Patent Publication Number: US-2012037295-A1

Title: Sheet material with index openings and method for making and using

Description:
FIELD OF THE INVENTION 
     The invention relates generally to sheet materials for use in printing and processing cards. More specifically, the invention relates to sheet materials with registered elements used to cover or protect a card, to print information to a card, or to add a feature to a card such as a hologram. 
     BACKGROUND OF THE INVENTION 
     Cards are used in a large number of applications, such as identification cards, security badges, employee badges, licenses, credit cards, and membership cards. These cards are often carried with a person continuously, so that they must be durable, resistant to breaking, and resistant to abrasion. In addition, these cards typically contain personal or unique information or images that are printed or recorded on the card and that must not degrade over time. Card printers are used to perform any of a number of processing steps to cards, including such steps as printing unique or custom information onto a card and applying a protective layer to the card. Card printers may be stand-alone devices, or may comprise multiple separate modules that operate together. Card printers may also be referred to as card processors. 
     A card printer may use any of a number of types of sheet materials in the course of processing a card. These various card processing sheet materials are typically supplied in the form of a strip of thin, flexible material wound onto a roll, and typically have a length that is much longer than their width. Certain card processing sheet materials may have registered elements. A registered element is a feature or part that must be accurately positioned relative to the card. 
     For example, it may be desired to protect the surface of a card by lamination. One way in which a card may be laminated is by applying a patch of laminating material onto the card surface. The lamination material is typically provided to a card printer on a sheet of substrate material with a plurality of lamination patches spaced thereon, where each lamination patch is pre-cut to be slightly smaller in size than the card that is to be laminated. For the lamination patch to be properly applied, the card and the patch element must be registered in the card printer so that they are accurately aligned prior to the lamination patch being applied to the card. The size of the patch allows for slight inaccuracies in positioning the patch relative to the card, so that the patch covers the card surface without the patch extending over any of the card edges. However, it is desired to have as much of the card surface laminated as possible. Inaccuracy in registering the lamination patch to the card may reduce the amount of the card surface that is laminated. 
     In addition, a card may contain a hologram that is used to verify the authenticity of the card and to make counterfeiting the card more difficult. The hologram may be applied to the card by transferring a hologram from a substrate of sheet material. The position of the hologram may need to be registered relative to the card so that the hologram is accurately positioned at the desired location on the card. If the hologram is not positioned accurately, it may, for example, obscure other information on the card. 
     Similarly, a card printer may be used to apply a registered topcoat to a card after the card is printed. The topcoat protects the surfaces of the card. A topcoat sheet may contain images or features, such as a hologram, that need to be accurately positioned on a card. 
     Further, a card printer may utilize an ink ribbon for printing information to a card. The ink ribbon may constitute a sheet of substrate material with alternating ink patches of various colors to allow a full color image to be printed to the card from a single ribbon. The location of the ink patches may need to be registered relative to the card to allow for accurate color printing. 
     To provide the correct position of registered sheet materials relative to cards, sheet materials have typically used printed index marks on the sheet. The index marks are sensed by a suitable sensing mechanism, and the sheet is advanced a certain distance once a mark is sensed, thereby placing the sheet material in proper position relative to the card. An example of the use of printed index marks on a sheet material is disclosed in U.S. Pat. No. 6,263,796. 
     While the use of printed index marks has proved generally adequate, further improvements in the positioning of sheet materials are desirable. 
     SUMMARY OF THE INVENTION 
     The invention relates to registered sheet materials used in processing a substrate, and a method of utilizing registered sheet materials in processing a card. The substrates are preferably plastic cards, for example identification cards, security badges, employee badges, driver&#39;s licenses, credit cards, membership cards, etc. The sheet materials are any registered sheet material that is used in the processing of a card, for example a sheet containing lamination patches or holograms. 
     The sheet material is configured to enable the sheet material to be positioned accurately relative to a card or other item to be processed. Preferably, the sheet material is provided with index openings which are used to provide the proper positioning of the sheet materials relative to the card. 
     In one aspect of the invention, the sheet material comprises a strip of substrate material having a plurality of index openings formed in the substrate material at spaced locations along the length thereof. A plurality of registered elements, such as lamination patches, are disposed on the substrate material at spaced locations along the length thereof. The strip of substrate material can be wound onto a core as part of a supply of the material. 
     A method of using a sheet material comprises a light-emitting source that directs light toward the sheet material and a light sensor that detects the reflection of the light from the sheet material. The light-emitting source and light sensor are configured so that the presence of an index opening can be determined and a corresponding signal may be communicated to a control system of the card printer. 
     A method of manufacturing a sheet material comprises adhering a lamination material to a substrate material, ladder cutting the lamination material without cutting the substrate material, removing the ladder cut lamination material thereby leaving behind a plurality of lamination patches on the substrate material, and punching index openings through the lamination material so that the index openings are spaced from the lamination patches. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a top view of a preferred embodiment of a card processing sheet material with index openings for laminating patches to a card. 
         FIG. 2  is a schematic view of a portion of a laminating mechanism that utilizes the sheet material of  FIG. 1 . 
         FIG. 3  illustrates a sheet material with multiple index openings. 
         FIG. 4A-B  illustrates steps in the formation of the sheet material. 
         FIG. 5  illustrates a sensing mechanism used to sense the location of an index opening in a sheet material. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The invention relates to registered sheet materials used in processing a substrate, such as a card, a method of utilizing registered sheet materials in processing a substrate, and a method of manufacturing a registered sheet material used in processing a substrate. The sheet material is configured to enable a substrate (i.e., a card) to be positioned accurately relative to the sheet material. The sheet material may be used in a card processor, such as that disclosed in U.S. patent application entitled “Desktop Card Processor,” attorney docket number 02968.0262US01, filed Feb. 4, 2005. 
     The substrates will be described herein as being plastic cards, for example identification cards, security badges, employee badges, driver&#39;s licenses, credit cards, membership cards, etc. However, the invention could be used with other substrates as well. 
     The sheet material is any long, thin material that is consumed during the processing of substrates, including cards, and that must be positioned accurately with respect to the substrate. For example, sheet materials may include lamination material, holograms, topcoats, or ink ribbons. 
     Attention is now directed to the figures.  FIG. 1  illustrates a portion of sheet material  20  in accordance with a preferred embodiment of the present invention, for use in a card processor. In particular,  FIG. 1  represents a sheet material for laminating patches to a card. The sheet material  20  comprises a strip of substrate material  22  having first and second edges  23   a ,  23   b . As shown in  FIG. 2 , the sheet material  20  will typically be provided as a length of material on a supply roll  36 , with the sheet material  20  wound onto a supply core  37 . 
     The sheet material  20  includes a plurality of laminating patches  24  provided on the substrate  22  at spaced locations along the length thereof, and a plurality of index openings  26  formed in the substrate  22  at spaced locations along the length thereof. The card printer may be configured so that sheet material  20  moves in the direction indicated by the arrow in  FIG. 1 . In this manner, lamination patch  24  may be said to have a leading edge  32  and a trailing edge  33 . Similarly, index opening  26  has a leading edge  30  and a trailing edge  28 . As shown in  FIG. 1 , the index openings  26  and the lamination patches  24  repeat in alternating order, with an index opening  26  formed downstream of the associated lamination patch  24 , in the direction of the intended movement of the sheet material  20 . Alternatively, an index opening  26  may be formed upstream of the associated lamination patch  24 , in the direction of the intended movement of the sheet material  20 . 
     The lamination patches  24  are configured and sized to cover the substantial entirety of a card surface when laminated thereto. For example, if the card is a standard ID-1 card, which has a length of approximately 3.370 inches and a height of approximately 2.125 inches, each patch is slightly less than 3.370 inches by 2.125 inches. The size of each patch  24  is slightly less than the size of the card surface to account for slight inaccuracies in positioning the card and patch. 
     The material used to form patch  24  should resist wear and abrasion, and should also be sufficiently transparent to allow the underlying information present on the card to be accessed, either visually or by electronic means. An example of a suitable material for the patches  24  is polyethylene terephthalate (PET). 
     There is at least one index opening  26  associated with each registered element, such as lamination patch  24 . The index openings  26  are sensed by a sensing mechanism, described below, as part of the process of achieving alignment of the patch with a card. In the illustrated embodiment, the index openings  26  are positioned approximately midway between successive patches  24  and between the edges  23   a ,  23   b  of the substrate  22 . However, the index openings may be positioned at other locations on the substrate  22 . 
     The index openings  26  shown in  FIG. 1  are generally rectangular holes that are cut through the substrate  22 . Both the leading edge  30  and the trailing edge  28  are preferably straight and parallel to the leading edge  32  of each laminating patch  24 . However, index openings  26  having other shapes may be used. A suitable size for the index openings  26  is about ¼ of an inch wide (from leading edge  30  to trailing edge  28 ) and about ⅜ of an inch tall. However, index openings  26  having other sizes may be used. 
     Substrate  22  is formed of a material that is at least partially reflective, such that at least a portion of light incident upon a surface of substrate  22  is reflected. Alternatively, substrate  22  may be formed of a material that is at least partially opaque, such that at least a portion of light incident upon a surface of the substrate  22  is not transmitted through the substrate  22 . An example of a suitable substrate material is polyethylene terephthalate (PET). The substrate  22  is preferably about two and ⅝ inches wide as measured between the side edges  23   a ,  23   b  and about 1.5 mils (about 0.0015 inches) thick. The substrate  22  may also contain an adhesive on one surface to help secure the lamination patches  24  to the substrate  22 . 
       FIG. 2  shows schematically how the sheet material  20  is used within a lamination mechanism  40 . The lamination mechanism  40  can form a portion of a card printer, or other card processing equipment, that performs printing operations on cards prior to the cards being laminated. Alternatively, the lamination mechanism can be separate from the card printer or other card processing equipment. 
     The lamination mechanism  40  comprises a pair of rollers  42   a ,  42   b  that are rotatable about their central axes. Preferably, the roller  42   b  is rotatably driven through a suitable connection to a DC stepper motor (not shown). A servomotor could also be used. The roller  42   a  is driven in the opposite direction at the same speed as the roller  42   b  through frictional engagement with the roller  42   a  or the sheet material  20  or both. Preferably, the roller  42   a  is heated and the roller  42   b  is unheated, and the roller  42   a  is further mounted so as to be moveable towards and away from the roller  42   b  between a first position, in which the roller  42   a  is disposed adjacent the roller  42   b  (shown in dashed lines in  FIG. 2 ), and a second position, in which the roller  42   a  is spaced from the roller  42   b  (shown in solid lines in  FIG. 2 ). The roller  42   a  is preferably driven to the first position by a gearmotor (not shown). In the first position of the roller  42   a , a roller nip is formed between the rollers  42   a ,  42   b  with the sheet material  20  and a card  44  to be laminated passing through the roller nip, with the heated roller  42   a  pressing a patch  24  on the sheet material  20  into contact with one side of the card  44  and the roller  42   b  pressing against the other side of the card. 
     The sheet material  20  is supplied from the supply roll  36  and is guided through the lamination mechanism by idler rollers  64   a ,  64   b ,  64   c . Capstan roller  62  is driven by a stepper motor (not shown) to advance sheet material  20  through the laminating mechanism. Idler roller  66  is driven through frictional engagement with capstan roller  62  or sheet material  20  or both. Consumed sheet material  20  is taken up onto a take-up roll  46 . The take-up roll  46  is rotatable in the direction of the arrow in  FIG. 2  by a suitable connection to a stepper motor (not shown), to thereby wind the consumed sheet material  20  to the take-up roll  46 . The stepper motor is connected to take-up roll  46  through a slip clutch, to allow the take-up roll to maintain tension on the sheet material  20  without pulling the sheet material  20  through the nip created by capstan roller  62  and idler roller  66 . 
     Further, a pair of drive rollers  48   a ,  48   b  are disposed upstream of the rollers  42   a ,  42   b , with the card  44  extending between the drive rollers  48   a ,  48   b  such that the roller  48   a  engages one side of the card and the roller  48   b  engages the opposite side of the card. The rollers  48   a ,  48   b  are rotatable in opposite directions at the same speed. Rollers  48   a ,  48   b  are driven through a suitable gear train connection to roller  42   b  (not shown). Alternatively, rollers  48   a ,  48   b  may be driven through a suitable belt connection to roller  42   b . The rollers  48   a ,  48   b  are used to drive the card  44  into the nip of the rollers  42   a ,  42   b.    
     A registration photocell  50  is mounted upstream of the drive rollers  48   a ,  48   b  to detect the presence of the card  44 , thereby providing an input to the control system of the lamination mechanism  40 . 
     Further, an index opening sensing mechanism  52  is provided to sense each index opening  26  in sheet material  20 , thereby providing another input to the control system of the lamination mechanism  40 . The sensing mechanism  52  is preferably configured to sense the presence of each index opening and thereby provide input to the control system of the position of patch  24 . 
     Referring to  FIG. 5 , the sensing mechanism  52  comprises a light emitting source  54  positioned adjacent the sheet material  20  that projects infrared light toward the sheet material  20 , and a light sensor  56 , such as a reflective photocell, that receives light from the light emitting source. The source  54  and sensor  56  are positioned so that light from the source  54  reflects off of the substrate material and travels to the sensor  56 . Whenever substrate material is proximate to the source  54 , the sensor  56  will register the reflection of light from the substrate. However, when an index opening is proximate to the source  54 , the light will travel through the index opening instead of being reflected to the sensor  56 . The difference in light intensity received by the sensor  56  when the index opening is present determines the presence of the index opening  26 . 
     Alternatively, the light emitting source  54  may be positioned on one side of the sheet material  20  and the light sensor  56  may be positioned on the opposite side of the sheet material. In this embodiment, the source  54  and sensor  56  are positioned so that light from the source  54  can travel through the sheet material  20  and to the sensor  56 . This embodiment requires that the substrate material be at least partially opaque. Whenever the substrate material is between the source  54  and the sensor  56 , the amount of light striking light sensor  56  will be less than the amount of light emitted from light emitting source  54  because of the opacity of the substrate. However, when an index opening is between the source and sensor, light travels relatively unimpeded through the index opening to the sensor. The difference in light intensity received by the sensor  56  when the index opening is present determines the presence of the index opening. 
     In operation, sensing mechanism  52  looks for an index opening  26  in the sheet material  20 . When an index opening is sensed, a signal is sent to the control system of the lamination mechanism  40 . The control system then operates the drive rollers  48   a ,  48   b , capstan roller  62 , and take-up roll  46  so that the leading edge of the patch  24  is positioned at an optimal location between the drive rollers  48   a ,  48   b . The control system then advances the card  44  so that the leading edge is also positioned at an optimal location between the drive rollers  48   a ,  48   b . The roller  42   a  is then driven toward the roller  42   b  and the patch is laminated onto the card using known techniques. Further details on achieving registration between a card and a lamination patch are disclosed in U.S. Pat. No. 6,263,796 which is hereby incorporated by reference in its entirety. 
       FIG. 3  illustrates the optional use of multiple index openings  34 . These multiple index openings  34  may have any orientation on the sheet material, such as in-line with the length of the sheet material or transverse to the length of the sheet material. The sensing mechanism  52  may then be adapted to function appropriately according to the orientation of these multiple index openings  34 . Alternatively, multiple index openings may be provided only at or near the end of sheet material  20 . In this way, the sensing mechanism  52  may sense the succession of index openings  34  to recognize that the end of the sheet material  20  is approaching. Alternatively, the end of the sheet material  20  can be determined without the use of multiple index openings  34  by sensing whether the end of the sheet material has pulled away from the supply core  37 . 
     With reference to  FIG. 4A-4B , the sheet material  20  is manufactured by adhering together a sheet of the substrate material and a sheet of the lamination material to create a laminated sheet. The width of the laminated sheet is preferably several multiples (such as 4 to 5) of the width of strip  60 , to allow multiple sheet materials  20  to be produced simultaneously. Alternatively, the laminated sheet could be a strip the same width as sheet material  20 . The laminated sheet is then preferably cut with a single die cutting tool to form the edges  23   a ,  23   b  of a strip  60  and the index openings  26 , and the laminated sheet is also ladder cut with the same die cutting tool to create the shape of the laminating patches  24  by cutting through only the laminating material and not through the substrate material. Alternatively, multiple die cutting tools may be used to form these features. The ladder cut lamination material outside of the patches is then pulled away from the substrate material for disposal, leaving a continuous strip of substrate material with a plurality of lamination patches as shown in  FIG. 4B .