Patent Publication Number: US-6220327-B1

Title: Apparatus for automated printing and assembly of passport booklets

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to automated apparatus for printing and assembling travel documents, such as passport booklets, and more particularly to an automated system for instant, one-up custom printing, die-cutting and fusion of an identification card in a passport booklet, to form a data page in the booklet. 
     2. Discussion of the Related Art 
     Traditional identification booklets, such as passport booklets, typically comprise a number of paper pages bound to a cover made from a paper stock which is heavier than the inside pages. Identification information is typed or printed onto the inside of the cover of the booklet and a photographic insert is laminated to the inside cover. The photographic insert typically comprises a die-cut sheet of Polaroid instant film wherein a photograph of the passport holder is optically superimposed over the inside cover of the booklet having the booklet holder&#39;s personal information typed or printed thereon. A laminate sheet is placed over the inside cover and then fed into a roll laminator, wherein the photographic image is sealed between the laminate and the inside cover of the booklet. In most cases, multiple photographs are exposed on a single sheet of photographic film in order to reduce waste of the expensive instant photographic material, and thereby reduce the per booklet cost of production. In other systems, a plurality of booklet holder&#39;s photographs are taken in 35 mm format, and then combined with the booklets having their corresponding printed identification information at central issuance centers. Central issuance of identification booklets has been found to be efficient as well as cost effective. However, the current system for producing passports is labor intensive and slow, often resulting in delays in receiving booklets, as well as the potential to incorrectly match personal information with the correct photograph. Furthermore, the central issuance system discourages the production of cards in small batches, as well as the custom production of individual booklets when replacements are necessary. While the above technologies are effective for their intended purpose, it has been found that there is an increasing need in the industry for an automated system which automatically prints and die-cuts identification cards and fuses them inside an identification booklet in an instant, one-up format, wherein a single identification booklet can be easily and inexpensively produced, with very little labor involved, in a single apparatus. 
     SUMMARY OF THE INVENTION 
     The present invention provides a system for the automated production of identification booklets, such as passports, comprising a two-part thermoplastic security media and apparatus for printing, die-cutting and fusing of the security media into the booklets. The security media comprises an opaque thermoplastic backing film which is bound into the binder of the booklet. The backing film essentially forms a page in the booklet. The security media also comprises a transparent thermoplastic cover film which acts as a receptor for receiving a thermally printed digital image. More specifically, the backing film preferably comprises a white amorphous copolyester film, while the cover film preferably comprises a clear polyvinyl chloride film. In general, the apparatus consists of a thermal printing apparatus for printing the digital image onto the cover film, die-cutting means for die-cutting a predetermined size identification card from the cover film, means for transporting the identification card into contact with the backing film within the booklet and means for fusing the identification card to the backing film. The cover film is provided in roll format wherein a continuous web comprises the clear cover film. The thermal printing apparatus is based on a digital imaging system wherein a digital portrait of the booklet holder is combined by custom computer software with a background, booklet holder signature and alphanumeric text to produce a complete digital full-color card image. A thermal web printer is operative for printing the color card image onto an inner surface of the cover film adjacent a terminal end of the cover film web. The computer software automatically mirrors the card image so that it appears in its correct orientation when viewed through the top of the cover film. The thermal web printer preferably comprises a thermal dye-transfer printer apparatus having a reverse print direction for printing from a midpoint of the web toward a terminal end thereof. The printed terminal end of the cover film is advanced through a guide to a cutting station where it is clamped and severed from the web, wherein the film is cut to include rounded comers on one edge. A tilt tray, having the cover film clamped thereto, is tilted to a vertical orientation and transported into contact with the backing film of the booklet, which is held in place below the tilt tray. Once the identification card is brought into contact with the backing film, the tilt tray pushes the booklet, including the identification card, into a laminating station including a heated input roller pair for initial laminating of the backing and cover films, a heated platen for heat-fusing the laminated films together and a pair of exit nips for removing the booklet from the laminating station. The result is a custom printed passport booklet which is produced in a minimal amount of time. 
     In one embodiment of the present invention, an automated apparatus for fusing an identification card to a backing is disclosed. The apparatus comprises fusing means for fusing the identification card and the backing together, transport means including a rotatable blade and clamp means disposed on the rotatable blade, for clamping the identification card to the rotatable blade. The transport means causes the rotatable blade to rotate, transports the rotatable blade into contact with the backing, with the identification card being disposed therebetween, and transports the identification card and backing into the fusing means, wherein the identification card and the backing are fused together. 
     In another embodiment of the present invention, an apparatus for forming and attaching an identification card comprising a cover film in a booklet having a backing is disclosed. The apparatus comprises means for holding the booklet in an open position with the backing exposed, printing means for printing indicia onto an inner surface of the cover film, transport means including an insertion blade rotatably mounted thereon, the insertion blade including a damp for holding the cover film in place thereon, die-cut means for cutting the cover film to a predetermined size while the cover film is held in place on the insertion blade by the clamp, to form the identification card and fusing means for fusing the identification card and the backing together. The insertion blade is rotated while the transport means transports the insertion blade with the identification card clamped thereto into the booklet, with the identification card contacting the backing, the transport means pushes the booklet into the fusing means with the insertion blade, and the fusing means fuses the identification card to the backing. 
     In yet another embodiment of the present invention, a method of forming and attaching an identification card comprising a cover film in a booklet having a backing attached therein. The method comprises the steps of printing identification information on the cover film, cutting the cover film to a predetermined size to form the identification card, inserting the identification card into the booklet adjacent the backing and applying heat to the booklet to fuse the identification card and the backing together within the booklet. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In the drawings which illustrate the best mode presently contemplated for carrying out the present invention: 
     FIG. 1 is a perspective view of the identification booklet production apparatus of the present invention, including the web printer; 
     FIG. 2 is a cross-sectional view of the apparatus of the present invention, taken at approximately half the depth of the apparatus; 
     FIGS. 3-7 are front views of the apparatus of the present invention, showing the operation of the apparatus; 
     FIG. 8 is a right side perspective view of the die-cut station of the apparatus of the present invention; 
     FIG. 9 is a left side perspective view of the die-cut station of the apparatus of the present invention; 
     FIG. 10 is a left front perspective view of the laminating station of the apparatus of the present invention; 
     FIG. 11 is a right rear perspective view of the laminating station of the apparatus of the present invention; 
     FIG. 12 is a left front perspective view of the booklet drawer system of the apparatus of the present invention; 
     FIG. 13 is a right rear perspective view of the booklet drawer system of the apparatus of the present invention; 
     FIG. 14 is a right front perspective view of the transport station of the apparatus of the present invention; and 
     FIG. 15 is a cross-sectional view of the die of the apparatus of the present invention, showing the type of cut made by the die. 
    
    
     DETAILED DESCRIPTION 
     Referring now to the drawings, the apparatus of the present invention is illustrated and generally indicated at  10  in FIGS. 1-7. As will hereinafter be more fully described, the present apparatus  10  is operative for the automated production of a passport booklet from a two-part security media. The security media preferably comprises a proprietary media developed by Minnesota Mining and Manufacturing Company of St. Paul, Minn., comprising a thermoplastic cover film for receiving a thermally printed, computer generated digital image and an opaque thermoplastic backing film. The specific properties of the cover film and backing film are set forth in commonly-owned U.S. Pat. No. 5,637,174, the disclosure of which is herein incorporated by reference in its entirety. In the present invention, the backing film is bound into a booklet, thereby forming one of the pages of the booklet from the backing film. In the preferred embodiment, the booklet is a passport, whereby the backing film is glued or sewn into the binder of the passport as the first page of the passport. 
     The printer  12  shown in FIG. 1 is a thermal web printer of the type disclosed in commonly-owned U.S. Pat. No. 5,565,902, the disclosure of which is herein incorporated by reference in its entirety. The printer  12  prints the identification information and image on the inner surface of the cover film, preferably in a reverse printing direction, i.e. the printing is done from a midpoint of the web to a terminal end. This reverse printing method ensures that little or no media is wasted at the terminal ends due to leader loss as found in conventional forward-driven printing methods. 
     Referring now to FIG. 2, which is a cross-sectional view of the apparatus, the cross-section taken at approximately half the depth of the apparatus, the configuration of the apparatus will be described. For simplicity, thermal printer  12  and pedestal  14  are not shown in FIG.  2 . After the cover film is printed in printer  12 , the cover film is guided by lower and upper media guides  16  and  18  of a die-cutting station  22 , where the cover film web is cut into an identification card of a predetermined size. Die-cutting station  22  is described in detail below with reference to FIGS. 8 and 9. A transport station  24  receives the cover film web, clamps it in place as it is cut in die-cutting station  22 , and transports the identification card into a booklet drawer system  26 , which holds a booklet in place with the booklet held open to allow the identification card to be inserted into the booklet in contact with the backing film bound in the booklet. Transport station  26  is described in detail below with reference to FIG.  14  and drawer system  26  is described in detail below with reference to FIGS. 12 and 13. Once the identification card is received in the booklet, the booklet is inserted into laminating station  28 , where the identification card and the backing film are fused together within the booklet. Laminating station  28  is described in detail below with reference to FIGS. 2,  10  and  11 . After the identification card is fused to the backing film in laminating station  28 , the booklet is ejected from laminating station  28  and is retrieved via exit chute  30  of pedestal  14  (FIG.  1 ). 
     Referring now to FIGS. 8 and 9, the die-cutting station  22  will be described. Die-cutting station  22  includes lower media guide  16  and upper media guide  18 . A splice sensor  32  optically determines when a splice in the cover film web is present, as when two rolls of cover film have been spliced together. When a splice is present, the spliced portion of the cover film is advanced by the printer  12  through die-cutting station  22 , so that the splice can be cut out by the die  62 , described below, and ejected from the apparatus. Die-cutting station  22  includes brackets  34   a  and  34   b  which are mounted together by a beam  36 . Brackets  34   a  and  34   b  mount the die-cutting station  22  to the apparatus  10  through bolt opening  35  in bracket  34   a  and a similar bolt opening (not shown) in bracket  34   b.  A DC motor  38  is mounted to bracket  34   a  by bolts  40   a  and  40   b.  DC motor  38  includes a drive shaft  42  on which a drive gear  44  is mounted and held in place by locking device  46 . Drive gear  44  meshes with and drives a secondary gear  48  which is mounted on a camshaft  50 . Secondary gear  48  is cooperatively mounted to a two position cam  52 , including detents  54   a  and  54   b.  Also mounted on camshaft  50  are die-actuating cams  60   a  and  60   b.  Die  62  is mounted in a die holder  64 , which rides on columns  65   a  and  65   b,  which are mounted on brace  66 , having a slot  66   a,  through which die  62  passes and through which scrap pieces, which are punched out of the cover film by die  62 , pass. Brace  66  is mounted between brackets  34   a  and  34   b.  Die holder  64  is biased in an upward position against stops  70   a  and  70   b,  which are mounted to beam  36 , by springs which are mounted around each of columns  65   a  and  65   b  between die holder  64  and brace  66 . One of the springs is indicated by reference numeral  68  in FIG.  2 . Die holder  64  includes cam followers  72   a  and  72   b,  which are in direct contact with die-actuating cams  60   a  and  60   b.  A die position sensor  56  includes a mechanical sensor  58  which rides along the outer surface of two position cam  52  and mechanically senses the position of the die  62  by engaging detents  54   a  and  54   b.  A clamp-actuating bar  74 , including fingers  76   a  and  76   b  is mounted to die holder  64 . The operation of two position cam  52 , die position sensor  56  and damp-actuating bar  74  is described below. 
     Transport station  24  will now be described with reference to FIGS. 2 and 14. Transport station  24  includes a vertical slide carriage  78  having bores  80   a  and  80   b  for receiving vertical slide rails  82   a  and  82   b.  Vertical slide rails  82   a  and  82   b  are mounted between a base  84  and a truss  86 . A DC motor  88  is mounted to truss  86  via a plate  90 . Motor  88  drives includes a drive shaft (not shown) on which a one-stop cam  92 , including a detent  92   a,  is mounted. A vertical slide carriage position switch  93  is mounted to plate  90  and includes a mechanical sensor  95  which is biased to maintain contact with the outer surface of one-stop cam  92  and to engage detent  92   a.  Mechanical sensor  95  is in an open position when engaged with detent  92   a  and is in a closed position when the transport is moving and mechanical sensor  95  is biased against the outer surface of one-stop cam  92 . Linkage system  94  comprises a primary link  96  which is mounted at one end  96   a  on the drive shaft of motor  88  and which is rotatably mounted at a distal end  96   b  to a secondary link  98  at one end  98   a  thereof by a mounting device  102   a.  Distal end  98   b  of secondary link  98  is rotatably mounted to vertical slide carriage  78  at a center bore  100  thereof by a mounting device  102   b.  Ends  98   a  and  98   b  of link  98  may be mounted to link  96  and carriage  78  with any of a number of mounting devices known in the art, which will allow the ends  98   a  and  98   b  to rotate about the mounting devices  102   a  and  102   b.    
     Transport station  24  further includes a tilt tray  104  which is rotatably mounted on a shaft  106  which in turn is mounted to vertical slide carriage  78 . Tilt tray  104  is biased in the horizontal position shown in FIG. 14 by a spring  108 . A blade  110  is adjustably mounted to the top surface of tilt tray  104  via bolts  111   a  and  111   b,  and includes a main body portion  110   a  and two extensions  110   b  and  110   c  disposed at either end of main body portion  110   a.  A clamping device  112  is mounted on tilt tray  104  and includes a pair of mounting shafts  113   a  and  113   b,  which hold damp bar  114  in place. Springs  116   a  and  116   b,  which are mounted on shafts  112   a  and  112   b,  respectively, bias clamp bar  114  downwardly, against blade  110 . A tilt tray actuator shaft  118 , having a beveled top end  118   a,  is mounted to base  84  in such a way to enable the shaft  118  to be adjusted vertically. Preferably, shaft  118  includes a threaded end (not shown) which is threaded into base  84 . The vertical positioning of shaft  118  is adjusted by threading the shaft  118  into base  84  to lower shaft  118  and by threading shaft  118  out from base  84  to raise shaft  118 . Once the shaft  118  is at the desired height, a lock nut  120  is tightened against base  84  to prevent shaft  118  from turning. The adjustability of the height of shaft  118  enables the tilt tray  104  and blade  110  to be adjusted in order to keep blade  110  horizontal. A set screw  122  is threaded into tilt tray  104 , which enables the tilt tray  104  to be adjusted in order to keep tilt tray  104  perpendicular with respect to vertical slide carriage  78 . A bottom portion  122   a  of set screw  122  abuts with the top end  118   a  of shaft  118 , so that when set screw  122  is threaded into tilt tray  104 , tilt tray  104  is pivotally raised, and when set screw  122  is threaded out of tilt tray  104 , tilt tray  104  is pivotally lowered. 
     Drawer system  26  will now be described with reference to FIGS. 2,  12  and  13 . Drawer system  26  includes a drawer  130  and a drawer retaining device  132 . Drawer  130  includes a front plate  134  having a handle  136 , left drawer rail  138  and right drawer rail  140 . Front plate  134  is attached to left drawer rail  138  and right drawer rail  140  by bolts  142   a  and  142   b.  Left booklet slide  144  is mounted to left drawer rail  138  and includes a clip  146  which is slidably attached thereto. Right booklet slide  148  is mounted to right drawer rail  140  and includes a clip  150  slidably attached thereto. Drawer retaining device  132  includes left rail retainer  152 , including left runner  152   a,  and right rail retainer  154 , including right runner  154   a.  Left drawer rail  138  is received by left runner  152   a  and right drawer rail  140  is received by right runner  154   a.  Left rail retainer  152  includes mounting holes  139   a  and  139   b  for mounting left rail retainer  152  to wall  200  of apparatus  10  and right rail retainer  154  includes mounting holes  141   a  and  141   b  for mounting right rail retainer  154  to wall  200  of apparatus  10 . Left rail retainer  152  and right rail retainer  154  are each coupled to frame  156 . A top booklet guide  158  is coupled to frame  156  by bolts  162   a  and  162   b,  and includes a magnetic lock device  160  for maintaining drawer  130  in the closed position by magnetically engaging front plate  134 , a left top booklet guide  164  and a right top booklet guide  166 . Left top booklet guide  164  includes a tab  165  which is inserted into a slot  167  in left rail retainer  152 . A scrap slide  170  is coupled to right rail retainer  154  and includes a shelf  172  which holds scrap tray  174 . An adjustable backstop  176  is slidably mounted to left rail retainer  152  by bolts  178   a  and  178   b,  which mount adjustable backstop  176  to left rail retainer  152  via slots  180   a  and  180   b,  respectively. Bolts  178   a  and  178   b  may be slid back and forth in slots  180   a  and  180   b  to adjust the depth of the drawer retaining device  132 , thereby allowing different size booklets to be used. A booklet position sensor  182  is mounted on adjustable backstop  176  and includes a mechanical sensor which determines whether a booklet is fully inserted in drawer retainer  132  against adjustable backstop  176 . 
     Laminating station  28  will now be described with reference to FIGS. 2,  10  and  11 . Laminating station  28  includes a series of nips and rollers which advance the booklet and identification card into a heat source and then out from the heat source. A first roller stage comprises nips  220   a  and  220   b  which are mounted on rollers  222   a  and  222   b,  respectively, and each include a one-way clutch mechanism which only allows the nips to rotate toward the center of the laminating station in order to pull the booklet from the drawer system  26  and into a second roller stage, which comprises a heated roller  224   a  and a cooperating guide roller  224   b.  A third roller stage comprises exit rollers  226   a  and  226   b.  Laminating station also includes heating plate  228   a  and a cooperating guide plate  228   b  and exit guides  230   a  and  230   b  for guiding the finished product from laminating station  28  via exit slot  232 . In a preferred embodiment, heating plate  228   a  is coated with a non-stick material, such as SILVER STONE, to prevent the cover or backing films from sticking to it as the booklets are heated. Rollers  222   a,    224   a  and  226   a  and heating plate  228   a  are fixedly mounted within laminating station  28 , while rollers  222   b,    224   b  and  226   b  are rotatably mounted within laminating station  28  by a floating linkage which will be described in detail below. Guide plate  228   b  is also floatably mounted within laminating station  28  and is biased against heating plate  228   a  by spring  234  which is mounted to wall  236  of laminating station  28 . 
     An AC gear motor  202  drives driveshaft  204  having a pulley  206  mounted thereon. A belt  208  is mounted between pulley  206  and a drive gear  210 . Drive gear  210  directly drives exit roller  226   a  and includes an internal gear (not shown) which drives idler gear  212 . Idler gear  212  drives second roller stage gear  214 , which directly drives heated roller  224   a.  Second roller stage gear  214  also drives primary drive transfer gear  216   a,  which drives drive transfer shaft  238 , which drives secondary drive transfer gear  216   b  on the front of laminating station  28 . Primary drive transfer gear  216   a  also drives first roller stage gear  218 , which drives roller  222   a,  and consequently, nip  220   a.  Secondary drive transfer gear  216   b  drives idler gear  240 , which drives first stage roller gear  242 , which drives roller  222   b,  and consequently, nip  220   b.  Idler gear  240  also drives second stage roller gear  244 , which drives guide roller  224   b.  Second stage roller gear  244  drives idler gear  246 , which drives third stage roller gear  248 , which drives exit roller  226   b.    
     As discussed above, rollers  222   b,    224   b  and  226   b  are mounted within laminating station  28  by means of a floating linkage. The floating linkage comprises link  250  which connects the non-geared ends of rollers  222   b  and  224   b,  and a link  252  which connects the non-geared ends of rollers  224   b  and  226   b.  Rollers  222   b,    224   b  and  226   b  are mounted in slots  254   a,    254   b  and  254   c,  respectively, which allow rollers  222   b,    224   b  and  226   b  to float toward and away from fixed rollers  222   a,    224   a  and  226   a,  respectively. In a similar manner, the geared ends of rollers  222   b,    224   b  and  226   b  are mounted through slots in the front wall  259  of laminating station  28  and are interconnected by means of a floating linkage. The geared ends of rollers  222   b  and  224   b  are interconnected by a link  260   a,  and the geared ends of rollers  224   b  and  226   b  are interconnected by a link  261 . Furthermore, the end of drive transfer shaft  238  on which drive transfer gear  216   b  is mounted is interconnected to the shaft (not shown) on which idler gear  240  is mounted by a link  260   b,  which is formed integrally with link  260   a.  Pressure adjustment spring systems  262   a  and  262   b  comprise rods  264   a  and  264   b  and springs  268   a  and  268   b,  respectively. Rods  264   a  and  264   b  are coupled to link  250  through slots  266   a  and  266   b,  respectively. Pressure adjustment spring systems  269   a  and  269   b  comprise rods  270   a  and  270   b  and springs  272   a  and  272   b,  respectively. Rods  270   a  and  270   b  are coupled to link  252  through slots  274   a  and a second slot in link  252  (not shown), respectively. Likewise, pressure adjustment spring systems  276   a,    276   b,  which comprise rods  278   a  and  278   b  and springs  280   a  and  280   b,  respectively, and pressure adjustment spring systems  282   a  and  282   b,  which comprise rods  284   a  and  284   b  and springs  286   a  and  286   b,  respectively, are coupled to links  260   a  and  261 . Pressure adjustment spring systems  262   a,    262   b,    269   a,    269   b,    276   a,    276   b,    282   a  and  282   b  operate to bias rollers  222   b,    224   b  and  226   b  against rollers  222   a,    224   a  and  226   a,  respectively. The amount of pressure between the rollers can be adjusted by the pressure adjustment spring systems, in order to allow booklet of varying thicknesses to be used with the present invention. Laminating station  28  also comprises a switch  288  having a mechanical sensor  290  which contacts roller  222   b  and determines when a booklet has passed through nips  220   a  and  220   b,  by the movement of roller  222   b  as the booklet passes through nips  220   a  and  220   b.    
     The operation of the apparatus  10  will now be described with reference to FIGS. 3-7 and  15 . For simplicity, the top booklet guide  158 , drawer front plate  134  and pedestal  14  are not shown in FIGS. 3-7. As shown in FIG. 3, drawer  130  is removed from drawer retainer device  132 , and a booklet  300  is inserted into drawer  130  and held against left and right booklet slides  144  and  148  by dips  146  and  150 , respectively. As described above, booklet  300  includes a cover and a backing film  302  bound into the binder of booklet  300  to form a page therein. Booklet  300  also includes a plurality of paper pages  304  bound therein. Booklet  300  is inserted into drawer  130  such that backing film  302  is exposed and clipped under clip  146  of left booklet slide  144 . Drawer  130  is then inserted into drawer retaining device  132 , such that booklet  300  rests against backstop  176  and booklet position sensor  182 . 
     The cover film, after being printed on as described above, is advanced in the direction of arrow  310  between lower media guide  16  and upper media guide  18  into die-cutting station  22 . The terminal end of the cover film is advanced to the distal edge of blade  110  of transport station  24 . Motor  38  then rotates drive gear  44  which rotates secondary gear  48 , turning two position cam  52 , and consequently, cam shaft  50  in the counter-clockwise direction, FIG.  4 . Cams  60   a  and  60   b  depress cam followers  72   a  and  72   b,  driving die  62  into the cover film, thereby cutting the cover film. FIG. 15 shows the type of cut performed by die  62 . In FIG. 15, a cross-section of die  62  is shown, and also shows the resulting cut cover film. As is shown in FIG. 15, die  62  punches out a portion of the terminal end of the cover film to form an identification card  312  having rounded comers on one edge  314  thereof. Identification card  312  is approximately the same width and length as a page of booklet  300 . Opposite edge  314 , a straight edge  316  is formed on the new terminal end of the cover film. The scrap piece of cover film which is punched out by die  62  falls through slot  66   a  in beam  66  into scrap tray  174  via scrap slide  170 . As shown in the figure, card  312  also includes a flat edge  316 . As die  62  is driven downwardly into the cover film, die holder  64  also is driven down, causing clamp-actuating bar  74  to also be driven downwardly. Consequently, fingers  76   a  and  76   b  release clamp bar  114 , thereby clamping identification card  312  to blade  110  of transport station  24 . Mechanical sensor  58  stops motor  38  from rotating camshaft  50  when it is received in detent  54   a  of two position cam  52 . 
     Motor  88  of transport station  24  then rotates cam  92  in the direction indicated by arrow  320 , FIG. 5, causing link  96  to turn in the same direction, thereby pushing link  98  and, consequently vertical slide carriage  78  downward. Tilt tray actuator  118  causes tilt tray  104  to rotate 90° downward about shaft  106 , as vertical slide carriage  78  and tilt tray  104  are pushed downward by link  98 . Tilt tray  104  and blade  110  are held in place in the vertical orientation by maintaining contact with tilt tray actuator  118  while tilt tray  104  is driven downward. Blade  110 , with identification card  312  clamped thereto, is driven into the binder of booklet  300 , bringing identification card  312  into contact with backing film  302  with straight edge  316  of identification card  312  being proximate the binder, and edge  314 , with the rounded corners, being located opposite the binder. The side edges of the identification card  312  are aligned with the side edges of the backing film  302 . Blade  110  pushes booklet along drawer booklet slides  144  and  148  into nips  220   a  and  220   b  of laminating station  28 . Driven by motor  202 , nips  220   a  and  220   b  receive booklet  300  from blade  110  in the area between extensions  110   b  and  110   c,  so that only booklet  300 , including identification card  312 , and not blade  110  is received between nips  220   a  and  220   b.  Motor  88  continues to rotate cam  92  until it makes a complete revolution and links  96  and  98  have pulled tilt tray  104  back to the horizontal position shown in FIG.  6 . Motor  88  stops rotating cam  92  when sensor  93  is received in detent  92   a  and tilt tray  104  has returned to the horizontal position. 
     Booklet  300 , having identification card  312  in contact with backing film  302 , is passed from nips  220   a  and  220   b  to heated roller  224   a  and roller  224   b,  which passes booklet  300  between heating plate  228   a  and guide plate  228   b.  Roller  224   a  is heated to a temperature of about 200° C., and performs an initial lamination of the identification card  312  to the backing film  302 , while removing air from between identification card  312  and backing film  302 . Heating plate  228   a  is heated to a temperature of about 160° C. to define a full laminating stage. As the booklet is passes between rollers  224   a  and  224   b,  air bubbles are squeezed from between the identification card  312  and the backing film  302  as they are initially heated by roller  224   a.  After the initial lamination, booklet  300  is passed between heated plate  228   a  and guide plate  228   b,  and identification card  312  and backing film  302  are heated for a longer duration and are fully fused together. Rollers  226   a  and  226   b  remove booklet  300 , with identification card  312  and backing film  302  completely fused together, from between heated and guide plates  228   a  and  228   b,  and pass the finished product through exit slot  232 , guided by exit guides  230   a  and  230   b,  FIG.  7 . While booklet  300  is being laminated in laminating station  28 , motor  38  of die-cutting station  22  rotates camshaft  50  in the counterclockwise direction to raise die  62 , and consequently, clamp-actuating bar  74 . Two position cam  52  rotates until mechanical sensor is received by detent  54   b,  which signals motor  38  to cease rotating camshaft  50 . The cover film is then retracted by the printer  12 , and the next identification card is printed, as described above. 
     Mechanical sensor  290  of switch  288  senses the movement of booklet  300  through nips  220   a  and  220   b  and notifies the operator when booklet  300  has passed through nips  220   a  and  220   b,  so that another booklet can be loaded into drawer system  26 , while the next identification card is printed. The above-described process is then repeated to form another passport booklet in accordance with the invention. 
     It can therefore be seen that the present invention provides a novel apparatus for instant, one-up printing, die-cutting and laminating of passport booklets from two-part security media. The apparatus  10  provides a thermal web printing device  12 , for thermally printing a digital card image onto the security media, die-cutting apparatus  22  for die-cutting a predetermined sized identification card, drawer apparatus  26  for holding the booklet in place, transport apparatus  24  for transporting the identification card into the booklet, laminating apparatus  28  for fusing the security media together and the appropriate guide and advancing mechanisms for guiding and advancing the security media and booklet through the die-cutting, transport and laminating apparatus. The apparatus  10  is quick and efficient and therefore it provides a convenient and cost-effective means for instant custom production of passport booklets. For these reasons, the present invention is believed to represent a significant advancement in the art which has substantial commercial merit. 
     While there is shown and described herein certain specific structure embodying the invention, it will be manifest to those skilled in the art that various modifications and rearrangements of the parts may be made without departing from the spirit and scope of the underlying inventive concept. For example, while the invention is disclosed as being for producing passport booklets, any type of booklets may be produced by the present invention, including bank account booklets, visas and novelty booklets. Therefore, the underlying inventive concept is not limited to the particular forms herein shown and described except insofar as indicated by the scope of the appended claims.