Patent Publication Number: US-6902518-B2

Title: Card package production system with adhesive card attachment station and method

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims under 35 U.S.C. 119(e) the benefit of U.S. Provisional Application No. 60/184,443, filed Feb. 23, 2000, and entitled “Card Package Production System and Method”, and assigned to the assignee of the present application. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention generally relates to card package production systems of the type that automatically produce card packages of cards, such as credit cards, to matching carrier forms for mailing, and more particularly to a mechanism and method for attaching the cards to the carriers through use of adhesive labels. 
     2. Description of the Prior Art 
     Card package production systems that produce card packages comprised of cards, such as plastic credit or debit cards, to matching paper carriers that bear printed information including the card owner&#39;s name and address in a location for viewing through a window envelope into which the carrier packages are ultimately inserted, or “stuffed”, for mailing to the owner. 
     In some card package production systems the cards are mechanically attached to the carriers by means of die cut slots while in others the cards are directly adhered to the carriers by adhesive or by means of double-sided adhesive pads. In some systems, the cards, the carriers or both are produced by the system before attachment. In others, the cards or the carriers are provided to the system in a pre-prepared condition. In either event, in known systems the card and carriers travel unidirectionally towards each other and meet at an attaching or insertion station at which the cards are actually attached to the matching carriers, and the loaded carriers pass to a folding station at which the loaded carriers are folded before completion and insertion into an envelope. 
     Examples of such card package production systems in which the cards are mechanically attached to the carriers are shown in U.S. patent application Ser. No. 09/081,312, filed May 19, 1998, of Bretl et al. and entitled “Card Package Production System with a Multireader Card Track and Method”, and in U.S. Pat. No. 5,494,544 issued Feb. 27, 1996 to Hill et al. and entitled “Automatic Verified Embossed Card Package Production Methods”; U.S. Pat. No. 5,541,395 issued Jul. 30, 1996 to Hill et al. and entitled “Card Package Production System with Burster and Code Reader”; U.S. Pat. No. 5,388,815 issued Feb. 14, 1995 to Hill et al. and entitled, “Embossed Card Package Production System with Modular Inserters for Multiple Forms”; U.S. Pat. No. 5,509,886 issued Apr. 23, 1996 to Hill et al. for “Card Package Production System with Modular Carrier Folding Apparatus for Multiple Forms”; and U.S. Pat. No. 5,433,364 issued Jul. 18, 1995 to Hill et al. for “Card Package Production System with Burster and Carrier Verification Apparatus”, all assigned to the assignee of the present invention, and all of which together with the references cited therein are hereby incorporated by reference. 
     While mechanical attachment mechanisms are successful, they are capable of being readily separated from the carrier. A problem with cards that are adhered directly to the carriers is that they cannot be easily removed and sometime the adhesive sticks to the card after removal from the carrier. 
     While double-sided adhesive labels, or pads, overcome the problem of adhesive sticking to the card after removal they are generally believed to be not as secure. It is of the utmost importance that the cards are adhered to the carriers sufficiently to prevent their separation during further processing. In addition, the card should remain attached to the carrier when the card and carrier are removed from an envelope by the ultimate user of the card upon receipt in the mail until it is intentionally removed. A card package production system in which the cards are attached by means of a double-sided adhesive label or pad is shown in U.S. Pat. No. 5,896,725 issued to Lundstrom et al. 
     In the known card package production system that employs use of double-sided adhesive labels to attach the cards to the carriers, the cards can be selectively placed at different locations on the carrier this is accomplished by means of an attachment apparatus that requires multidirectional movement by a card attachment mechanism in addition to unidirectional movement the carriers. 
     SUMMARY OF THE INVENTION 
     In accordance with the present invention a card package production system is provided in which the cards are attached to the matching carriers by means of adhesive pads that are securely fashioned to the carriers and the cards and in which both the carriers and the cards are required to move only along one direction. 
     This objective is achieved by providing a card package production system for producing card packages with printed paper carriers with matching cards attached by adhesive to the carriers with an adhesive label attachment station having a supply of double sided adhesive labels adhered to a roll of backing paper, one side of the labels against the backing paper having a permanent adhesive and the other side facing away from the backing paper having a heat activated adhesive, a heating platen with a width for heating at least two labels simultaneously, a label attachment position, a card transport for moving the cards to the card attachment position, a label transport system for passing the labels over the platen, a labeler downstream from the heating platen with a pressing member for pressing a heated adhesive label against a card at the attachment position by pressing against a side of the backing paper opposite the heated adhesive label. 
     Preferably, the label pressing member has an eccentric shape and is mounted for rotation into engagement with the backing tape. A counter member holds the card against force from the pressing member and is mounted rocking movement relative to the card. The counter member is located above the card, and the pressing member presses the adhesive labels upwardly toward the counter member. Also, the counter member is removeably mounted to a pivot post about which the counter member rocks, and the rocking movement is about an axis parallel to an axis of rotation of the eccentric member. The card is transported along a track in a horizontal position past the counter member. 
     The platen is maintained at an average temperature of no less than approximately 210 degrees Fahrenheit and the labels are engaged with the platen for no less than 100 milliseconds. Then the pressing member presses the label against the card within no less than approximately 100 milliseconds after being heated. 
     The objective of the invention is also obtained in part by providing in a card package production system for producing card packages with printed paper carriers with matching cards attached by adhesive to the carriers, an adhesive label attaching method comprising the steps of providing a supply of double sided adhesive labels adhered to a roll of backing paper, one side of the labels against the backing paper having a permanent adhesive and the other side facing away from the backing paper having a heat activated adhesive, heating at least two labels simultaneously with a heating platen, moving the cards a card transport for to a card attachment position, passing the labels over the platen with a label transport system, pressing, with a pressing member of a labeler located downstream from the heating platen, a heated adhesive label against a card at the attachment position by pressing against a side of the backing paper opposite the heated adhesive label. 
     The objective of the invention is also partly achieved by providing a card package production system for producing card packages with printed paper carriers with matching cards attached to the carriers with adhesive with an adhesive label attachment mechanism, having means for providing double sided adhesive labels on a roll of backing tape to an adhesive label attachment station, means for heating only an intermediate section of the adhesive to activate a heat activated adhesive carried by an outer side of the adhesive label, leaving end portions of the label relatively unheated and unactivated, and means for pressing the intermediate section of the adhesive after heating to a card. 
     Further, the objective is obtained in part by providing a in a card package production system for producing card packages with printed paper carriers with matching cards attached to the carriers with adhesive, method of attaching an adhesive label to the card, by performing the steps of providing double sided adhesive labels on a roll of backing tape to an adhesive label attachment station, heating only an intermediate section of the adhesive to activate a heat activated adhesive carried by an outer side of the adhesive label, leaving end portions of the label relatively unheated and unactivated, and pressing the intermediate section of the adhesive after heating to a card. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The forgoing advantages and objectives will be described in detail and others will be made apparent in the detailed description of the best mode of practicing the present invention which is given below with reference to the several views of the drawing, in which: 
         FIG. 1  is a perspective view of the card package production system of the present invention; 
         FIG. 2  is a perspective of a card package of the type produced by the card package production system of  FIG. 1  with the card attached to the carrier; 
         FIG. 3  is a an end view of the card package of  FIG. 2  in a folded state ready for mailing; 
         FIG. 4  is a perspective of the card package of  FIG. 2  but with the card detached and showing the adhesive label remaining attached to carrier; 
         FIG. 5  is a front elevational view of the card package production system of  FIG. 1 ; 
         FIG. 6  is a side elevational view of the card package production system of  FIG. 1  with portions of the card attachment module broken away to show selected internal features; 
         FIG. 7  is a plan view of the card package production system of  FIG. 1 ; 
         FIG. 8  is side, partially schematic view of the inter-module guide extending between the carrier printer module outlet to the card attachment module carrier inlet shown as also seen in the plan view of  FIG. 7 ; 
         FIG. 9  is a plan view of the inter-module guide showing the release opening in the upper guide body; 
         FIG. 10  is a sectional side view taken along section line  10 — 10  of  FIG. 9 ; 
         FIG. 11  is a plan view of the carrier transport showing the carrier inlet station, the intermediate standby station, the card attachment station and the folding station; 
         FIG. 12  is a side view of the carrier transport with carrier restraint assemblies shown in broken line in their inoperative elevated positions to provide access to enable clearing of jams and general maintenance; 
         FIG. 13  is a schematic illustration of a side view of only the multilevel carrier transport shown in  FIG. 12 ; 
         FIG. 14  is a schematic illustration of the movement and the overlapping position of the carriers on the multilevel support of  FIGS. 12 and 13  in the event of the card package production system being stopped during operation; 
         FIG. 15  is a plan view of the adjustable carrier restraint assembly for keeping the carriers on the carrier transport path; 
         FIG. 16  is a sectional side view taken along section line  16 — 16  of  FIG. 15 ; 
         FIG. 17  is an exploded perspective view of the carrier guide adjustment assembly shown in  FIGS. 15 and 16 ; 
         FIG. 18  is a schematic illustration of the movement of the carrier being passed to the card loading station; 
         FIG. 19  is a schematic illustration of the carrier at the card attachment station immediately before the card drops onto the carrier to which it is to be attached; 
         FIG. 20  is a schematic illustration of the carrier at the card attachment station after the card has dropped onto the carrier and slid downwardly to the nib of the card attachment station carrier feed rollers; 
         FIG. 21  shows the carrier feed rollers reversing direction to again pass, in reverse direction, the carrier and the card resting on the card partially back through the set of rollers to press the card with the attached adhesive label to the carrier sufficiently to ensure adhesive attachment of the card to the carrier; 
         FIG. 22  shows the carrier with adhesively attached card being passed to the second stage of the carrier folder; 
         FIG. 23  shows the carrier with adhesively attached card being passed to the second stage of the carrier folding station; 
         FIG. 24  shows the carrier at the third stage location in which the newly folded carrier is being moved to the card count detection stage; 
         FIG. 25  shows the card count stage in which the thickness of the loaded and folded carriers are measured at a plurality of locations to determine the number and correct location of the card or cards attached to the carrier; 
         FIG. 26  shows the folded carrier with attached card or cards being moved to the FIFO stacker module due to the uplifting actuation of the stacker gate; 
         FIG. 27  shows the card package passing the card stacker gate to move to a reject gate; 
         FIG. 28  shows the card package being moved past the reject gate to a card package outlet that is generally connected to an envelope stuffer (not shown); 
         FIG. 29  shows the card package being directed away from the primary card package outlet by a reject gate and, instead, being re-directed to a card package reject bin; 
         FIG. 30  is a side elevational view of one side of the “clam shell” card package distribution module of the card package production system of  FIG. 1  with parts broken away to show the rollers and integrated drive system, and also illustrating in broken line the pivotal open position in which card packages may be removed or jams may be cleared and maintenance be easily performed; 
         FIG. 31  is a side elevational view of another side of the “clam shell” card package distribution module of  FIG. 30  showing the intermeshing drive and driven gears in the hinged lower and upper module frames; 
         FIG. 32  is an enlarged perspective view of the side of the distribution module of  FIG. 31  providing a better view of the intermeshing gears and resilient mounting of the rollers; 
         FIG. 33  is an enlarged perspective view of either side of the distribution module of  FIGS. 30 and 32  showing the releasable fasteners used to hold the upper frame and the lower frame in closed operative engagement; 
         FIG. 34  is a front elevational view of the adhesive label attachment station at which the heat activated adhesive on one side of the adhesive label is attached to the back side of the card; 
         FIG. 35  is a side elevational, cross sectional view through section line  35 — 35  of  FIG. 34  showing the label attachment station with the label roll feed and backing paper take-up reels and the variable label tape drive used to drive both reels; 
         FIG. 36  is a cross sectional view of the counter member of  FIG. 35  that holding the card down while the adhesive label is being applied; 
         FIG. 37  is an enlarged side view of the label attachment station of  FIG. 35  with the label attachment finger in a position at which the heated label is first pressed against the card during the card attachment stroke; 
         FIG. 38  is an enlarged side view similar to that of  FIG. 35  but with the label attachment finger in another position at the end of a card attachment stroke after the label has been swiped onto the back of the card; 
         FIG. 39  is a perspective view of the pivotably and manually removably mounted, card counter member, or card retention member, preveiously shown in cross section in  FIG. 36  which holds the card down against the upward force of the label attachment finger during the card attachment stroke; 
         FIG. 40  is a perspective view of the label attachment station showing the manner of manual removal of the card retention member of  FIG. 39 , and with a portion broken away to show the heating platen with offsets on the sides that are spaced from the opposite ends of the label to create a heating “dead zone” on the opposite ends of the label to facilitate the removal of the label from the card after attachment; 
         FIG. 41  is a perspective view of a card sled section of the card transport mechanism, or card track, that moves the card with the attached label to a card drop position at which the card is dropped onto the matching carrier; 
         FIG. 42  is a perspective view of an end of the card track with a card reject bin to receive cards that have been rejected and have not been dropped onto a carrier at the card drop position; 
         FIG. 43  is a perspective view of the FIFO card package stacker that stacks the completed card packages in which newly completed card packages are inserted at the bottom of a stack of completed card packages and earlier completed card packages are located at higher positions on the stack, with a stack pusher being in a first position awaiting the card package to be laterally inserted into a loading position beneath a stack inlet opening; 
         FIG. 44  is a perspective view similar to that of  FIG. 43  but with the stack pusher in a relatively elevated position to push the card package through the inlet opening and past the underlying resilient; 
         FIG. 45  is a an enlarged perspective view showing the drive linkage for the stack pusher; 
         FIG. 46  is a schematic side view of the card transport track from the card track inlet to the card reject bin; 
         FIG. 47  is a schematic illustration showing the relative locations of the sensors and drive motors associated with the card transport path; 
         FIG. 48  is a schematic side view of the entire carrier transport path and from the inlet to the card folding station; 
         FIG. 49  is a schematic illustration showing the relative locations of the carrier sensors and carrier transport drive motors of the carrier transport of path of  FIG. 48 ; 
         FIGS. 50A and 50B  are elevational views of the control module arrays composed of a controller board, a brain board and a plurality of control modules used to control the system that is made by OPTO 22 described more fully below; 
         FIG. 50C  is a chart showing all of the connections of the control modules of FIG.  50 A and  FIG. 50B  to the various sensors and motors that make up the control system; 
         FIGS. 51-60B  are all special programming flow charts of the controller made pursuant to the protocols and procedures specified by OPTOCONTROL to operate the control module, controller board and brain board of the controller of  FIGS. 50A ,  50 B and  50 C; 
         FIG. 51  is a flow chart of the power up routine of the preferred embodiment; 
         FIGS. 52A , B, and C. is a flow chart of the interrupt routine of the preferred embodiment; 
         FIG. 53  is a flow chart of the card label routine of the preferred embodiment; 
         FIG. 54  is a flow chart of the card push routine of the preferred embodiment; 
         FIG. 55  is a flow chart of the form feed C routine of the preferred embodiment; 
         FIG. 56  is a flow chart of the form feed D routine of the preferred embodiment; 
         FIG. 57  is a flow chart of the heater routine of the preferred embodiment; 
         FIG. 58  is a flow chart of the card picker mechanism Routine of the preferred embodiment; 
         FIGS. 59A and B  is a flow chart of the card position routine of the preferred embodiment; and 
         FIG. 60  is a generic flow chart illustrating the operation for sensing the numbers of cards in each card package and rejecting card packages if the correct number of cards preselected for each designated location are not present in the carrier. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIG. 1 , the preferred embodiment of the card package production system printer  100  of the present invention is seen to include a free standing printer module  102  and a card attachment module  104 . Referring to  FIG. 2 , the printer module prints card holder name and address and other account information  106 , on one of three panels  108 ,  110  and  112  of a paper sheet carrier  113 , such as the middle panel  110 . The three panels are defined by two pre-weakened fold-lines  114  and  116 . The printer module also prints a bar code  120  representative of information concerning the account on another of the panels, such as the end panel  112 , such as the account number and the number of cards that are to be attached to the carrier  113 . The printer module is controlled by a computer (not shown)and controller, described below. The printer preferably prints carriers at a minimum speed of 32/minute and has a resolution of no less than 300 dpi×300 dpi. The normal speed of operation is approximately 2000 carriers per hour, or approximately thirty-three carriers per minute. The printer module  102  is preferably a model PLAY PLEX printer made by OLYMPUS, or equivalent. The details of the printer module form no part of the present invention but reference may be made to operator&#39;s guide for the above identified model MS32NSS published by OLYMPUS. 
     The operation is described pursuant to the example of the card holder information  106  being located on panel  108  and the bar code  120  being mounted at the location shown on panel  112 . However, the PRINTER is capable of printing both the card holder information  106  and the bar code information  120  at other selected locations on the carrier  113 . The card attachment module  104  is capable of reading the information at other informational locations on the carrier  113  than the example shown in FIG.  2 . The printed carriers  113  from the printing module  102  are passed to the attachment module  104  by means of an inter-module carrier guide  122 . The inter-module carrier guide is better seen in  FIG. 7 , and is described in detail with reference to  FIGS. 8-10 . Referring to  FIGS. 6 and 7 , the guide  122  passes carriers  113  from an outlet  124  of the carrier printer module  102  to a carrier inlet  126  of the attachment module  104 . 
     Referring again to  FIGS. 1 and 2 , the attachment module takes cards from a stack of pre-embossed cards  128 ′ from a card picker assembly  140  and attaches cards  128 , such as embossed and/or magnetically encoded credit cards, encoded chip cards, R/F cards, etc. to the carrier  113  at one or more locations  130  and  132  or on like locations on one or more or all of the three panels. It then folds the carrier, as shown in  FIG. 3 , to form a card package  115 . 
     The details of the card picker assembly forms no part of the present invention, and preferably is substantially the same as the one shown in U.S. patent application of Bretl et al., Ser. No. 09/081,312, filed May 19, 1998, and entitled “Card package Production System With a Multireader Card Track and Method”, which is hereby incorporated by reference. 
     The cards  128  generally have an account number and an account holder&#39;s name embossed on the card and the same information encoded on a magnetic stripe on the back of the card  128 . Additional information, such as the number of cards to be attached to the carrier may also be contained in the bar code. In addition, the back of the card has the account number and account name encoded in bar code printed on the back of the card. This information is checked for proper encoding and if the coding is not correct or if the coding does not match the encoded information of a carrier to which it is to be attached, the card  128  is passed through the attachment module  104  to a card reject bin  134 . 
     Other wise the cards  128  are attached to the matching carrier  113  to form the card package  115 , and the card packages  115  are passed to a card package distribution module  136  for distribution in three different ways depending upon circumstances. In one case, if the card packages  115  are unacceptable due to having too many cards, not enough cards or cards in the wrong location, then they are passed to a card package reject bin  142 . If the card package is correctly prepared and is to be passed directly to an envelope stuffing machine (not shown), such as a model SERIES 5 envelope stuffer made by PITNEY BOEWES, then the card packages are passed directly to the envelope stuffer through a primary card package outlet  144 . Otherwise, the card package  115  is passed to a FIFO card package stacker  146  to form a stack of card packages  115 ′. 
     Referring to  FIGS. 3 and 4 , the card  128  is attached to the carrier  113  by means of an adhesive label  148 . One side of the adhesive label  148  is attached to the card by a heat activated adhesive, such as releasable adhesive made by MAPLE ROLL, a division of ITW. The other side of the label is attached to the carrier by means of a permanent adhesive. The labels are adhered to a roll of backing paper tape by the permanent adhesive. Preferably, the adhesive labels  148  are those made by MAPLE ROLL note above, or the like. 
     As illustrated in  FIG. 4 , when the card  128  is lifted off the carrier  113 , the adhesive label  148  remains attached to the carrier  113  and does not adhere to back  128 ′ of the card  128 . This is because the attraction of the permanent adhesive to the carrier  113  is stronger than the bond between the heat activated adhesive and the back of the card and, because in keeping with one aspect of the invention only a middle section of the label is heat activated to provide a “dead zone” of nonactivated adhesive at opposite ends of the label  148 . Advantageously, once the heat activated label  148  is removed from the back  128 ′ of the card  128 , the heat activated adhesive losses its adhesive qualities unless it is again heated to the necessary minimum activation temperature of approximately 160-degrees Farenheit. 
     Turning now to  FIG. 5 , the housing has a flat top on which a computer display monitor  152  and a computer keyboard  154  of the computer (not shown) are supported. The computer is protectively contained within the housing section  161 . The computer housing section  161  has a hinged door to enable access to the computer. Preferably, the computer that is used to control the card package production system  100  including the attachment module  104  is a model PRESARIO computer made by COMPAQ having a minimum processor speed of 333 MHZ and a minimum hard drive memory capacity of 4 GB, or the like. The computer controls all of the automatic operations of the attachment module  104  and the printer module  102 , in accordance with the flow charts of  FIGS. 50-60B  and  61 . 
     The card attachment module  104  also has a hinged housing section  156  with an upper housing portion  156 ′ that may be elevated for access to the carrier and card transport paths. Both housing sections  104  and  156  are supported on a lower housing section  158  that has a storage space  161 . In keeping with one aspect of the invention, the card distribution module  136  which extends in cantilever fashion from the housing frame (not shown) in front of the upper portion  156 ′ of the tracks housing  156 , but does not interfere with the opening of the upper housing portion  156 ′. It is mounted to the frame by means of two elongate bars  160  and  162  that are received within mating bar receptors described below to facilitate easy removal and attachment to facilitate shipping of the distribution module. During shipping of the distribution module  136 , the distribution module  136  is detached from the main frame of the attachment module  104  and is inserted into the storage space  161 . Upon safe arrival at the customer&#39;s site it is easily securely reattached to the housing and in proper alignment due to the two mounting bars  160  and  162  and mounting bar receptors. 
     Referring to  FIG. 7  again, the inter-module guide  122  is aligned with a carrier transport path  164  that extends straight from the carrier inlet  126  toward the card package distribution module  136 . However before the carrier reaches the card package distribution module  136 , it intersects at a right angle with the card transport path  166  that extends from the card tray  140  to an intersection  168  with the carrier transport path  164 . At the intersection  168  card attachment station attaches the card or cards  128  to the carriers. The carriers with attached cards are then folded at a folding station to form card packages  115 . The card packages  115  then move along a card package transport path  170  to the card package distribution module and distributed according to the circumstances note above. The card transport path is elevated relative to the carrier transport path and the cards are dropped onto the carriers for attachment. If rejected and not attached, they proceed past the card attachment station along a card reject transport path  172  to the card reject bin  134 . 
     Referring to  FIG. 6 , it is seen that the printer module  102  is kept in proper alignment with the attachment module by means of a generally triangular brace member  174  fixedly attached to a printer stand  176  of the printer module  102  and at one end. The opposite end is attached to a back wall  178  of a housing portion  158 ′ beneath the track housing  158 . The attachment to the back wall  178  is by way of a universal joint with two orthogonal pivot axis defined by locking serews  180  and horizontal pin  182 . This universal connection joint facilitates interconnection of the two modules despite slight misalignments of the modules in any direction. 
     Still referring to  FIG. 6 , the carrier transport path is seen to include a carrier inlet station with carrier inlet rollers  184 , and intermediate station with carrier intermediate rollers  186  and a card attachment rollers  188  at the card attachment station  190  at the intersection  168  of the card carrier transport path  164  and the card path  164 , as seen here and in FIG.  7 . Following the card attachment station is the carrier folding station  192 , and then the card packages are passed to a card package inlet of the card package distribution module  136 . 
     Referring now to FIGS.  8 , 9  and  10 , the inter-module carrier guide, or guide assembly,  122  includes a lower guide body  194  with a generally flat, rectangular, underlying support member  196  extending from the carrier inlet  126  of the attachment module  104  to the outlet end of the printer module  102 . Generally right triangularly shaped, parallel guide walls  198  and  199 , located at a pair of opposite sides of the underlying support member  196 , keep the carriers from moving laterally off of the support member  196  and insures that the carriers straightly enter the attachment carrier inlet. An upper guide body  200  overlying the support member  196  is pivotally mounted to the guide walls  198  and  199  at a pivot axis  202  by means of a suitable hinge pins, and has a cover plate  204  that spans the space between the parallel guide walls  198  and  199 . Restraint members  206  and  207  extend downwardly from the cover plate  204  between and respectively adjacent to the guide walls  198  and  199 . The bottom edges of the restraint members  206  restrains carriers  113  at their opposite sides against upward movement above the top edge or level of the guide walls  198  and  199  which would result in loss of lateral restraint. In addition, the upper guide body also restrains the carriers  113  against vertical movement to positions out of vertical alignment with the attachment module carrier inlet  126 . A curled forward edge  208  of the cover plate  204  is supported atop the walls  198  and  199 . 
     At least one release opening  210  to allow moisture contained within the paper carriers to escape to atmosphere prior to entry into the attachment module. This minimum ventilation has been empirically determined necessary to prevent condensation water from forming within the attachment module adjacent the inlet station. 
     The condensation is believed to occur when some of the moisture in carrier paper heated from the heat sources and inside the printer, including the light sources used to print onto the carriers, first evaporates. Then as the carrier is passed though cooler air and past the relatively cooler surfaces adjacent the carrier inlet opening of the attachment module  104  the evaporated moisture condenses out onto the cooler surfaces. While the moisture from only one carrier is not significant, when approximately two thousand carriers per hour are passed into the carrier inlet the inlet area becomes wet in the absence of the release opening. 
     Preferably, there are a plurality of substantially identical, elongate release openings  210  extending in a direction generally parallel to the sidewalls  198  and  199 . The eight release openings  210  are generally evenly distributed across the width of the support member  196  and extend a substantial the entire length of the cover plate  204 . 
     Thus, it is seen that in an attachment module of a card package production system being fed carriers from a carrier printer module, a method of reducing the formation of condensation in the attachment module from moisture evaporating from the carriers is provided. This method comprises the steps of (1)providing underlying support for the carriers from an outlet of the printer to an inlet of the card attachment module by means of a lower guide body with a generally flat, rectangular support member extending between the printer, (2) restraining the carriers to remain on the support member with a pair of parallel guide walls carried by the support member, (3) restraining the carriers to remain between the guide walls with an upper guide body having at least one release opening, and (4) passing moisture evaporated from the carrier paper through the at least one release opening to atmosphere before the carrier enters the attachment module. 
     Because the release openings are elongate in a direction generally parallel to the sidewalls, the moisture is passed through the elongate opening substantially along the entire guide body. 
     Snagging of the carriers by the forward edge of the release openings is reduced by the step of providing the upwardly recessed portion  216 ′ of the bottom surface  216 . 
     Because there are a plurality of substantially identical release opening distributed generally equally across the support member the step of passing moisture is performed generally evenly across substantially an entire width dimension of the carrier while the carrier is crossing from the printer module to the attachment module. 
     Referring to  FIG. 10 , each of the elongate release openings  210  has a forward edge  212  closest to the carrier inlet  126  that is arcuate. The support member  196  has a top surface  214  and a bottom surface  216 . Apportion  216 ′ of the bottom surface  216  adjacent the forward edge  212  of the elongate opening  210  is recessed upwardly toward the top surface  214 . This recessed portion  216 ′ reduces snagging of the carriers  113  by the forward edge  212  of the release opening  210 . The arcuate shape of the recessed portion  216 ′ is generally concentric with and generally conforms in shape arcuate shape of the forward edge  212 . Adjustable legs  214 ,  FIG. 6 , provide the means for mounting the underlying support member  196  in alignment with the carrier inlet  126  of the attachment module  104 . 
     Referring to  FIGS. 11-14 , another advantageous feature of the invention is provision of a carrier transport path with an anti-jamming carrier transport mechanism. The carrier transport path  164  has a carrier inlet station  218 , followed by an intermediate, standby station  220  which, in turn, is followed by a card attachment station  222 . These stations have underlying carrier support members  224 ,  226  and  228  as best seen in FIG.  12 . The forward, or upstream, edges of carrier support members  224  and  226  are elevated relative to the downstream edges of carrier support members  226  and  228 , respectively, at junctures  225  and  227 , as best seen in FIG.  13 . Accordingly, should a carrier still be in a position resting on support members  224  and  226 , another carrier may be still passed into the standby station  220  and the card insertion station  222  without jamming into the end of the preceding carrier and thereby causing a jam. Instead, referring to  FIG. 14 , because of the relative differences in elevation at  225  and  227 , a carrier  113 A may be passed from the inlet station  126  into overlying relationship with respect to the downstream end of the carrier  113 B which is already at the intermediate standby station  220 , as illustrated in FIG.  14 . Likewise, if the carrier  113 B enters into the card attachment station while another carrier  113 C is still at the card attachment station, the carrier  113 B will pass over the top of the carrier  113 C instead of jamming into the lagging end of the carrier  113 C. This anti-jamming feature can be used to increase the rate of carrier throughput rate down the carrier path. However, under normal speed operation only the carrier  113 A will overlap the carrier  113 B only when an incorrectly prepared card package  115  is detected and the printer passes one more carrier  113  to the carrier inlet  126  after the carrier transport mechanism has been stopped and the printer given a stop command. 
     Referring to  FIGS. 11 and 12 , the intermediate standby station  220  and the card attachment station  222  have movably mounted carrier restraint assemblies  230  and  232 , respectively. Carrier restrain assembly  230  is mounted for pivotal movement about a pivot axis  234 , and carrier restraint assembly  232  is pivotally mounted for rotation about an axis  236  by a suitable hinge assembly. Each of the carrier restraint assemblies  230  and  232  has a pair of parallel, elongate, vertical restraint members, such as vertical restraint members  230 A and  230 B of restraint member  230  which are fastened together by a protective cover plate  238 . The restraint members are thus mounted for pivotal movement between an operative, down position in which they disposed generally parallel to the carrier transport path and slightly above it to prevent the carriers from rising off the path, and an inoperative position. In the inoperative position, as shown in broken line in  FIG. 12 , the restraint assemblies are pivoted up and away from the carrier transport path  164  to enable manual access to the carrier path  164  for maintenance and for manually removing carrier forms  113  from the carrier transport path. The protective carrier plate, such as cover plate.  238 , is made of substantially transparent plastic to enable viewing of the carriers  113  moving along the carrier transport path  164 . 
     When in the operative position, the parallel arms, such as arms  230 A and  230 B are held in operative position by a generally C-shaped resilient snap fasteners  240  at the ends of the arms opposite the pivotal connection. The resilient snap fasteners  240  of the restraint assembly  230  releasably lock the ends of the arms  230 A and  230 B to the axle of an upper roller  242 A of an intermediate roller assembly  242 , and resilient snap fasteners  241  at the ends of arms  232 A and  232 B are resiliently locked to mating posts  244  fixedly mounted at opposite sides of the carrier transport path  164 . The snap fasteners enable the carrier restraint assemblies to be moved into and out of the operative positions without the need for any tools. 
     Another feature of the present invention is the provision of a bar code reader  246  that is mounted to the carrier restraint assembly  232  and moves with the restraint assembly  232  when pivoted to the inoperative position. Unlike most bar code readers that employ a laser light source which could scan over and damage a person&#39;s eye when being moved to different positions with the restraint member  232 . However, in the present invention a non-laser light source is employed in the bar code reader  246  to read bar code  120  from carriers  113  passing by the restraint member  132 . When the restraint assembly  132  is in an operative, down position the bar code  120  can be read and the bar code reader  246  is operative. When the restraint assembly  132  is moved to the inoperative position then the bar code  120  cannot be read and the bar code reader  246  is in an inoperative position. The use of a non-laser light source eliminates any risk of laser beams striking a person&#39;s eye during movement of the bar code reader  246  between the operative and inoperative positions and thus enable such movable mounting. Preferably, the bar code reader  246  is a model BL185 bar code reader made by KEYENCE. 
     As best seen in  FIG. 11 , the bar code reader  246  is adjustably mounted to the restraint assembly  232  by means of a mounting member  248  with an elongate slot  250  and fasteners  252  that are attached to the bar code reader  246  and ride within the slot  250 . The elongate slot  250  substantially spans the carrier path to enable reading of bar code at different locations on the carrier  113 . 
     As seen in  FIG. 11 , the intermediate station also has a pair of parallel, lateral guide walls  231  and  233  on opposite sides of the carrier path to keep them moving in a direction parallel to the carrier transport path  164  and normal to the elongate directions of the rollers. The entry ends have canted, or funnel, portions  239  and  241  that are farther apart than the remaining interior portion of the guide walls  231  and  233  and wider than the carriers  113  at their open ends and then taper inwardly to insure receipt of the carriers  113  within the opening between the funnel portions. Advantageously, the separation between the lateral guide walls  231  and  233  is easily adjustable to accommodate carrier of different size by means of manual movement of a simple lever  241 ,  FIG. 15 , between two different positions. 
     Referring to  FIGS. 15 ,  16  and  17 , the manually actuatable lever  243  is mounted for pivotal movement between two positions respectively associated with two different carrier widths: standard U.S. letter width and European A4 width. When the lever is in the forward position as shown in  FIG. 15 , the guide walls are located relatively far apart to accommodate standard U.S. letter size carriers and when the lever  243  is moved to an a rearward position, as shown in  FIG. 16 , then the lateral guide walls  231  and  233  are moved through a linkage with the lever  243  to move the guide walls nearer to each other to accommodate A4 size carriers. The linkage advantageously maintains the walls in generally parallel relationship while they are being moved. The walls are respectively carried at the opposite sides of two separate plates  245  and  247  that are mounted for movement toward and away from each other in response to actuation of the lever  243 . The plates  245  and  247  are separated across their width and also along their length at edges  245 ′ and  247 ′ at two junctures  249  and  251 . As best seen in  FIG. 17 , the edges have arcuate slots  253  and  255 . A pair of cylindrical pins  257  and  259  are carried by a pin holder  261  with an axle  263 . The passes through a central mounting hole  265  of fixedly mounted support member  267  and into locked engagement within a mounting hole in a lever connector  269 . The drive pins  257  and  259  that also mounted within mounting hole in the top of the pin holder  261  also extend through arcuate pin guide slots  271  and  273  and into the slots  253  and  255 , respectively, on opposite sides of the axle mounting hole  265 . When the lever connector  269  is rotated by movement of the lever  243 , the axle is rotated which causes the pins  257  and  259  to rotate. When the pins are rotated in one direction the plates edges  245 ′ and  247 ′ of the plates are slid closer together and when the pins are rotated to another position that is normal to the one position then the plates are moved to their closest position. 
     In addition to adjusting for the widths of different types of carrier, the card package production system also has means for adjusting for the different lengths of the carriers  113 . Referring again to  FIG. 21 , the fixed folding wall  254  has a stop  254 ′ at the top and a stop mounting bracket with adjustment screws and slots for mounting the stop  254 ′ at different levels, as shown in broken line. Likewise, Referring to  FIG. 24 , the end  259 ′ of the pivotal folding wall  259  is likewise adjustable in the same manner to different positions as shown in broken line. 
     Referring to  FIG. 12 , another advantageous feature of the invention is that the card attachment station  190  has a set of rollers  253  that are controlled to reverse direction after a card  128  with a heat activated label  148  has been dropped onto the carrier  113 . The rollers  252  first rotate in one direction to move the selected portion of the carrier  113  to the card drop location. The card  128  with an adhesive label attached  148  is then dropped onto the portion of the carrier that is resting on the upwardly slanted carrier support  254  on the upstream side of the set of rollers  252 . After the card is dropped onto the carrier  113 , the card  128  slides down the slanted carrier at the slanted carrier support  254  and against the upstream one of the set of rollers  252 . Then the rollers  252  are controlled to reverse direction to partially pass the carrier  113  with the card  128  on the carrier in a downstream direction back past and between the set of rollers  252 . The set of rollers  252  then press the permanent, pressure sensitive adhesive on the label attached to the card and the card  128  against the carrier  113  to adhere the card  128  to the carrier  113 . After the card  128  has been adhered to the carrier  113  during this reverse rotation of the rollers  252 , the rollers  252  are controlled to again reverse direction move the carrier with the adhered card in the upstream direction toward the folding station  192 . 
     This sequence of events is schematically illustrated in the sequence of drawing  FIGS. 18-22 . In  FIG. 18 , the carrier  113  is seen approaching the set of rollers  252 . In  FIG. 19 , the carrier  113  pauses in the correct position for receipt of the card  128  on the middle panel, for example. In fact, the carrier may be positioned for receipt of cards at any of the three panels. In such case the cards are attached to the different panels at different time with the panels moving successively into position to receive the cards and then backing up each time to press the cards against the carriers. The card attachment station has a plurality of different lateral positions from which the card can be dropped, and the controller controls the card attachment station to drop the card at a preselected one of the plurality of different lateral positions. The card attachment station includes means for dropping a plurality of cards onto a plurality of different preselected card attachment positions on a single carrier, and if multiple cards are to be attached to the carrier  113  then the carrier is held in the correct position to receive all of the cards before the carrier is backed through the set of rollers  252  so that all cards are pressed against the carrier simultaneously. 
     In  FIG. 20 , the card  128  has dropped onto the carrier  113  and slid down to a position with an edge held between the nib of the upstream roller and the carrier  113 . In  FIG. 21 , the set of rollers  252  is reversed and the carrier is partially backed through the set of rollers  252  to press the card  128  against the carrier  113 . In  FIG. 22 , the set of rollers have again reversed direction to pass the carrier with adhesively attached card to the folding station  192 . 
     Advantageously, the bottom one of the set of rollers  252  is mounted for resilient self-adjustment to accommodate different thickness of carriers without attached cards and carriers with different number of attached cards. The axle to which the lower roller is mounted is mounted in a slot and is spring biased in an upward direction in a manner that will be illustrated with reference to other resiliently movably mounted rollers of the card package distribution module  136 . 
     The card package distribution module  136 , as previously note, has a card package reject bin  142  to which card packages are passed that have too many cards, too few cards or cards in an incorrect location. Referring to  FIGS. 25 , this determination is made by measuring the thickness of the card packages after they have been produced at the folding station  192 . 
     The folding begins when the forward edge of the card is pressed against a stop member  254  at the top of a folding wall  256 , schematically shown in  FIG. 22 , and also seen in FIG.  12 . After hitting the stop member, continuing forward movement caused by forward rotation of the set of rollers  252  causes the carrier  113  to buckle at fold line  116 . The fold line  116  is then pushed into engagement with another set of rollers  258 , seen in  FIGS. 22 and 23 . Referring to  FIG. 23  the leading edge of the partially folded carrier is then pushed into a V-shaped, pivotally mounted folding wall  259 , and the carrier  113  is folded along fold line  114 . referring to  FIG. 24 , the panels on opposite sides of the fold line  114  are then pushed into the nib of a pair of rollers  260 . This causes the entire carrier to pivot upwardly whiles still contained within the V-shaped folding wall  262  and to then pass entirely through the rollers  260  to card package input rollers of the  262 , as schematically illustrated in FIG.  25 . 
     Referring to  FIG. 25 , between the outlet rollers  260  of the folding station and the intake rollers  262  of the distribution module  136 , a defective carrier detector  264  located along the primary carrier transport path  164  detects defective card packages  115 . The determination of whether a card package is defective is made by measuring the thickness of the card package at a plurality of locations across the carrier  113 . This measurement is made with a plurality of substantially identical linear potentiometers  266 , each of which is linked through a resiliently biased, bent, elbow-shaped lever  268 . The bent lever  268  is mounted for pivotal movement about a pivot axis  269  and is resiliently biased by a spring (not shown) of the linear potentiometer to pivot against and ride on top of the carrier packages  115  as they pass. A roller  270  is attached at the end of a relatively short arm  272  extending from the pivot axis  269  that resiliently presses against the carrier packages  115 . Another relatively longer arm  274 , approximately twice as long as the relatively short arm  272 , is attached to a plunger  276  of the linear potentiometer  266 . When the roller moves up a given distance the end of the long arm  274  and the plunger  276  moves approximately twice the distance for an enhanced resolution factor of approximately 2:1. 
     The movement of the plunger creates different levels of voltage output signals of the potentiometer  266  that are translated by the controller and compared to the thickness that the card package  115  under consideration should have if it has the correct number of cards  128  that have be preselected for the particular carrier  113 . The linear potentiometer  264  is preferably one made by BOURNS. 
     If the card package  115  has the correct number and locations of cards  128  that have been pre-designated for the carrier  113  in question, then depending upon other pre-selections for the card package  115 , it is passed to either the primary card package outlet  144 ,  FIG. 1 , as shown in  FIG. 28 , or is diverted to a card stacker location as shown in FIG.  26 . However, if correctness is not the case, then the card package  115  is passed to the card package reject bin  142 , as shown in  FIG. 29. A  simplified flow chart for control of the reject gate is shown in  FIG. 61  to which reference should be made. 
     Referring to  FIG. 26 , if the card package has been selected for stacking and is not to be rejected, then after thickness measurement by the linear potentiometer  266 , the card package is passed through another set of rollers  278  to a stacker gate assembly  280  which is moved to a stacker position as shown. The stacker gate assembly  280  has a gate  282  that engages the bottom of the carrier package  115  to direct the card package upwardly into a pair of stacker rollers  284  when in the uplifting stacking position shown. The gate is pivotally mounted to a linkage  286  that, in turn, is connected through another pivotal linkage  288  to a rotatable arm  290  of a rotary solenoid  292 . When this stacker gate solenoid  292  is energized by the controller, the arm  290  rotates in the direction of arrow  294  to the stacking position shown in FIG.  26 . 
     Referring to  FIG. 27 , if the stacker solenoid  292  is not energized, then the stacker gate  282  is moved to a generally horizontal position to direct the card package to another set of rollers  296  and through a guide  298  to yet another pair of rollers  300 . After entering the pair of rollers  300 , the card package is either allowed to continue on a primary card package transport path past a reject gate  302  to the primary card package outlet  144  for passage to an envelope stuffing machine (not shown), as illustrated in  FIG. 28 , if not detected to be a reject, or the reject gate  302  is actuated to redirect the card package to the card package reject bin  142  primary output  144 , as shown in  FIG. 29 , if the card package is to be rejected. Actuation of the solenoid is achieved by means of a rotary solenoid  304  connected directly to the reject gate  302  by an arm  306 . both solenoids  292  and  304  are preferably solendoids made by LUCAS LEDEX. The stacker gate solenoid is Model No. 810-282-530 and the reject gate solenoid is Model. No. H-1146-033. Referring to  FIGS. 30 and 31  another advantageous feature of the card package distribution module is that has a foldable “claim shell” configuration to enable easy access to the internal workings of the distribution module  136  previously describe with reference to  FIGS. 26-29 . The distribution module  136  has a base distribution module frame  308  and a top distribution module frame  310 . A hinge  312  interconnects the base distribution module frame  308  and the top distribution module frame  310  for relative pivotal movement. The relative pivotal movement is between an open position for access to the interior of foldable distribution module  136  between the base distribution module frame  308  and the top distribution module frame  310 , as shown in broken line in  FIGS. 30 and 31 , and a closed, operative position in which the internal workings are protected between the top frame  310  and the bottom frame  308 , as shown in solid line in  FIGS. 30 and 31 . 
     Referring to  FIG. 30 , the base module frame  308  contains the bottom rollers of the roller sets  278 ,  296  and  300  one transport roller for engagement with and transport of the carrier while the top distribution frame  310  mounts the mating upper rollers of the roller sets  278 ,  296  and  300 . When the top distribution frame  310  is closed on top of the base distribution frame  308 , the mating rollers of the roller sets are moved into operative interrelationship with one another, but when the top frame  310  is moved to the open position shown in broken line then they are completely separated and any card packages previously held between the upper and lower rollers may be easily accessed and removed. 
     As best seen in  FIG. 32 , this is achieved in part by mounting each of the opposite ends of the axles of the top rollers of the roller sets, such as roller set  300 , to a male axle mount  314  that has a rectangular cross section and is mounted for sliding movement toward and away from the bottom roller of the roller set within a slot  316  within in the side of the upper frame  310 . The axle mount  314  is spring biased toward the bottom roller by means of a coil spring  318  that is stretched over the top of the axle mount protruding through the slot  316  from the top frame  310  and anchored to posts  320  on opposite sides of the mounting slot  316 . This resilient mounting of the upper rollers causes the upper rollers to self adjust into operative relationship with the lower rollers when the two halve of the “clam shell” are brought together and to adjust for card packages of different thickness. 
     Still referring to  FIGS. 31 and 32 , the “clam shell” design is also made possible by means of arranging a drive gear  322  mounted the base distribution frame  308  and powered by a motor  324  and a pulley linkage  326 ,  FIG. 30 , both of which are mounted within the base distribution frame  308  to mesh with a driven gear  328  mounted within the top distribution frame  308 . The driven gear  328  is linked to another gear  330  that, in turn, drives the bottom roller of the stacker roller set  284  to move card packages into the stacker loading position. Thus, the upper frame neither requires its own motor or wiring connection for a motor and the upper and lower rollers automatically self-adjust so no manual adjustments are needed after the distribution module is opened and again closed. 
     Still referring to  FIG. 32 , the upper distribution frame also carries a photosensor  332  for sensing the card package  115  when it is opposite the sensor. The photosensor  332  is mounted for movement within a slot to two different positions associated with sensing card packages using standard 8-½″×11″ sized carriers  113  or carriers of A4 size which is slightly narrower and slightly longer. 
     Also, seen in  FIG. 32 , is an adjustment mechanism  334  for adjusting the bypass level of the stacker gate  282 . The stacker gate pivots with a rotating axle  336 , and blocking adjustment screw  338  engages a mating radial arm  340  extending from the axle  336  to prevent the axle  336  from further rotation. The blocking screw is threaded into a mounting tab  342  to enable threaded adjustment of the level at which the blocking adjustment screw  338  engages the mating radial arm  340 . 
     The distribution module also has a pair of substantially identical, releasable lock assemblies on opposite sides of the distribution module, such as lock assembly  344 ,  FIG. 32 , that releasably hold the upper frame  310  lateral movement relative to the lower frame  308 . Referring to  FIG. 33 , the distribution module lock assembly  344  has a male lock member  346  with a tapered end  347 . The male lock member is threaded into a bore in the bottom end of the upper frame side wall to allow for vertical adjustment. The tapered end  347  is aligned with and received within a mating female lock receptor slot  348  in a U-shaped cross member  350  whenever the upper and base frames are closed together in operative relationship. The cross member  350  spans a slot  352  in the upper end of the base frame side wall. Screws  354  secure the ends of the cross member  350  to the top of the side wall, and cutouts  356  provide space for the mounting screws  354 . 
     Referring to  FIG. 30 , the mounting bars  160  of  FIG. 6  that enable easy removal of the card package distribution module  136  plural, have a generally rectangular cross section and are fixedly attached to the underside by means of an L-shaped mounting bracket  358  with one leg bolted to the underside of the base distribution frame  308  by bolts  360 . The other leg extends vertically downwardly and is attached to one end of the mounting bar  160  by means of four other bolts  362 . The protruding end of the bar  160  has a beveled end  160 ′ to facilitate insertion into a mating mounting bar receptor  364  fixedly attached to the main frame of the attachment module  104 . The receptor  364  has a rectangular tubular body for providing snug support in all direction for the mounting bar. A pair of bolts  366  extending cross ways to the elongate directions of the mounting bar  160  and the mounting bar receptor  364  hold them together. They extend through bolt holes in the bottom wall of the mounting bar receptor  364  and are threaded into aligned threaded bores in the mounting bar  160  to releasably hold the mounting bar  160  against sliding removal from within the mounting bar receptors  364 . The mounting bar  160  is preferably made of machine finished aluminum bar stock and has a rectangular cross section with dimensions of 1″×3″. 
     Referring to  FIGS. 34 ,  35  and  36  the label attachment station  358  heats and then attaches the heat activated adhesive side to each of the cards  128  prior to dropping the card onto the carrier  113 . The double adhesive sided labels  148  are adhered to a roll  360  of backing paper  362  by pressure sensitive permanent adhesive. The outwardly facing side of the labels bear a coating of heat activated adhesive that is used to attach the labels to the cards  128 . The adherence of the heat activated label  148  to the card  128  is stronger than the adherence of the other side of the label to the backing paper, and once the label is attached to the card movement of the card away from the backing paper removes the label from the backing paper. After the label is attached to the card, the card is passed to the card drop location for attachment to the carrier as explained above. 
     Referring to  FIG. 35 , the full roll  360  is mounted for rotation within a roller caddie  364  and passes around a roller  366  and over the label pressing member  372 . A heating element  373  at the underside of the pressing member heats at least two labels to activate the heat activated adhesive on the label immediately before being pressed onto the card. Importantly, as seen in  FIG. 40 , the heating platen  361  over which the labels travel have offsets  363  on opposite sides at which the labels are not heating leaving adhesive “dead zones”  365  on opposite sides of the label at which the adhesive is not activated and will not adhere to the card. It has been determined that these dead zones facilitate removal of the label from the card. As seen in  FIG. 40 , the labels are heated through the backing paper  362 . The pressing member  372  presses the heated adhesive label against a card  113  at the attachment position by pressing against a side of the backing paper opposite the heated adhesive label and opposite the heat activated adhesive. 
     A removably mounted, pivotal, counter member  375  holds the card down against upward pressure from the pressing member  372 , as shown in  FIG. 36. A  photosensor  367  senses the presence of labels between the roller  366  and the roller  368 . 
     After the label has been attached to the card the backing paper alone is routed over a roller  374  and a driven roller  376  and wrapped around a driven take-up reel  378 . The roller  376  is driven by a drive roller  380  powered by an electrical drive motor  382 . The backing paper tape is squeezed between the drive roller  380  and the driven roller  376  and is driven toward the take up reel  378 . At the same time a pulley  384  connected between the driven roller  376  and the take up reel  378  rotates the take up reel  378 . The pulley  384  has a smooth circular cross section that facilitates clutch-like slippage when the roller  376  and the reel  378  rotate at different speeds due to the increasing diameter of the roll of spent backing tape on the take up reel  378 . 
     Also, importantly, the  361  has a length sufficient to heat two labels  148 , simultaneously. It has been determined that the additional heating time is needed to insure good activation of the heat activated adhesive. 
     Referring now to  FIGS. 37 and 38 , it is seen that the movement of the pusher member is not merely pushing but is pushing while sliding across the surface, i.e. the adhesive label is swiped onto the card with the pusher member  372 . The pusher member  372  is pivotally mounted for rotation about a pivot axis  384  at the end of an arm  386 . Arm  386 , in turn, is mounted for pivotal movement about a pivot axis  388 . The arm  386  is also pivotally attached at a pivot axis  390  to one end of a drive link  392 . The other end of the drive link  392  is pivotally mounted to an eccentrically mounted post  394  on a rotating disc  396 . The rotating disc  396  has a central rotary axis  398 . The disc is driven by an electrical control motor. The pressing member  372  is spring biased toward counter-clockwise toward the card  113  by a leaf spring  400 . Accordingly, as the disc rotates from the position shown in  FIG. 37  to the position shown in  FIG. 38 , the end of the arm moves the pusher member across the label while the leaf spring  400  and pivotal connection of the pusher member allows the pusher member to pivot as necessary to slide along the surface of the back side of the tape and card. 
     Referring now to  FIGS. 39 and 40 , the counter member  375  is mounted for pivotal rocking movement to a post  402  that is removably received within a mounting bore  404  that passes through a front section  406  of the counter member  375  and communicates with the end of a horizontal slot  408 . This slot enables tool-less mounting and dismounting of the counter member  375  to the pivot post  402  with the bottom surface  410  in adjacent, counter-pressing relationship with the card  113  while still permitting a small amount of rocking motion. The counter member is attached by first laterally sliding it along the card track until the bore  404  is aligned with the pivot post  402  and then pushing it onto the post  402 . The rocking motion is needed to facilitate the movement of the top of the embossed card beneath the bottom surface  410 . The bottom surface is preferably TEFLON coated to minimize friction between the bottom surface  410  and the card  113 . Also, the card receiving end  412  is canted to guide the top surface of the card beneath the bottom surface  410  of the counter member. In addition, to accommodate the raised embossed alphanumeric letters (not shown) at the front of the card, the counter member  375  has upwardly extending slots  414 , as seen in  FIGS. 37 and 38 , that are aligned with the standard embossed character locations on the card  113 . 
     During application of the labels  148 , the platen  361  is maintained at an average temperature of no less than 200 degrees Farenheit and the labels are engaged with the platen for no less than 1000 milliseconds. The pressing member  372  presses the label against the card within no less than 500 milliseconds of the label leaving the heating platen and takes 500 milliseconds for one label swipe cycle. 
     Referring to  FIGS. 41 and 42 , the card transport path  166  includes a portion that is downstream of the label attachment module  358  referred to as the card shuttle  412 . The card shuttle  412  is mounted via a pulley mount  414  to a pulley  416  driven by a shuttle pulley motor, FIG.  47 . At the beginning of each card shuttle cycle, the card shuttle is located against a wall  418  at a shuttle home position and awaits receipt of a card  128 . The presence of the shuttle at this home position is sensed by a photosensor  494 ,  FIG. 47 , when a sensor tab  417  is received within a mating slotted member  419  at the wall  418 . The card  128  is pushed along the card track  166  by a card pusher  420  and at the same time read with readers of various types and compared to data to make sure the card is the correct card for the carrier. The details of how this pusher is moved, the part of the card track  166  down which it moves and the reading of the card during this portion of the cycle does not form a part of the present invention, and is substantially like the card path and reading and verifying system as shown and described in the aforementioned U.S. patent application Ser. No. 09/081,132, which is incorporated by reference. 
     Further details concerning cards and their manufacture and insertion into carrier that are needed to understand any of the part of the system  100  that have not been disclosed in detail may be had by reference to the following patent, which are hereby also incorporated by reference: U.S. Pat. Nos. 5,494,544; 4,034,210; b1 4,194,685; 4,429,217; and 5,388,815. 
     When the leading edge of the card  128  engages the beveled guide surface  422  of a card shuttle pusher member  423 , the card is cammed downwardly, being a resilient plastic, and then snaps back up to ride along an upper edge  424  of the card shuttle  412  until it engages a downwardly extending card stop  414 . At that point, the lagging edge of the card  128  is received in front of the card shuttle pusher member  423  and nestles within the card shuttle between the pusher member  423  and the stop member  414  and is tangent along its top surface with the downwardly facing card engaging surface  424  of the card shuttle  412 . As it passes a sensor arm  426  the presence of a card nestled within the card shuttle  412  is detected and reported to the controller. The card  128  is then moved by the shuttle  412  to the preselected card drop location, at which point the removable card support member  428  is pivoted out of supporting relationship with the card  128  and is dropped onto the carrier  113 . 
     Advantageously, unlike known card movement mechanisms, the card shuttle captures the card  113  between the card stop  414  and the inner wall of the card shuttle pusher member  423 . Accordingly, the card shuttle is capable of moving the card in either of two directions and not only in the direction of normal travel indicated by arrow  434 . The card shuttle is capable of moving the card to any selected drop location to drop the card at any selected location on the carrier. In keeping with on aspect of the invention the card track is moved by means of an encoded motor that drives the pulley  416 . The controller first applies full power to the shuttle to accelerate the card toward the desired drop location, but then when the encoder signal indicates that the selected location is near power is reduced and the speed of the shuttle is slowed to prevent over travel due to the momentum of the card shuttle at the higher speed. After the card drop, the shuttle  412  rapidly returns to the home position in which a T-shaped member  436  is received within a mating slot of a sensor member  438 . Once the shuttle is sensed being at the home position, the pusher  420  is actuated to load the next card into the shuttle  412 . 
     Turning now to  FIG. 42 , in the event the card  128  is determined to be defective, then the shuttle  412  continues past any possible card drop location and to an open end  438  of the card track portion  172 , FIG.  7 . The underlying support of the card  128  is lost at the end, and the card  128  slides into the card reject bin  134 . A sensor  440  senses the passage of the rejected card to the reject bin and the controller responds by recording the reject and information relating to the rejected card. 
     Referring now to  FIGS. 43 ,  44  and  45 , the FIFO stacker module  146  is seen to include a rectangular, tubular stacking frame, or housing,  442  within which the card packages  115  are stacked. The stacker module  146  also has open top  444  and an elongate finger slot  446  to facilitate removal of the card packages  115  from the stacking frame  442 , as best seen in FIG.  1 . 
     The card packages  115  are passed through a bottom opening  448  adjacent the bottom of the stacker frame  442  by a set of rollers  284 , as shown in  FIG. 26 , when a card package is selected for stacking and the stacker gate  280  has been activated. The card packages  115  are placed on top of a stacker pusher plate  450  when the pusher plate is in a home position as shown in FIG.  43 . In the home position the pusher plate is located beneath a set of four, substantially identical resilient support members  452  to allow for passage of the card package beneath the support members  452 . Each of the support members  452  is made of spring steel and have inwardly and upwardly projecting support tab  453 . Two of the support members  452  are on the back side, and the other two are located on the front side directly opposite the two on the back side. The distance between the opposed card package support tabs  453  on opposite sides is less than the width of a carrier package  115 . 
     After a card package is inserted into the opening  448 , which is sensed by a card stack sensor  454 ,  FIG. 26 , and is resting atop the pusher plate  450 , a pusher plate motor  456  raise the pusher plate in the direction of arrow  458  from the home position shown in  FIG. 43  toward a loading position, as shown in FIG.  44 . When the loading position is reached, the carrier package  115  is elevated by the plate  450  above the card package support tabs  453 . Any card packages already in the stack are also raised at the same time to make room for the latest card package to be added to the bottom of the stack. The stacker plate  450  is then lowered to the home position while the card package it was previously carrying remains at the bottom of the stack and supported by the four card package tabs  453 . Thus, as the card packages  115  are added to the bottom of the stack, one package at a time, the stack is moved upwardly toward the open top from which they the first card package of a run is advantageously located on top. The first card package into the stacker is the first one to reach the open top  444 , FIG.  1  and may be easily removed. 
     The movement of the stacker plate is achieved by means of a linkage  459  also shown in  FIG. 45. A  pusher link  460  is supported for sliding movement within support tracks of a support member  462 . The linkage has a slot  464  within which is slideably receive a metal pin roller  466 . The roller  466  is attached to the end of a crank arm  468 . The crank arm  468  is driven by the motor  456  to rotate about a rotary axis  470 , and as the crank arm rotates, the linkage  459  moves up and down with the up and down movement of the the pin roller  466  within the slot  464 . A sensor  472  detects when a detection member  474  attached to the linkage  459  and thus the linkage have reached the home position so that another card may be inserted through the lateral load opening  448  and placed into loading position. 
     Turning now to  FIGS. 46 and 47 , the card transport track  166  including the card shuttle section  166 ′ is seen to include a plurality of servo motors and sensors some of which are not well seen in the other drawing figures. The relative location and of these card track elements are schematically shown in FIG.  47 . The controller, that will be described below receives information from the sensors and use such information to control the application of power to motors. Starting from the beginning of the card track  166  on the right, the first motor is a card pusher motor  474  which powers a card pusher to push a card dropped onto the card track from a card hopper  144 , FIG.  1 . Next, there is a first “pusher home right” sensor  476  is a photosensor that detects when the pusher is in a first home position on the right and is ready to receive a card from the right hand card drop location of the right hand side of the two card stack hopper  140 . The card is dropped on the left of the right home position to push the card to the left. The “card dropped right” proximity switch sensor  478  has detects when the card has been dropped to the right side card drop location and is in position to be pushed down the card track  166 . The next “pusher home left” photosensor  480  performs the same function as the sensor  476  but does so for the left home position for pushing cards dropped from the left side of the dual stack card hopper from the left home position. Likewise, the “card dropped left” proximity switch sensor  482  senses when a card has been dropped to the left side card drop location. 
     Advantageously, the proximity switch sensors  478  and  482  have rounded caps attached to the conventional actuation levers  484  to protect the levers  484  against damage in the event a card is inadvertently moved across the lever in a direction opposed to its normal direction of movement. 
     The next sensor is the “reading position” photosensor  488  which detects when the card is in position at the beginning of a portion of the track at which data is read from the card and compared to the data base and to the information carried by the carrier. 
     The following sensor is the “labeling position” photosensor  490  which detects when the card  128  is in position for receipt of an adhesive label  148 . This is followed by a “pusher away” photosensor  492  that detects when a card pusher (not shown), has moved from its home position. 
     The remaining elements of the card track  166  are on the card shuttle portion  166 ′. The first sensor is the “shuttle home” photosensor  494  as also seen in  FIG. 41  which detects when the shuttle  412  is in the home position when the tab  417  is received within slot  419 , FIG.  41 . The last “card present” sensor  496  detects when the card the sensor arm  426 ,  FIG. 41  has been moved to the detection position when the card becomes fully nested within the card shuttle. The shuttle motor  498  moves the shuttle pulley belt  416  by driving pulley wheel  421 , FIG.  41 . 
     Referring to  FIGS. 48 and 49 , the first sensor along the carrier path  164  is seen to include the carrier inlet feed sensor  234 ,  FIG. 12 , which detects that a carrier  113  has been fed into the carrier inlet  126 . This causes the carrier inlet drive motor  500  to drive the carrier inlet rollers  235  to move the carrier to the second set of rollers  242 ,  FIG. 12 , which are driven by the intermediate carrier drive motor  502 . Next, a photosensor  504  detects when the carrier has emerged from the intermediate carrier rollers  242 . Then a photosensor  506  detects when the carrier  113  is at the card attachment station in front of attachment rollers  252 . These card attachment rollers are driven by the reversing motor  508 . Next there is folding station photosensor  510  that detects when the partially folded carrier is being passed to the folding station rollers  258 . These motors can also be seen in FIG.  11 . All of the mechanically actuated proximity switches are preferably Model No. OP8850 made by OPTEK. 
     By controlling the above described motors based on the information sensed from the various sensors card package production system  100  is capable of attaching cards, up to six cards anywhere on the carrier  113 . There is only room to mount two cards on each of the three panels but each panel can have two cards mounted for a total of six cards. If only one card is to be mounted to the carrier then it may be mounted in the middle of a panel. This ability is achieved by controlling the longitudinal position of the carrier relative to the card drop location when the card is dropped to select which of the three panels will receive the dropped card. On the other hand, the lateral position of the card on a panel is determined by what position along the card shuttle path  166 ′ the shuttle is controlled to be when the card is dropped, there a plurality of card loading, or drop, positions located across the width of the carrier path. 
     The controller described below controls the card loading station to selectively laterally position the card across the width of the form and to selectively align one of the plurality of positions with the card loading station to longitudinally position the card along the length of the carrier. 
     Referring now to  FIGS. 50A and 50B  the control system is seen to include an OPTO 22 model controller system made by OPTO 22 of Temecula, Calif. and having a web site at www.optto22.com. The OPTOCONTROL system has two brain boards  600 A and  600 B that interface an LCSX controller  605  with a plurality of control modules  606 . The control modules interface with the sensors and the control motors. The controller, in turn, operates in accordance with the OPTOCONTROL programming flow chart. Pursuant to the OPTOCONTROL, the OPTOCONTROL software automatically generates the code needed to effectuate the flow chart. The actual code is attached as Appendix A. 
     Referring now to  FIGS. 51 ,  52 A, B, C,  53 ,  54 ,  55 ,  56 ,  57 ,  58 ,  59 A, and B showing the operational routine flow charts of the preferred embodiment. The flow charts are compiled and entered into a software designer program to generate a source code, attached as APPENDIX A, used to control mechanical devices such as the preferred embodiment. The software designer program is called “OPTOCONTROL” manufactured by OPTO 22. Instructions on the use of this software and-the flow chart conventions and protocol can be found in the OPTOCONTROL USER&#39;S GUIDE, Form number 724-990831-August, 1999; the OPTODISPLAY USER&#39;S GUIDE, Form 23-990831-August, 1999; and the OPTOCONTROL COMMAND REFERENCE, Form number 725-990831-August 1999, all of which are hereby incorporated by reference.