Patent Publication Number: US-2005123719-A1

Title: Method and system for forming a printed identification card

Description:
The present application is based on and claims the benefit of U.S. provisional patent application Ser. No. 60/526,632, filed Dec. 3, 2003, the content of which is hereby incorporated by reference in its entirety. 
    
    
     FIELD OF THE INVENTION  
      The present invention relates to devices for forming identification cards. More particularly, the present invention relates to a device for attaching thin films to card substrates.  
     BACKGROUND OF THE INVENTION  
      Identification cards, along with the aid of a computer, are typically formed by printing an image on a card substrate and laminating a protective layer over the printed surface. The image generally includes a photograph and other information relating to the cardholder, such as the cardholder&#39;s name, employee number, and other information. The image that is to be printed by an identification card printer is generally formed by combining textual and graphical portions received from host applications running on the computer or from other input devices such as keyboards, scanners, and digital cameras.  
      Typical components used to form an identification card include a print mechanism, a transport mechanism, and a lamination mechanism. Example print mechanisms include a thermal printhead having a thermal print ribbon and an ink jet printhead having a supply of ink. The transport mechanism is generally configured to transport cards to the print mechanism for printing and to transport cards to the lamination mechanism for laminating a protective layer onto the card. The protective layer can be an individual laminate sheet received from a web or a roll of laminate material. The lamination mechanism generally includes a lamination roller for laminating the laminate sheet onto one side of the card substrate.  
      Current devices form dual-sided identification cards by utilizing many steps. A transport mechanism transports cards to a print mechanism for printing a first side of the card substrate. The transport mechanism also transports cards to a lamination mechanism for laminating a protective layer onto the first side of the card substrate. Following the printing and laminating steps on the first side of the card substrate, a card flipper mechanism flips the card substrate. The card is fed back to the print mechanism and lamination mechanism to repeat the above process on the second side of the card substrate.  
      Such a device for forming a dual-sided identification card leads to a time consuming process and inefficient card production. A device that has complicated moving components, such as the flipper, and complicated processes can lead to errors, which further decreases card producing efficiency.  
     SUMMARY OF THE INVENTION  
      The present invention includes a method and system for forming an identification card. In one embodiment, the system includes a patch laminate transport mechanism configured to transport a patch laminate along a patch laminate path. A card transport mechanism is configured to transport a card substrate along a card path. The card path is substantially perpendicular to the patch laminate path and the patch laminate path intersects the card path at an intersecting junction. A controller is configured to align a middle portion of the patch laminate with the intersecting junction. A lamination mechanism is configured to laminate a first laminate portion of the patch laminate to a first face of the card substrate and a second laminate portion of the patch laminate to a second face of the card substrate.  
      In another embodiment, the method for forming an identification card includes transporting a patch laminate along a patch laminate path to an intersecting junction of the patch laminate path and a card path. The patch laminate path is substantially perpendicular to the card path. The method also includes aligning a middle portion of the patch laminate with the intersecting junction. An intersecting edge of the card substrate is driven along the card path into the middle portion of the patch laminate at the intersecting junction. The patch laminate is folded about the card substrate such that a first laminate portion overlays a first face of the card substrate and a second laminate portion overlays a second face of the card substrate. The second face is opposite the first face.  
      In yet another embodiment, the patch laminate includes a first laminate portion including an adhesive layer having a shape that conforms to a first face of the card substrate. The patch laminate includes a second laminate portion including an adhesive layer having a shape that conforms to a second face of the card substrate. The patch laminate also includes a bridge portion or middle portion connecting the first laminate portion at a first edge and the second laminate portion at a second edge. The first and second edges are displaced from each other by a distance corresponding to a thickness of the card substrate.  
      In yet another embodiment, the present invention includes a method of feeding patch laminate sheets. The method includes providing a patch laminate feeder including a housing containing a platform that supports a stack of patch laminate sheets and a feed roller. The platform is raised to force a top patch laminate sheet of the stack of patch laminate sheets against the feed roller. The platform is lowered after the feeder roller engages the top patch laminate sheet. The top patch laminate sheet is driven through a gap in the housing after the lowering of the platform. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       FIG. 1  illustrates a schematic diagram of a device for forming an identification card in accordance with embodiments of the present invention.  
       FIG. 2  illustrates a schematic diagram of a device for forming an identification card in accordance with embodiments of the present invention.  
       FIG. 3  illustrates a top plan view of a patch laminate in accordance with embodiments of the present invention.  
       FIG. 4  illustrates a top plan view of a patch laminate in accordance with embodiments of the present invention.  
       FIG. 5  illustrates a top plan view of a patch laminate in accordance with embodiments of the present invention.  
       FIG. 6  illustrates a top plan view of a patch laminate in accordance with embodiments of the present invention.  
       FIG. 7  illustrates a sectional view of a patch laminate in accordance with embodiments of the present invention.  
       FIG. 8  illustrates a sectional view of a patch laminate in accordance with embodiments of the present invention.  
       FIG. 9  illustrates an exploded perspective view of a feeder cartridge in accordance with embodiments of the present invention.  
       FIG. 10  illustrates a top perspective view of a feeder cartridge in accordance with embodiments of the present invention.  
       FIG. 11  illustrates a side view of a feeder cartridge portion and an intersecting junction portion in accordance with embodiments of the present invention.  
       FIG. 12  illustrates a side view of a feeder cartridge portion and an intersecting junction portion in accordance with embodiments of the present invention.  
       FIG. 13  illustrates a block diagram of a method of feeding patch laminate sheets in accordance with embodiments of the present invention.  
       FIGS. 14-16  illustrate schematic side views of feeding patch laminate sheets in accordance with embodiments of the present invention.  
       FIG. 17 a  transport mechanism for detaching plurality patch laminate sheets that are adjoined in accordance with embodiments of the present invention.  
       FIG. 18  illustrates a block diagram of a method for forming identification cards in accordance with embodiments of the present invention.  
       FIGS. 19-21  illustrate schematic sectional view of an intersecting junction portion for forming an identification card in accordance with embodiments of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       FIGS. 1 and 2  illustrate schematic diagrams of devices  100  and  200  for forming identification cards in accordance with embodiments of the present invention. Device  100  includes a feeder cartridge  102 , a print mechanism  104 , a card hopper  106 , card output hopper  108  and a controller  109 . Controller  109  is configured to manage the operation of the components in  FIG. 1 . Device  200  includes a feeder cartridge  202 , a card printer  207 , a card output hopper  208  and a controller  209 . Controller  209  is configured to manage the operation of the components in  FIG. 2 .  
      In  FIG. 1 , feeder cartridge  102  is operably configured to feed a patch laminate  110  along a patch laminate path  112  in a direction  114 . Print mechanism  104  is positioned adjacent patch laminate path  112  and is operably configured to print an image on a surface  111  of patch laminate  110 . In one embodiment of the present invention, print mechanism  104  prints a reverse image on surface  111  of patch laminate  110 .  
      In  FIG. 2 , feeder cartridge  202  is operably configured to feed patch laminate  210  along a patch laminate path  212  in a direction  214 . Before describing the embodiments illustrated in  FIGS. 1 and 2  in more detail, embodiments relating to the structure of patch laminate  110  and  210  and feeder cartridges  102  and  202  in devices  100  and  200  should be described.  
      The Patch Laminate  
       FIG. 3  illustrates a top view of a patch laminate  310  in accordance with an embodiment of the present invention. Patch laminate  310  can be used in conjunction with the devices illustrated in  FIGS. 1 and 2 . Patch laminate  310  is a sheet  313  of patch laminate that includes a first laminate portion  316  and a second laminate portion  318 . First portion  316  can have a shape that conforms to a first face of a card substrate, such as a first face  137  of a card substrate  138  as illustrated in  FIG. 1 . Second laminate portion  318  can have a shape that conforms to a second face of a card substrate, such as a second face  139  of card substrate  138  as illustrated in  FIG. 1 . Although  FIG. 3  illustrates first laminate portion  316  and second laminate portion  318  as being sized to cover the entire surface area of first face  137  and second face  139 , those skilled in the art should recognize that the first and the second laminate portions can also be sized to cover an area that is less than the surface area of the first and second faces of a card substrate.  
      Patch laminate sheet  313  has a middle portion that connects first laminate portion  316  to second laminate portion  318 . In  FIG. 3 , the middle portion is illustrated as bridge portion  320 . Although bridge portion  320  connects first laminate portion  316  to second laminate portion  318  that are equally sized, those skilled in the art should recognize that the middle portion can connect a first laminate portion to a second laminate portion that are differently sized. Therefore, instead of the middle portion extending across the center of sheet  313  as illustrated in  FIG. 3 , the middle portion can extend across the sheet at a position offset from center.  
      In  FIG. 3 , bridge portion  320  includes a first edge  322  and a second edge  324  that are displaced from each other by a distance that substantially corresponds to a thickness of a card substrate. For example, the distance can be greater than 20 mils. In particular, the distance can be between 28 and 30 mils. First edge  322  connects bridge portion  320  to first laminate portion  316 . Second edge  324  connects bridge portion  320  to second laminate portion  318 .  
      Bridge portion  320  includes a plurality of spaced apart perforations  326 . Each perforation of perforations  326  has a length that is approximately 200 mils. In one embodiment of the present invention,  FIG. 3  illustrates that patch laminate  310  includes a first set of perforations  328  that extend along first edge  322  and a second set of perforations  330  that extend along second edge  324 . The first set of perforations  328  and the second set of perforations are substantially parallel to each other. Each perforation of the first and second sets of perforations  328  and  330  are displaced from each other by a section of bridge portion  320 .  
      In an alternative embodiment,  FIG. 4  illustrates a top view of a sheet  413  of patch laminate  410  having a similar configuration as  FIG. 3  and including a first laminate portion  416 , a second laminate portion  418  and a bridge portion  420 . Bridge portion  420  includes a plurality of perforations  426  that include a single set of perforations  429 . The single set of perforations  429  extend between a first edge  422  and a second edge  424  of the bridge portion. First edge  422  and second edge  424  are displaced from each other by a distance that substantially corresponds to a thickness of a card substrate. Each perforation of the single set of perforations  429  is displaced from each other by a section of bridge portion  420 . In  FIG. 4 , each perforation is substantially square and has a width that is approximately equal to a distance from first edge  422  to second edge  424 . For example, the width of each substantially square perforation  429  and a distance from first edge  422  to second edge  424  is greater than 20 mils. In particular, the width and the distance are between about 28 and 30 mils.  
      In either of the above-described embodiments illustrated in  FIGS. 3 and 4 , those skilled in the art will recognize that first laminate portion  316 ,  416  and second laminate portion  318 ,  418  are connected to bridge portion  320 ,  420  in a manner that corresponds with a lengthwise edge of a card substrate. However, it should be understood that first laminate portion  316 ,  416  and second laminate portion  318 ,  418  can also be connected to bridge portions  320 ,  420  in a manner that corresponds with a widthwise edge of a card substrate.  
       FIG. 5  illustrates a top plan view of a patch laminate  510  in accordance with an embodiment of the present invention. Patch laminate  510  can be used in conjunction with the devices illustrated in  FIGS. 1 and 2 . Patch laminate  510  is a roll  513  of patch laminate. The roll  513  of patch laminate  510  includes a plurality of patch laminate sheets  537  that are coupled to each other at a line of perforation  538 . Each patch laminate sheet  537  includes a first laminate portion  516  and a second laminate portion  518 . First laminate portion  516  can have a shape that conforms to a first face of a card substrate, such as first face  137  of card substrate  138  illustrated in  FIG. 1 . Second laminate portion  518  can have a shape that conforms to a second face of a card substrate, such as second face  139  of card substrate  138  as illustrated in  FIG. 1 . Although  FIG. 5  illustrates first laminate portion  516  and second laminate portion  518  as being sized to cover the entire surface area of first face  137  and second face  139 , those skilled in the art should recognize that the first and the second laminate portions can be sized to cover an area that is less than the surface area of the first and second faces of a card substrate.  
      Each patch laminate sheet  537  of patch laminate roll  513  has a middle portion that connects first laminate portion  516  to second laminate portion  518 . In  FIG. 5 , the middle portion is illustrated as bridge portion  520 . Although bridge portion  520  connects first laminate portion  516  to second laminate portion  518  that are equally sized, those skilled in the art should recognize that the middle portion can connect a first laminate portion to a second laminate portion that are differently sized. Therefore, instead of the middle portion extending across the center of each sheet  537  as illustrated in  FIG. 5 , the middle portion can extend across each sheet at a position offset from center.  
      In  FIG. 5 , bridge portion  520  includes a first edge  522  and a second edge  524  that are displaced from each other by a distance that substantially corresponds to a thickness of a card substrate. For example, the distance can be greater than 20 mils. In particular, the distance can be between approximately 28 and 30 mils. First edge  522  connects bridge portion  520  to first laminate portion  516 . Second edge  524  connects bridge portion  520  to second laminate portion  518 .  
      Bridge portion  520  includes a plurality of spaced apart perforations  526 . Each perforation of perforations  526  has a length that is approximately 200 mils. In one embodiment of the present invention,  FIG. 5  illustrates that perforations  526  of each patch laminate sheet  537  includes a first set of perforations  528  that extend along first edge  522  and a second set of perforations  530  that extend along second edge  524 . Each perforation of the first and second sets of perforations  528  and  530  are displaced from each other by a section of bridge portion  520 .  
      In an alternative embodiment,  FIG. 6  illustrates a top plan view of a roll  613  of patch laminate  610 . The roll of patch laminate includes a plurality of patch laminate sheets  637  that are coupled to each other at a line of perforation  638 . Each patch laminate sheet  637  has a similar configuration to patch laminate sheet  537  in  FIG. 5  and includes a first laminate portion  616 , a second laminate portion  618  and a bridge portion  620 . First laminate portion  616  connects to bridge portion  620  at a first edge  622  and second laminate portion  618  connects to bridge portion  620  at a second edge  624 .  
      First edge  622  and second edge  624  are displaced from each other by a distance that substantially corresponds to a thickness of a card substrate. For example, the distance can be greater than 20 mils. In particular, the distance can be between 28 and 30 mils. The roll  613  of patch laminate  610  has a plurality of perforations  626  that include a single set of perforations  629  that extend between first edge  622  and second edge  624 . Each perforation of the single set of perforations  629  are displaced from each other by a section of bridge portion  620  and have a length that is approximately 200 mils. In  FIG. 6 , each perforation is substantially square and has a width that is approximately equal to the distance between first edge  622  and second edge  624 .  
      In either of the above-described embodiments illustrated in  FIGS. 5 and 6 , those skilled in the art will recognize that first laminate portion  516 ,  616  and second laminate portion  518 ,  618  are connected to bridge portion  520 ,  620  in a manner that corresponds with a lengthwise edge of a card substrate. However, it should be understood that that first laminate portion  516 ,  616  and second laminate portion  518 ,  618  are connected to bridge portion  520 ,  620  in a manner that corresponds with a widthwise edge of a card substrate.  
       FIG. 7  illustrates a sectional view of patch laminate  110  illustrated in  FIG. 1  in accordance with an embodiment of the present invention. Patch laminate  110  can have a configuration similar to patch laminate  310 ,  410 ,  510  or  610  as illustrated in  FIGS. 3, 4 ,  5  or  6 . Patch laminate  110  includes a layer of ink receptive material  732  sandwiched between a layer of adhesive  734  and a polyester layer  736 .  
      Ink-receptive material  732  generally contains inorganic ceramic materials and organic components. The principal ceramic component of ink-receptive material  732  can be the boehmite form of alumina hydrate (Al 2 O 3 ). Material  732  is formed using an alumina sol to which a starch or PVA has been added to at a 5-50% weight percent (typically 10%) level based on alumina hydrate solids. Ink-receptive material  732  has an average pore radius in the range of 5-20 nanometers, with pore volumes in the range of 0.3-1.0 ml/gram.  
      The organic portion of material  732  acts as a binder. It should be noted that the binder can be made of many types of materials. For example, the binder can be made of a styrene-butadiene copolymer rubber (NBR) latex, carboxymethyl cellulose, hydroxymethyl cellulose or polyvinyl pyrrolidone. Ink-receptive material  732  is applied to polyester layer  734 . Besides layer  734  being of polyester, layer  734  can also include polymeric films and polyester resin, such as PET, polyester diacetate polycarbonate resins, fluroresisns (i.e. ETFE) and polyvinyl chloride resins, paper sheets and synthetic paper sheets.  
      Ink-receptive material  732  can also contain other materials to provide weather resistance, provide improved light and ozone resistance, assist in the stability of dyes and prevent dye fading. For example, additional polymerizable binders can be used to improve weather resistance, additional magnesium (Mg) and/or thiocyancate (SCN) ions can provide improved light and ozone resistance, additional organic materials such as dithiocarbamates, thiurams, thiocyanate esters, thiocyanates and hindered amines help prevent dye fading and additional non-ionic or cationic water insoluble resins particles can improve coating stability.  
      Other materials can be added to material  732 . For example, a silica gel coating can be applied to improve gloss and abrasion resistance and silica agglomerates can be used to promote receptivity for pigmented inks.  
      Suitable ink-receptive materials are produced by Ikonics Corporation of Duluth, Minn., such as AccuArt™ and AccuBlack™, which are generally used for the production of film positives, negatives, color proofs and full-color presentation transparency displays. The ink-receptive coating of AccuArt™ includes many of the desired features and components for ink-receptive material  732 . Although the AccuArt™ coating is a suitable material for the present invention, those skilled in the art should recognize that other ink-receptive coatings can be applied to polyester layer  734 .  
      When print mechanism  104  ( FIG. 1 ) prints an image on patch laminate  110 , the image is printed through the layer of adhesive  734  and onto the ink receptive coating  732 . The layer of adhesive  734  comprises a thermal adhesive. The combined layer of adhesive  734  and the ink receptive material  732  has a thickness between about 0.01 mil and 1 mil. The layer of polyester  736  has a thickness between about 1 mil and 2 mils. For example, a thickness of adhesive  734  and ink receptive coating  732  can be 0.5 mil and a thickness of polyester can be 1.5 mil. In this example, the total thickness of patch laminate  110  is 2.0 mils.  
       FIG. 8  illustrates a sectional view of patch laminate  210  illustrated in  FIG. 2  in accordance with an embodiment of the present invention. Patch laminate  210  can have a configuration similar to patch laminate  310 ,  410 ,  510  or  610  as illustrated in  FIGS. 3, 4 ,  5  or  6 . Patch laminate  210  includes a layer of adhesive  834  coupled to a polyester layer  836 . The layer of adhesive  834  comprises a thermal adhesive. Besides polyester layer  834  comprising polyester, polyester layer  834  can also include polymeric films and polyester resin, such as PET, polyester diacetate polycarbonate resins, fluroresisns (i.e. ETFE) and polyvinyl chloride resins, paper sheets and synthetic paper sheets. The layer of adhesive  834  has a thickness between about 0.01 mil and 1 mil. The layer of polyester  836  has a thickness between about 1 mil and 2 mils. For example, a thickness of adhesive  834  can be 0.5 mil and a thickness of polyester  836  can be 1.5 mil. In this example, the total thickness of patch laminate  210  is 2.0 mils.  
      The Feeder Cartridge  
      A need exists to improve the feeding of flexible thin films to be attached to an identification card. For example, flexible thin films that are fed from a stack of thin films tend to stick to each other due to frictional and static forces. It is desirable to develop improved feeders that overcome and eliminate these tendencies to multiple feed or mis-feed.  
       FIG. 9  is an exploded perspective view of a patch laminate feeder cartridge  902  in accordance with an embodiment of the present invention. Feeder cartridge  902  can be used in conjunction with the device illustrated in  FIGS. 1 and 2 . Feeder cartridge  902  includes a housing  940  having an interior cavity configured to accommodate a stack of patch laminate sheets, such as the patch laminate sheets illustrated in  FIGS. 3 and 4 . Housing  940  includes a top portion  942  that includes a front wall  943 , a back wall  944 , opposing side walls  945  and a top cover  946 . Top cover  946  includes a first opening (illustrated in  FIG. 10 ) sized to accommodate a feed roller. Housing  940  also includes a bottom cover  947  and contains a platform  948  for supporting the stack of patch laminate sheets. Bottom cover  947  includes a second opening  949  sized to accommodate a biasing mechanism. Platform  948  is not constrained and is slidable between top cover  946  and bottom cover  947  within housing  940 .  
       FIG. 10  illustrates a top perspective view of feeder cartridge  902  in accordance with an embodiment of the present invention. As discussed above and as illustrated, top cover  946  of housing  940  includes a first opening  950  sized to accommodate a feed roller. In addition, front wall  943  includes a gap  951  sized to allow a patch laminate sheet to feed out of feeder cartridge  902  to a patch laminate path. As illustrated in dashed lines, housing  940  can also include an adapter  952  for reducing a size of gap  951 . For example, adapter  952  can comprise rubber.  
       FIG. 11  illustrates a side view of a feeder cartridge portion  953  and also illustrates an intersecting junction portion  955  in accordance with an embodiment of the present invention. Intersecting junction portion  955  is described in detail with respect to  FIGS. 19-21 . In  FIG. 11 , feeder cartridge portion  953  includes a feeder cartridge receiver  954  configured to receive a feeder cartridge (not illustrated in  FIG. 11 ). Feeder cartridge portion  953  also includes a feeder roller  956  configured to feed patch laminate sheets from feeder cartridge to a patch laminate transport mechanism  966 .  
      Feeder cartridge receiver  954  includes a pair of holders  958  for retaining and securing a feeder cartridge in place. In addition, feeder cartridge receiver  954  includes a biasing mechanism  960 . Biasing mechanism  960  is sized to fit through a second opening (not illustrated in  FIG. 11 ) of a feeder cartridge. Biasing mechanism  960  includes a ramp  962  coupled to a loaded spring  964 . However, those skilled in the art should recognize that spring  964  can be other mechanisms that create a biasing force.  
       FIG. 12  illustrates a side view of a feeder cartridge portion  953  and also illustrates an intersecting junction portion  955  in accordance with an embodiment of the present invention. Intersecting junction portion  955  is described in detail with respect to  FIGS. 19-21 .  FIG. 12  illustrates a feeder cartridge  902  secured and placed in feeder cartridge receiver  954 . Feeder cartridge  902  includes front wall  943 , back wall  944 , opposing side walls  945  and top cover  946 . Top cover  946  includes a first opening sized to accommodate feed roller  956 . Feeder cartridge  902  also includes a bottom cover  947  and contains a platform  948  for supporting a stack of patch laminate sheets. Bottom cover  947  includes a second opening  949  sized to accommodate a biasing mechanism. Biasing mechanism  960  fits through second opening  949  of bottom cover  947 .  
       FIG. 13  is a block diagram  1300  illustrating a method of feeding a patch laminate sheet using the feeder cartridge illustrated in  FIGS. 9-12 . In block  1302 , a patch laminate feeder is provided. The patch laminate feeder includes a housing containing a platform for supporting a stack of patch laminate sheets and a feed roller. At block  1304 , the platform is raised to force a top patch laminate sheet against the feeder roller. At block  1306 , the platform is lowered after the feeder roller engages the top patch laminate sheet. At block  1308 , the top patch laminate is driven through a gap in the housing after the platform is lowered.  
       FIGS. 14-16  schematically illustrate sectional views of feeder cartridge  902  while the feeder cartridge is secured in a feeder cartridge receiver  954  (illustrated in  FIGS. 11 and 12 ) in accordance with an embodiment of the present invention. In addition,  FIGS. 14-16  graphically illustrate the steps associated with feeding a patch laminate sheet to a patch laminate path  912  as illustrated in FIG.  13 . In  FIG. 14 , housing  940  of feeder cartridge  902  is loaded with a stack of patch laminate sheets  913 . For example, each patch laminate sheet can be patch laminate sheet  313  or  413  illustrated in  FIGS. 3 and 4 . The stack of patch laminate sheets  913  are loaded onto platform  948  such that the platform is situated between bottom cover  947  of feeder cartridge  902  and the stack of patch laminate sheets  913 . As illustrated in  FIG. 14 , the stack of patch laminate sheets are in a loaded position and, therefore, biasing mechanism  960  is configured into a non-actuated position. In a non-actuated positioned, loaded spring  964  is compressed such that ramp  962  is in alignment with bottom cover  947  and the stack of patch laminate sheets  913  are spaced from feed roller  956 .  
      Upon receiving a signal from a controller, such as controller  109  illustrated in  FIG. 1 , to feed a patch laminate sheet, the stack of patch laminate sheets  913  are configured into a feed position as illustrated in  FIG. 15 . In a feed position, spring  964  is deployed or released from compression and ramp  962  raises platform  948  and the stack of patch laminate sheets  913  toward top cover  946  and feed roller  956 . In the feed position, feed roller  956  is configured to rotate and engage top laminate sheet  965  of the stack of patch laminate sheets  913 . In one embodiment of the present invention feed roller  956  comprises a surface having friction. For example, the surface of feed roller  956  can be tacky.  
      Upon engaging the top sheet of the stack of patch laminate  913 , the controller instructs biasing mechanism  960  to compress or return to the loaded position as illustrated in  FIG. 16 . By returning biasing mechanism  960  to the loaded position, the biasing mechanism lowers platform  948  and the stack of patch laminate  913  away from feed roller  956  such that only top sheet  965  is fed to patch laminate path  912 . This prevents the remaining patch laminate sheets from also feeding with top sheet  965 . As top laminate sheet  965  is being fed, the top laminate sheet is guided towards the patch laminate transport mechanism by a guide  974 .  
      Referring back to  FIG. 1 , feeder cartridge  102  is configured to feed patch laminate  110  to patch laminate path  112 . In one embodiment, feeder cartridge  102  feeds patch laminate sheets, such as patch laminate sheet  313  and  413  of  FIGS. 3 and 4 , to patch laminate path  112  in accordance with feeder cartridge  902  illustrated in  FIGS. 9-16 . In another embodiment, feeder cartridge  102  feeds a roll of patch laminate or a plurality of adjoining patch laminate sheets, such as patch laminate  510  and  610  of  FIGS. 5 and 6 , to patch laminate path  112 . Each of the plurality of patch laminate sheets are adjoined to each other by a line of perforation, such as perforation line  538  and  638  of  FIGS. 5 and 6 . In the latter embodiment, device  100  is equipped with a mechanism for separating each adjoining patch laminate sheet from each other.  
      In one embodiment, and as illustrated in  FIG. 17 , a patch laminate mechanism  1766  includes a first set of pinch rollers  1767  and a second set of pinch rollers  1768 . As illustrated in  FIG. 17 , feeder  1702  feeds a roll of patch laminate  1710  along patch laminate path  1712  and through each set of pinch rollers in a direction  1714 . The first set of pinch rollers  1767  is operably configured to affix one sheet of patch laminate  1710  while the second set of pinch rollers  1768  is operably configured to drive the adjoining sheet of patch laminate. Therefore, each patch laminate sheet is separated from an adjoining patch laminate sheet at a line of perforation  1741 . Those skilled in the art should recognize that are other methods of separating adjoining patch laminate sheets can be used.  
      Referring back to  FIG. 1 , patch laminate  110  is transported along patch laminate path  112  past print mechanism  104  by patch laminate transport mechanism  166  as instructed by controller  109 . An example print mechanism  104  includes an ink jet print mechanism. However, other types of print mechanisms can be used. In one embodiment of the present invention, patch laminate transport mechanism  166  includes multiple sets of pinch rollers. During operation, each of the sets of pinch rollers drive patch laminate  110  in direction  114  along patch laminate path  112 .  
      Card hopper  106  is configured to hold a plurality of card substrates  138  and is operably configured to feed each card substrate  138  to a card path  168  in a direction  169  as instructed by controller  109 . Card path  168  is substantially perpendicular to patch laminate path  112 . A card transport mechanism  170  is operably configured to transport each card substrate  138  along card path  168  as instructed by controller  109 . In one embodiment of the present invention, card transport mechanism  170  includes multiple sets of pinch rollers. Each of the sets of pinch rollers drives a card substrate  138  in direction  169  along card path  168 .  
      Device  100  also includes a sensor  115 . Sensor  115  is configured to sense the position of patch laminate  110  with respect to card substrate  138 . Sensor  115  assists controller  109  in aligning patch laminate  110  to card substrate  138  such that an identification card can be formed. In one embodiment of the present invention, sensor  115  is a slotted optical sensor. In another embodiment of the present invention, sensor  115  is an interrupt sensor having a mechanical arm. However, those skilled in the art should recognize that other types of sensors can be used.  
      Referring back to  FIG. 2 , feeder cartridge  202  is configured to feed patch laminate  210  to patch laminate path  212 . As discussed with reference to  FIG. 1 , feeder cartridge  202  is configured to feed patch laminate sheets, such as patch laminate  310  and  410  of  FIGS. 3 and 4 , to patch laminate path  112  in accordance with feeder cartridge  902  illustrated in  FIGS. 9-15 . In another embodiment, feeder cartridge  102  feeds a roll of patch laminate or a plurality of adjoining patch laminate sheets, such as patch laminate  510  and  610  of  FIGS. 5 and 6 , to patch laminate path  212  in accordance with the embodiment illustrated in  FIG. 17 . Patch laminate  210  is transported along patch laminate path  212  as instructed by controller  109 . Patch laminate transport mechanism  266  includes multiple sets of pinch rollers. During operation, each of the sets of pinch rollers drives patch laminate  210  in direction  214  along patch laminate path  212 .  
      Card printer  207  is configured to print an image on a first card face  237  and/or a second card face  239  of card substrate  238 . In addition, card printer  207  is operably configured to feed each card substrate to a card path  268  in a direction  269  as instructed by controller  209 . Card path  268  is substantially perpendicular to patch laminate path  212 . A card transport mechanism  270  is operably configured to transport each card substrate  238  along card path  268  as instructed by controller  209 . In one embodiment of the present invention, card transport mechanism  270  includes multiple sets of pinch rollers. Each of the sets of pinch rollers drives a card substrate  238  in direction  269  along card path  268 .  
      Device  200  also includes a sensor  215  similar to sensor  115  of  FIG. 1 . Sensor  215  is configured to sense the position of patch laminate  210  with respect to card substrate  238 . Sensor  215  assists controller  209  in determining instructions for patch laminate mechanism  266  in align patch laminate  210  to card substrate  238  such that an identification card can be formed.  
       FIG. 18  is a block diagram  1800  illustrating a method of forming an identification card in accordance with an embodiment of the present invention. At block  1802 , a patch laminate is transported along a patch laminate path to an intersection junction of the patch laminate path and a card path. The patch laminate path is substantially perpendicular to the card path. At block  1804 , a middle portion of the patch laminate is aligned with the intersection junction. At block  1806 , an intersecting edge of the card substrate is driven along the card path and into the middle portion of the card substrate. At block  1808 , the patch laminate is folded about the card substrate such that a first laminate portion overlays a first face of the card substrate and a second laminate portion overlays a second face of the card substrate, which is opposite the first face. The following description, in association with  FIGS. 19-21 , is a detailed description of the method illustrated in  FIG. 18  using devices  100  and  200 .  
      Forming an Identification Card  
       FIGS. 19-21  illustrate schematic sectional views of an intersecting junction portion  55  for forming an identification card in accordance with an embodiment of the present invention. The intersecting junction portion  55  illustrated in  FIGS. 19-21  can be used in conjunction with devices  100  and  200 . When the process is used in conjunction with device  100 , an image is printed to the patch laminate and then laminated to a card substrate to form a dual-sided image identification card. When the process is used in conjunction with device  200 , an image is printed to a card substrate and then laminated with a patch laminate to form a dual-sided image identification card. However, those skilled in the art should recognize that a single-sided image identification card could also be formed.  
      In  FIG. 19 , a patch laminate  10  is transported by a patch laminate transport mechanism  66  along a patch laminate path  12  in a direction  14 . A guide  74  surrounds patch laminate path  12 . Guide  74  is configured to constrain patch laminate  10  to patch laminate path  12 . A card substrate  38  is transported by a card transport mechanism  70  along a card path  68  in a direction  69 . Guide  74  includes an opening  75  configured to allow the card substrate  38  to substantially intersect with patch laminate path  12  at an intersecting junction  77 . The point where card path  68  intersects with patch laminate path  12  is intersecting junction  77 . In addition, opening  75  includes arcuate lead-in edges  76  and arcuate lead-out edges  78 . Opening  75  has a width that is greater than the thickness of card substrate  38 .  
      Patch laminate  10  can be a patch laminate such as those illustrated in  FIGS. 3, 4 ,  5  and  6 . Patch laminate  10  includes a first laminate portion  16  having a shape that conforms to a first face  37  of card substrate  38  and a second laminate portion  18  having a shape that conforms to a second face  39  of the card substrate. Patch laminate  10  also includes a middle portion or bridge portion  20  that includes a first edge  22  and a second edge  24 . First edge  22  is configured to couple bridge portion  20  to first portion  16 . Second edge  24  is configured to couple bridge portion  20  to second portion  18 . Bridge portion  20  is considered to be the center of patch laminate  10  and includes a plurality of perforations such that first laminate portion  16  and second laminate portion  18  can fold about card substrate  38 . Card substrate  38  includes a leading edge or intersecting edge  80 .  
      A sensor, such as sensor  115  or  215  of  FIG. 1  or  2 , is configured to sense the position of patch laminate  10  with respect to intersecting junction  77  and relay positional information to a controller, such as controller  109  or  209  of  FIG. 1  or  2 . The sensor assists the controller in aligning bridge portion  20  with intersecting edge  80  of card substrate  38 . Patch laminate transport mechanism  66  includes a first component  67  configured to support first laminate portion  16  on a first side  71  of card path  68 . Patch laminate transport mechanism  66  includes a second component  73  configured to support second laminate portion  18  on a second side  75  of card path  68 .  
      Although not clearly illustrated in  FIGS. 19-21 , after patch laminate transport mechanism  66  has aligned bridge portion  20  with intersecting edge  80  of card substrate  38 , the controller instructs first component  67  and second component  73  of the patch laminate transport mechanism to create a small amount of slack in patch laminate  10 . Creating slack in patch laminate  10  results in the patch laminate slightly bending at bridge portion  20  such that card substrate  38  does not break through the center or the bridge portion of the patch laminate. However, the amount of slack should be optimized. Too much slack will cause bridge portion  20  to become unaligned. Too little slack can potentially result in card substrate  38  breaking bridge portion  20 .  
      In  FIG. 20 , card transport mechanism  70  continues to transport card substrate  38  along card path  68 . Upon driving card substrate  38 , intersecting edge  80  comes into contact with the center or bridge portion  20  of patch laminate  10 . As card substrate  38  comes into contact, patch laminate folds about the card substrate such that first laminate portion  16  overlays first face  37  of the card substrate and second laminate portion  18  overlays second face  39  of the card substrate. The folding of patch laminate about card substrate  38  remains within the constraints of the lead-in edges  76  and lead-out edges  78  of opening  75 .  
      In  FIG. 21 , card transport mechanism  70  drives card substrate  38  and folded patch laminate  10  to lamination mechanism  82 . Lamination mechanism  82  is operably configured to simultaneously laminate or adhere first portion  16  to first face  37  and second portion  18  to second face  39 . Lamination mechanism  82  includes a first lamination roller  84  separated by a gap from a second lamination roller  86 . Lamination rollers  84  and  86  are heated rollers that are controlled by the assistance of at least one temperature sensor.  
      Referring back to  FIGS. 1 and 2  and in accordance with another embodiment of the present invention, devices  100  and  200  include a supply circuit  188  and  288 . Supply circuit  188 ,  288  is preferably an integrated circuit that includes a memory containing supply information relating to various parameters of feeder cartridges  102  and  202 , card hopper  107  and card printer  207 .  
      The supply information can include, for example, a card supply identifier, patch laminate identifier, a card type, a patch laminate type, card dimensions and patch laminate dimensions (length, width and thickness), card and patch laminate features, card and patch laminate identifiers, card and patch laminate orientation, a card and patch laminate count, card and patch laminate supplier information (i.e. lot number), dealer information, security codes, an expiration date, printer settings, and other information.  
      The card type identifies a pre-defined type of card such as a CR-80, CR-90 or other standardized type of card. The card features can include such things as whether the card has a magnetic stripe, is a “smart” card, and other conventional card features. The card supply identifier allows for a check to be performed to determine whether card hopper  107  or card printer  207  include card substrates that are compatible with the patch laminate  110  or  210 . The card identifiers can be a series of serial numbers that uniquely identify each card. This information can be used, for example to correlate the printed identification card with the person who formed the card. The card orientation relates to whether the cards are oriented lengthwise or widthwise with the card path. The printer settings allow either print mechanism  104  or card printer  207  to be configured for optimal performance. The card and patch laminate dealer information relates to the dealer that sold the cards and patch laminate, which may be responsible for customizing the supply information stored in the memory of supply circuit  188 ,  288 . The card count or patch laminate count relates to the number of cards in the card stack or in the stack of patch laminate. In addition, patch laminate count relates the number of patch laminate sheets that are adjoined in a roll.  
      The patch laminate type identifies a pre-defined type of patch laminate such as a patch laminate sheet or patch laminate roll. The patch laminate features can include such things as whether the patch laminate has a holographic or security features. The patch laminate supply identifier allows for a check to be performed to determine whether feeder cartridge  107  or feeder cartridge  207  include patch laminate that is compatible with the card substrates. The patch laminate identifiers can be a series of serial numbers that uniquely identify each patch laminate. This information can be used, for example to correlate the printed patch laminate or laminated patch laminate with the person who formed the identification card. The patch laminate orientation relates to whether the patch laminate is oriented lengthwise or widthwise with respect to the card substrates.  
      The security codes can be used to prevent unauthorized use of the cards or prevent the use of card hopper  107  or card printer  207 . An improper security code could, for example, trigger an interlock in device  100  and  200  to prevent the operation thereof. The expiration date can be used as a security measure to prevent the use of cards and patch laminate after a predetermined date.  
      In accordance with one embodiment of the invention, supply circuit  188 ,  288  includes radio frequency (RF) communication methods that can be implemented to provide wireless communication between supply circuit  188 ,  288  and controller  109 ,  209 .  
      Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.