization machine whereby the pass-through card punch mechanism is followed by another mechanism along the card transport path in the card personalization machine.