Patent Publication Number: US-6981536-B2

Title: Laminator swing arm assembly

Description:
The present application claims the benefit of U.S. provisional patent application Ser. No. 60/373,980, filed Apr. 19, 2002. 

   FIELD OF THE INVENTION 
   The present invention generally relates to identification card laminators and, more particularly, to a swing arm assembly for use in a card laminator. 
   BACKGROUND OF THE INVENTION 
   Identification cards are commonly used as a vehicle for identifying the bearer of the card (e.g., driver&#39;s licenses) for access control, and other purposes. These identification cards are produced using identification card manufacturing systems. 
   Identification card manufacturing systems generally include an identification card printer and laminator, such as the HDP and DTC line of identification card printers and laminators produced by Fargo Electronics, Inc. of Eden Prairie, Minn. Other card processing devices that can be utilized in identification card manufacturing systems include, for example, a card flipper and a data encoder. These devices are generally operated under the control of host applications running on a computer. 
   Identification card printers are configured to handle and print on rigid or semi-rigid card substrates, a function traditional paper sheet feed printers are incapable of performing. Identification card printers generally include a card supply, a card transport mechanism, a printhead, and a controller for controlling the components in response to print job instructions received from the host application. The card supply contains a stack of identification cards that are individually delivered to the printhead by the card transport mechanism. The printhead prints an image to a surface of the card in accordance with the print job. 
   Identification card laminators are generally configured to apply an overlaminate material to printed surfaces of cards. Such card laminators generally include a supply of overlaminate material, a card transport mechanism, and a laminating mechanism. The card transport mechanism is configured to transport individual cards between the laminating mechanism and a platen roller. The supply of overlaminate material extends between supply and take-up rolls and between the laminating mechanism and the card. The laminating mechanism includes a heating element, such as a heated roller, and applies pressure and heat to the overlaminate material, which causes a portion of the overlaminate material to transfer to the surface of the card. The transferred overlaminate material protects the surface of the card from the environment. Additionally, the overlaminate material can include security markings such as holograms, that can be used to authenticate the card and deter counterfeiting. 
   Some card laminators include swing arm assemblies, to which the heated roller of the laminating mechanism is mounted. The swing arm can be raised to an open position, and lowered to an operating position. This allows the user to gain access to the interior of the laminator so that a supply of overlaminate film can be installed or other items can be serviced. Additionally, the laminating roller is configured for movement between a laminating position, in which it is positioned proximate to the platen roller for laminating a card, and a recessed position, in which the laminating roller is displaced from the platen roller. A drive motor, usually mounted to a side wall of the frame of the laminator adjacent the swing frame, is configured to drive the laminating roller between the laminating and recessed positions through engagement with a drive mechanism that is mounted to the swing frame. The drive mechanism drives a cam, which in turn moves a laminating roller between the laminating and recessed positions. When the swing frame is open, the drive is disengaged from the motor. When the swing frame is closed, the drive is designed to reengage the motor to allow for the driving of the laminator between the laminating and recessed positions. 
   Unfortunately, the position of the drive mechanism upon reengagement with the motor can change from its previous position. Such a change can affect the position of the cam and, thus, the position of the laminating roller relative to the platen roller and a card that is to be laminated. This can result in inaccurate positioning of the laminating roller relative to the platen roller or card, which prevents the desired pressure and heat from being accurately applied to the overlaminate material and the card. As a result, laminating defects, card jams, and other laminator malfunctions can occur. 
   The present invention provides a solution to these and other problems and offers advantages over the prior art. 
   SUMMARY OF THE INVENTION 
   The present invention is directed to a swing arm assembly for use in a card laminator that avoids the problems described above. The swing arm assembly includes a swing frame, a laminating roller, and a motor. The swing frame is rotatably mountable to a frame for pivotal movement relative to the frame between open and closed positions. The laminating roller is movably mounted to the swing frame. The motor is mounted to the swing frame and is configured to drive a roller actuator to move the laminating roller relative to the swing frame between a laminating position and a recessed position. 
   Other features and benefits that characterize embodiments of the present invention will be apparent upon reading the following detailed description and review of the associated drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of an identification card manufacturing system. 
       FIG. 2  is a perspective view of an identification card laminator in accordance with embodiments of the invention. 
       FIG. 3  is a perspective view of an identification card laminator with a housing removed. 
       FIGS. 4 and 5  are simplified side views of an identification card laminator with a housing, a side plate of an interior frame, and a side plate of a swing frame removed. 
       FIG. 6  is a front view of a swing arm assembly with a front plate removed. 
       FIG. 7  is a side view of the swing arm assembly of  FIG. 6  taken generally along line  7 — 7 , but with a front plate present. 
       FIG. 8  is a simplified side view of an identification card laminator with a housing, a side plate of an interior frame, and a side plate of a swing frame removed. 
       FIG. 9  is a partial perspective view of swing arm assembly mounted to a frame with a portion of the swing arm assembly cut away to reveal components of a heat shield. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     FIG. 1  is a perspective view of an identification card manufacturing system  10  that includes an identification card laminator  12  that is formed in accordance with embodiments of the present invention. System  10  also includes an identification card printer  14  that is joined to laminator  12  by a unification mounting  16  to form system  10  as a single unit. This configuration allows for cards that are processed by printer  14  to be transferred to laminator  12  for lamination without user intervention. Such a system is described in co-pending patent application Ser. No. 10/419,055 for an “IDENTIFICATION CARD MANUFACTURING DEVICE MODULE UNIFICATION” filed on even date herewith and assigned to Fargo Electronics, Inc. of Eden Prairie, Minn., which is hereby incorporated by reference in its entirety. Alternatively, the identification card printer  14  and the identification card laminator  12  can be formed as separate units that operate independent of each other. 
     FIG. 2  is a perspective view of an identification card laminator  12  in accordance with embodiments of the invention. Identification card laminator  12  includes a housing  20  comprising side walls  22  and  24 , a top cover  26  shown as being opened, and an open end  28 . Laminator  12  can include an end cover (not shown) to cover open end  28  and include a card input for receiving and/or storing individual or multiple cards when the card laminator  12  is configured for stand-alone operation. Open end  28  allows for attachment to identification card printer  14  using unification mounting  16 , as illustrated in FIG.  1 . 
     FIG. 3  is a perspective view of laminator  12  with housing  20  removed. Laminator  12  includes a frame  30  that is enclosed by housing  20  and supports the primary card processing components of laminator  12 . Frame  30  includes side plates  32  and  34  to which the components of laminator  12  can be mounted. Frame  30  includes support legs  36  that can be attached to a base (not shown). 
   The general components of identification card laminator  12  will be discussed with reference to  FIGS. 4 and 5 , which are simplified side views of laminator  12  with housing  20  and side plate  34  of frame  30  removed. In general, laminator  12  includes a card transport  40 , a supply of overlaminate material  42 , swing arm assembly  44 , and a controller  46 . Card transport  40  includes feed rollers  48  and  50  and a platen roller  52 . Card transport  40  receives cards at an input  54  and transports individual cards, such as card  56  shown in  FIG. 4 , through laminator  12  during laminating operations. A card flipper or inverter  60 , driven by a motor  61 , can invert cards at input  54 , so that both sides of the cards can be laminated. Feed rollers  48  and  50  and platen roller  52  are driven by a motor  62  ( FIG. 4 ) through a suitable gear and pulley arrangement, as illustrated at  64  or FIG.  3 . 
   The supply of overlaminate material  42  extends between a supply roll  70  and a take-up roll  72  that are respectively mounted to hubs  74  and  76 , shown in FIG.  3 . Guide rollers  78  and  80  mounted to frame  30  are provided to guide overlaminate material  42  under swing arm assembly  44 . A laminating drive  82  can control the feeding and tension of the overlaminate material  42  between supply roll  70  and take-up roll  72 , in accordance with known methods. 
   Swing arm assembly  44  generally includes a swing frame  90 , a laminating roller  92 , a motor  94 , and a roller actuator  96 . Swing frame  90  includes side support plates  100  and  102 , a top plate  104 , and front and rear plates  106  and  108 , as shown in  FIGS. 3 ,  4  and  5 . Side support plate  102  is shown as being removed in  FIGS. 4 and 5 . Side plates  100  and  102  are each rotatably mounted to a corresponding side plate  32  or  34  of frame  30  by a hinge or bracket  110 . This connection allows swing frame  90  to pivot about axis  112  ( FIG. 4 ) relative to frame  30  between an open position, shown in  FIGS. 2 and 3  and a closed position, shown in  FIGS. 4 and 5 . 
   The positioning of swing arm assembly  44  in the open position allows for replacement of the overlaminate material  42 , or for the performance of other services to laminator  12 . Swing arm assembly  44  is placed in the closed position during laminating operations. Swing arm assembly  44  is held in a closed or operating position with latches  114 , which latch onto suitable latch pins  116  mounted on side walls  32  and  34  of frame  30 . 
   Swing arm assembly  44  includes overlaminate guides, such as bottom guide surface  118  of front plate  106  and rear overlaminate guide roller  120 . These overlaminate guides operate to align the overlaminate material  42  as desired relative to laminating roller  92 , as shown in FIG.  4 . Bottom guide surface  118  engages overlaminate material  42  and controls the angle at which overlaminate material  42  meets laminating roller  92  when swing frame  44  is in the closed position. Rear overlaminate guide roller  120  is mounted between side support plates  100  and  102  of swing frame  90  and operates to align overlaminate material  42  relative to laminating roller  92  as swing arm assembly is moved to the closed position. 
   Overlaminate material  42  is fed under laminating roller  92 , as shown in  FIGS. 4 and 5 . Laminating roller  92  is preferably a heated roller that is heated using conventional methods. However, other suitable laminating mechanisms can be substituted for laminating roller  92 . 
   Further discussion of swing arm assembly  44  will be provided with reference to  FIGS. 6 and 7 .  FIG. 6  is a front view of swing arm assembly  44  with front plate  106  removed.  FIG. 7  is a side view of swing arm assembly taken generally along line  7 — 7  of  FIG. 6 , but with front plate  106  present. Roller actuator  96  is driven by motor  94  to move laminating roller  92  relative to swing frame  90  between a laminating position shown in  FIG. 4 and a  recessed position shown in FIG.  5 . Laminating roller  92  is generally moved to the laminating position when swing arm assembly  44  is in the closed or operating position. When in the laminating position, laminating roller  92  is positioned adjacent to platen roller  52  to allow laminating roller  92  to apply pressure and heat to overlaminate material  42  and card  56  as desired, as shown in FIG.  4 . 
   One embodiment of roller actuator  96  includes a cam  130  and a slide frame  132 . Cam  130  is mounted to a cam shaft  134  that is mounted to swing frame side support plates  100  and  102 . Cam shaft  134  is driven by motor  94  through a suitable driving arrangement. In accordance with one embodiment of the invention, motor  94  drives a belt  138  to drive a pulley  140 , which in turn drives gears  142  and  144  to rotate cam shaft  134  and cam  130 . One advantage of swing arm assembly  44  of the present invention is that the drive mechanism between motor  94  and roller actuator  96  always remains connected. This configuration avoids laminating roller positioning problems of the prior art. 
   Slide frame  132  movably supports laminating roller  92  between the laminating and recessed positions in response to the position of cam  130 . Slide frame  132  includes side plates  146  and  148 , and upper and lower cam follower plates  150  and  152  that are mounted to a back plate  154 . Laminating roller  92  is supported for rotation between side plates  100  and  102  at brackets  156  and  158 . Cam  130  is positioned between upper and lower cam follower plates  150  and  152 , as shown in FIG.  6 . The angular position of cam  130  directs the position of slide frame  132  through engagement with upper and lower cam follower plates  150  and  152  to move between the laminating and recessed positions relative to swing frame  90 , as shown in  FIGS. 4 and 5 . A slide frame guide bar  160  extends between side support plates  100  and  102  and through slots  162  of side plates  146  and  148  of slide frame  132 . Slide frame guide bar  160  operates to maintain slide frame  132  in the desired plane while it moves between the laminating and recessed positions. 
   Another embodiment of swing arm assembly  44  includes a sensor  164 , shown in  FIG. 7  mounted to swing frame  90  that is configured to sense a position of roller actuator  96 . Sensor  164  can be of any suitable type and includes an output  166  that is received by controller  46  and indicates whether the laminating roller  92  is in the laminating or recessed position. Accordingly, sensor  164  can be located to directly detect a position of a component of slide frame  132  or laminating roller  92  to provide the desired position detection function. For example, sensor  164  can be mounted to side plate  102  of swing frame  90  and positioned to detect, for example, the position of upper follower plate  150  relative to swing frame  90  to detect whether laminating roller  92  is in the full laminating position, as shown in FIG.  7 . 
   Controller  46  operates to control the components of laminator  12  in accordance with instructions from a host application. The host application typically runs on a personal computer (not shown) and communicates with controller  46  through a suitable connection, such as cable  170  shown in FIG.  2 . Alternatively, laminator  12  can include memory for storage of the application, which can then be executed by controller  46 . Control signals from controller  46  and power can be provided to the components of laminator  12 , such as the heater for laminating roller  92 , card transport motor  62 , card flipper motor  61 , motor  94 , and sensor  164 , through conventional connections while allowing swing arm assembly  44  to pivot between the open and closed positions. 
   During a laminating operation, laminating roller  92  is placed in the laminating position, as shown in  FIG. 4. A  card  56 , that is received at input  54  by card flipper  60  or card feed rollers  48  of card transport  40 , is fed between laminating roller  92  and platen roller  52 . Laminating roller  92  applies pressure and heat to overlaminate material  42  and card  56  to cause a portion of the overlaminate material  42  to transfer to a surface  172  of card  56 . The transferred overlaminate material operates to protect surface  172  of card  56  from abrasion and environmental conditions. Card  56  can then be discharged by feed rollers  50  of card transport mechanism  40  to an output hopper  174 . 
   When swing arm assembly  44  is in the open position, a laminating side  180  of laminating roller  92  could be exposed sufficiently for accidental contact therewith by a person reaching into the interior of card laminator  12  between side plates  100  and  102  to remove a jammed card, replace the supply of overlaminate material, or perform some other service to card laminator  12 . In order to avoid such accidental contact with laminating roller  92 , one embodiment of swing arm assembly  44  includes a heat shield  190  that is movably mounted on swing frame  90  and covers laminating side  180  of laminating roller  92  when swing arm assembly  44  is moved to the open position, as illustrated in FIG.  8 . 
   In accordance with one embodiment of the invention, heat shield  190  includes a shield member  192  that is mounted to a slide support  194 . Slide support  194  is slidably supported between side support plates  100  and  102  of swing frame  90  and supports shield member  192  between shielding and retracted positions. When in the retracted position shown in  FIG. 4 , laminating side  180  of laminating roller  92  remains exposed for laminating operations. When heat shield  190  is in the shielding position shown in  FIG. 8 , shield member  192  covers the laminating side  180  of laminating roller  92  between front and rear plates  106  and  108  of swing frame  90  to protect a user from accidental contact therewith. 
   Shield member  192  is preferably a thin spring sheet that curls into a cylinder or partial cylinder when it is not guided or restrained. Shield guides, such as bottom flanges  196  and  198  and guide bar  200  control the location of shield member  192  as it is moved between the retracted and shielding positions, as shown in  FIGS. 3 ,  7  and  8 . 
     FIG. 9  is a partial perspective view of swing arm assembly  44  mounted to frame  30 , with a portion of swing arm assembly  44  cut away. In the example shown in  FIG. 9 , one or more springs  202  are mounted to slide support  194  at top edge  204  and to swing frame  30  at shield guide bar  200  to bias heat shield  190  toward the shielding position. 
   Slide support  194  preferably includes cam legs or wings  206  that extend through slots  208  of side support plates  100  and  102  of swing frame  90 , as shown in FIG.  3 . As swing arm assembly  44  is pivoted from the open position to the closed position, wings  206  each engage and slide along a top surface  210  of a lower or first guide member  212  mounted to side plates  32  and  34  of frame  30 . As the force applied by springs  202  is overcome by pressing on top plate  104  of swing frame  90 , the engagement of wings  206  with their corresponding first guide members  212  direct slide frame  194  to move toward the retracted position. Heat shield  190  reaches the full retracted position when swing arm assembly  44  is closed and latches  114  fully engage latch pins  116 . When latches  114  are flipped open to disengage latch pins  116 , the bias force generated by springs  202  causes swing arm assembly  44  to automatically open slightly thus preventing swing arm assembly  44  from re-latching in the closed position. 
   In accordance with another embodiment of the invention, upper or second guide members  214 , shown in  FIG. 9 , are used to ensure that heat shield  190  moves to the shielding position when swing arm assembly  44  is moved to the open position. During such movement of swing arm assembly  44 , wings  206  engage and slide along a bottom surface  216  of second guide members  214 . This engagement between wings  206  and second guide members restricts the movement of slide support  194  relative to frame  30  and forces movement of slide support  194  relative to swing frame  90  to move heat shield  190  toward the shielding position. Wings  206  are released from second guide member  216  at a back edge  218  as swing arm assembly  44  continues moving toward the full open position, as shown in FIG.  3 . Preferably, each pair of first and second guide members  212  and  216  are formed of a single component  220  that is mounted to one of the side plates  32  and  34  of frame  30 . 
   Laminating roller  92  can only perform laminating operations when heat shield  190  is in the retracted position and swing arm assembly  44  is in the full closed position. In accordance with one embodiment of the invention, a shield sensor  222 , shown schematically in  FIG. 7 , is provided to sense the position of shield  190 . For example, shield sensor  222  can be mounted to rear plate  108  of swing frame  90  and indicates a position of slide support  194 . Controller  46  is configured to receive a signal  224  from shield sensor  222  and preferably moves laminating roller  92  to the recessed position through control of motor  94  when heat shield  190  is in the shielding position. This produces a gap  226  between laminating roller  92  and shield member  192 , as shown in  FIG. 8 , which reduces heat transfer from laminating roller  92  to shield member  94  and ensures that shield member  94  will be safe to touch. Shield sensor  222  can be any suitable sensor and is preferably positioned to detect a position of slide support  194  relative to swing frame  90 . 
   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.