Source: http://www.google.com.tw/patents/US7824029
Timestamp: 2013-05-21 20:11:21
Document Index: 330196837

Matched Legal Cases: ['Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 2', 'Application No. 03713599', 'Application No. 2', 'art 2', 'art 1', 'Application No. 2004', 'Application No. 2004', 'Application No. 02805980']

�M�Q US7824029 - Identification card printer-assembler for over the counter card issuing - Google �M�Q�j�M �Ϥ� �a�� Play YouTube �s�D Gmail ���ݵw�� ��h »�i���M�Q�j�M | �������� | �n�J�i���M�Q�j�M�M�QThe present invention relates to assembling identification documents in an over-the-counter issuing environment. In one implementation of the present invention, an ink jet printer-based assembling system is provided. An identification document substrate receives ink jet printed information. The printed...http://www.google.com.tw/patents/US7824029?utm_source=gb-gplus-share�M�Q US7824029 - Identification card printer-assembler for over the counter card issuing���}��US7824029 B2�X���������v�ӽЮѽs��10/436,729�o�G���2010�~11��2���ӽФ��2003�~5��12�� �u���v���2002�~5��10����L���}�M�Q��US8087772US20040066441US20100020151�o��HDaoshen BiRobert JonesDennis Mailloux��M�Q�v�HL-1 Secure Credentialing, Inc.Bank Of America, N.A.Digimarc CorporationDigimarc Id Systems ���M�Q������347/101347/4347/2347/104��ڱM�Q������B41J11/00B41M5/00B41J3/00B42D15/10B41J3/60B41J13/12B41M5/50B41J2/01 �X�@����B41J11/0015B42D15/10B41M5/508B41J3/60B41J13/12B41M7/0027B42D2031/00 �ڬw������B41J 13/12B42D 15/10B41J 3/60B41J 11/00C�ѦҤ��m�M�Q�ޥ� (120)�D�M�Q�ޥ� (471)�Q�H�U�M�Q�ޥ� (2)�~���s�����M�Q�ӼЧ� ���M�Q�ӼЧ��M�Q����T�� �ڬw�M�Q��Identification card printer-assembler for over the counter card issuingUS 7824029 B2�K�n The present invention relates to assembling identification documents in an over-the-counter issuing environment. In one implementation of the present invention, an ink jet printer-based assembling system is provided. An identification document substrate receives ink jet printed information. The printed substrate is laminated. In another implementation, a carrier web carries lamination pieces. Both the carrier web and the document substrate include form feed holes or other registration notches. The holes or notches are used to align the substrate with the lamination pieces, and to align a laminated document substrate for final cutting.
Use of Pearlescent and Other Pigments to Create Security Documents (application Ser. No. 09/969,200, issued as U.S. Pat. No. 6,827,277, Inventors Bentley Bloomberg and Robert L. Jones, filed Oct. 2, 2001); Identification Card Printed With Jet Inks and Systems and Methods of Making Same (application Ser. No. 10/289,962, published as US 2003-0211296 A1, Inventors Robert Jones, Dennis Mailloux, and Daoshen Bi, filed Nov. 6, 2002); Contact Smart Cards Having a Document Core, Contactless Smart Cards Including Multi-Layered Structure, PET-Based Identification Document, and Methods of Making Same (application Ser. No. 10/329,318, issued as U.S. Pat. No. 6,843,422, filed Dec. 23, 2002�XInventors Robert Jones, Joseph Anderson, Daoshen Bi, Thomas Regan, and Dennis Mailloux,); Ink with Cohesive Failure and Identification Document Including Same (application Ser. No. 10/329,315, published as US 2003-0226897 A1, filed Dec. 23, 2002�XInventors Robert Jones and Bentley Bloomberg); Laser Engraving Methods and Compositions, and Articles Having Laser Engraving Thereon (application Ser. No. 10/326,886, published as US 2003-0234286 A1, filed Dec. 20, 2002�XInventors Brian Labrec and Robert Jones); Multiple Image Security Features for Identification Documents and Methods of Making Same (application Ser. No. 10/325,434, issued as U.S. Pat. No. 6,817,530, filed Dec. 18, 2002�XInventors Brian Labrec, Joseph Anderson, Robert Jones, and Danielle Batey); Covert Variable Information on Identification Documents and Methods of Making Same (application Ser. No. 10/330,032, published as US 2003-0173406 A1, filed Dec. 24, 2002�XInventors: Robert Jones and Daoshen Bi); Systems, Compositions, and Methods for Full Color Laser Engraving of ID Documents (application Ser. No. 10/330,034, published as US 2003-0234292 A1, filed Dec. 24, 2002�XInventor Robert Jones); Laser Etched Security Features for Identification Documents and Methods of Making Same (application Ser. No. 10/330,033, published as US 2004-0011874 A1, filed Dec. 24, 2002�XInventors George Theodossiou and Robert Jones); and Image Processing Techniques for Printing Identification Cards and Documents (application Ser. No. 10/411,354, published as US 2004-0074973 A1, filed Apr. 9, 2003�XInventors Chuck Duggan and Nelson Schneck). The present invention is also related to the following provisional applications:
Identification Document and Related Methods (Application No. 60/421,254, Inventors: Geoff Rhoads, et al); Identification Document and Related Methods (Application No. 60/418,762, Inventors: Geoff Rhoads, et al); Shadow Reduction System and Related Techniques for Digital Image Capture (Application No. 60/410,544, filed Sep. 13, 2002�XInventors: Scott D. Haigh and Tuan A. Hoang). Systems and Methods for Recognition of Individuals Using Combination of Biometric Techniques (Application No. 60/418,129, filed Oct. 11, 2002�XInventors James V. Howard and Francis Frazier); Systems and Methods for Managing and Detecting Fraud in Image Databases Used With Identification Documents (Application No. 60/429,501, filed Nov. 26, 2003�XInventors James V. Howard and Francis Frazier); Enhanced Shadow Reduction System and Related Technologies for Digital Image Capture (Application No. 60/447,502, filed Feb. 13, 2003�XInventors Scott D. Haigh, Tuan A. Hoang, Charles R. Duggan, David Bohaker, and Leo M. Kenen); Integrating and Enhancing Searching of Media Content and Biometric Databases (Application No. 60/451,840, filed Mar. 3, 2003); and Optically Variable Devices with Embedded Data for Authentication of Identity Documents (Application No. 60/459,284, filed Mar. 31, 2003�XInventor Robert Jones). Each of the above U.S. Patent documents is herein incorporated by reference in its entirety. The present invention is also related to U.S. patent application Ser. Nos. 09/747,735, filed Dec. 22, 2000 (published as US 2003-0038174 A1), Ser. No. 09/602,313, filed Jun. 23, 2000 (issued as U.S. Pat. No. 6,752,432), and Ser. No. 10/094,593, filed Mar. 6, 2002, (published as US 2002-0170966 A1), U.S. Provisional Patent Application No. 60/358,321, filed Feb. 19, 2002, as well as U.S. Pat. No. 6,066,594. Each of the above U.S. Patent documents is herein incorporated by reference.
Identification documents (hereafter ��ID documents��) play a critical role in today's society. One example of an ID document is an identification card (��ID card��). ID documents are used on a daily basis�Xto prove identity, to verify age, to access a secure area, to evidence driving privileges, to cash a check, and so on. Airplane passengers are required to show an ID document during check in, security screening, and prior to boarding their flight. In addition, because we live in an ever-evolving cashless society, ID documents are used to make payments, access an ATM, debit an account, or make a payment, etc.
An exemplary ID document can comprise a core layer (which can be pre-printed), such as a light-colored, opaque material (e.g., TESLIN (available from PPG Industries) or polyvinyl chloride (PVC) material). The core is laminated with a transparent material, such as clear PVC to form a so-called ��card blank��. Information, such as variable personal information (e.g., photographic information), is printed on the card blank using a method such as Dye Diffusion Thermal Transfer (��D2T2��) printing also described in commonly assigned U.S. Pat. No. 6,066,594, which is incorporated herein by reference in its entirety. The information can, for example, comprise an indicium or indicia, such as the invariant or nonvarying information common to a large number of identification documents, for example the name and logo of the organization issuing the documents. The information may be formed by any known process capable of forming the indicium on the specific core material used.
Referring to FIG. 2, the prior art OTC ID document 1 comprises a pre-printed core 5 (such as, for example, white PVC material) that is, for example, about 30 mil thick. The core 5 is laminated with clear PVC material 6, which, by way of example, is about 1-5 mil thick. The composite of the core 5 and clear PVC material 6 form a so-called ��card blank�� 7 that can be about 30 mils thick. Information 8 is printed on the card blank 7 using Dye Diffusion Thermal Transfer (��D2T2��) printing (which is described further below). To protect the information 8 printed by D2T2 printing, an additional layer of overlaminate 9 is coupled to the card blank 7 and D2T2 printing using, for example, 1 mil of adhesive (not shown).
One type of OTC identification document, available from the assignee of the present invention is a so-called ��Desktop Security Card (DSC), which has a core layer (also referred to as ��substrate��) formed from a sheet of an opaque printable material, such as an opaque sheet of printable silica-filled polyolefin, such as the materials sold commercially by PPG Industries, Inc., Pittsburgh, Pa. under the Registered Trade Mark ��TESLIN��. In the currently fielded versions of the DSC card, printing of the ID document in OTC environments is achieved with D2T2 printers. Printing quality of the printed image may depend at least on an ability of a mechanical printer system to accurately register a printing sequence, e.g., yellow, magenta, cyan, and black. Commonly assigned U.S. Pat. No. 6,066,594 describes this type of OTC identification document in greater detail, and the contents of this patent are incorporated hereto by reference in their entirety.
Printing of ID documents in OTC environments is often achieved with D2T2 printers. The ribbons uses with such D2T2 printers can be quite expensive, and the card blanks printed with D2T2 (e.g., PVC or other more expensive card blanks) also can be expensive. Copending and commonly assigned U.S. provisional patent application Ser. No. 60/379,704, entitled Application of pigmented jet inks to ID cards and U.S. nonprovisional patent application Ser. No. 10/289,962, entitled ��Identification Card Printed With Jet Inks and Systems and Methods of Making Same�� provide information about inventive methods and techniques for using ink jet printing (which can be significantly less expensive than using D2T2 ribbons) to print on blank sheets (e.g., TESLIN sheets) that can then be laminated to protect the printing.
Another aspect of the present invention is to use a so-called carrier web to carry and control the orientation of laminate patches in an ID document lamination process. The carrier web can be of a paper-based material. It will be appreciated that an OTC card issuing process is by its nature an intermittent�Xin comparison to a continuous�Xprocess. While so-called continuous roll laminating provides a fast and efficient method of card lamination in a central issue environment, the same continuous lamination process is not typically compatible with an intermittent process, due to poor material utilization. For example, consider a situation where only one card is produced in a run. Many inches (or even feet) of the roll lamination would be wasted since a subsequent card would not directly follow the first card. The use of a carrier web provides a unique method of using roll lamination in an intermittent card assembly environment with a high laminate yield.
In one implementation of the present invention we perforate the carrier web and/or substrate along a printing and/or laminating machine direction edge to provide a physical registration feature. Our perforation holes (or ��form feed holes��) can be used to reliably convey materials-and to accurately register multiple card layers (laminate�Xsubstrate�Xlaminate) as the layers are combined to make a laminated ID document. In some implementations we place holes along two parallel directional edges of the web or substrate.
In the foregoing discussion, the use of the word ��card�� is intended to include all types of ID documents. (For the purposes of this disclosure, the terms ��document,�� ��card,�� ��badge�� and ��documentation�� are used interchangeably. In addition, ID document shall include, without limitation, documents, magnetic disks, CD's, or any other suitable items that may record information, images, and/or other data, which may be associated with an object or other entity to be identified.)
The inventors have found that dye-based ink jet inks require a so-called receiving layer (or thin coating) to be applied to the ID document substrate in order to produce a high quality print appearance. Conventional receiving layers have water absorptive characteristics that can weaken the ID card's physical integrity. For example, a card substrate that is treated with a receiving layer absorbs water, particularly at the card's edges. Absorbing water can have disastrous effects�Xthe card can swell or warp, the laminate can peel away, a weakness point can form providing an intrusion entry point, and the printed ink can be blurred or even lost. The inventors of the instant application also have discovered that a receiving layer often weakens the bond between the substrate and laminate.
Another weakness of conventional dye based ink jet inks is the mobility of the inks in the document substrate. Often, after application to a document substrate, dye-based ink jet ink will penetrate through the entire thickness of the substrate, particularly when a receiving layer is not applied to the substrate. Ink mobility has at least two negative results. First, the ink visible on the surface of the document substrate is reduced, leading to a ��washed out�� image. Second, in a worst-case scenario, ink printed on a front surface of the substrate becomes visible on a back surface of the substrate.
The light and aging stability of such pigments inks are excellent. A receiving layer is not required when printing a microporous core such as a TESLIN sheet with pigment inks. Microporous core materials such as TESLIN tend to filter pigment particles out of pigmented ink leaving, in some instances, the vast majority of the ink's pigment close to the surface. Some penetration into the pores of the TESLIN does appear to occur, which aids in locking the pigment to the substrate. However, the pigmented ink penetration has been observed to be slight in comparison to traditional dye inks. The resulting bond strength of the laminate to the microporous material is excellent, and appears to be substantially unaffected by moisture. Since the level of penetration of the pigment into the substrate can be limited, bleed through from a front surface to a back surface of the substrate has not been observed. Attempts at delamination can result in showing obvious evidence that tampering has occurred. For example, if laminate is removed from a TESLIN-based substrate printed with pigmented ink jet inks, either he TESLIN can fracture cohesively (down the thickness of the material) or the ink fractures cohesively (most ink staying with the laminate and the remainder with the TESLIN) or a combination of these two modes. These failure modes make alteration quite obvious, photo replacement or data changing very difficult, and relamination impossible without adding an adhesive layer. We believe that our use of pigmented ink jet inks also may have application in central issue manufacturing of ID documents as well as over the counter manufacturing of ID documents, especially in situations where the resolution of ink jet printers surpasses that of laser printers used to print on TESLIN for the purpose of making ID cards. More details about our inventive use of pigmented inks can be found in our commonly assigned U.S. patent application Ser. No. 10/289,962, published as US 2002-0211296 A1, entitled ��Identification Card Printed with Jet Inks and Systems and Methods of Making Same��, the contents of which are incorporated herein by reference.
FIG. 3 is an illustrative example of an ID document 10 manufactured in accordance with one embodiment of the invention, The ID document 10 includes substrate 21 (which for illustrative purposes only is illustrated as having a ��card-like�� shape) and the ID document 10 optionally can be sealed between first and second laminate layers 23, 25 (it should be understood that the ID document 10 also may be sealed with only one laminate layer (either the first layer 23 or the second layer 25), and also may be sealed with a plurality of laminate layers.
Heat and/or adhesive are used to bond the laminate sheets 23 and 25 with the substrate 21. The adhesive can even be coated or provided on a substrate-engaging side of the laminates 23 and 25. Or a laminate can include a pouch into which the substrate 21 slips. Again, heat and/or adhesives would be used to bond the substrate 21 with the pouch laminate. Hence, our preferred finished ID document includes at least a three-layer structure (e.g., laminate�Xsubstrate�Xlaminate). The lamination provides a protective covering for the printed substrates and provides a level of protection against unauthorized tampering. (For example, a laminate would have to be removed to alter the printed information and then subsequently replaced after the alteration.). Various lamination processes are disclosed in assignee's U.S. Pat. Nos. 5,783,024, 6,007,660 and 6,159,327. Other lamination processes are disclosed, e.g., in U.S. Pat. Nos. 6,283,188 and 6,003,581. Each of these U.S. Patents is herein incorporated by reference. Our present disclosure provides improvements over these lamination techniques.
Embodiment 1�XProcess for Ink Jet Printing an Identification Document FIG. 4 is a flow diagram of the general processes included in an over-the-counter ID document assembling system 100 in accordance with one embodiment of the invention. This general process is applicable to at least some of the other embodiments of the invention described herein and is provided to give the reader a general overview of the processes, systems, apparatuses, and techniques to be further described herein. Any or all of the following processes can be controlled manually, using hardware, using software, or using any combination of two or more of these.
Embodiment 2�XDual Ink jet Printing Process This embodiment provides an inventive over-the-counter (��OTC��) ID document printing system and related methods. As a general overview, and with reference to FIG. 5, our inventive OTC system 200 preferably includes two ink jet printers 202 and 204 (e.g., such as those manufactured by HP, Epson, Canon and Lexmark) a roll type laminator 205, cooler 214, pulling rollers 216, and a cutter 218. Although not illustrated in FIG. 5, those skilled in the art will appreciate that the system 200 of FIG. 5 can include mechanisms to power and drive the illustrated elements, such as a motor(s) and drive assembly to drive the rollers, etc. In at least one embodiment, the above components cooperate with a controller (not shown) to facilitate the smooth transition of a substrate through our inventive assembling system. The controller can be a software module executing on general-purpose processing circuitry. Or the controller can alternatively be implemented with hardware controls or hardware/software controls. The controller may even cooperate with various system sensors. Control also can be completely or partially manual.
The substrate sheet 219 is conveyed along a path 203 into a feed tray 204 a of the second ink jet printer 204 preferably in a manner that presents a second side of the sheet to the second ink jet printer 204. (For example, path 203 is ��C�� shaped to present a second side of the sheet to the second ink jet printer's print head.). Path 203 can be achieved with a belt, roller system and/or vacuum, etc., as will be appreciated by those skilled in the art The second ink jet printer 204 applies desired printing to the second side of the sheet. The printed sheet is then conveyed from the second ink jet printer 204 to a laminator 205.
A common lamination material includes polycarbonate or polyester. Most frequently, such laminates include an adhesive layer or coating, such as EVA, EVA blends, etc. The laminator 205 receives laminate in the form of continuous webs from upper laminate supply 212 a and lower laminate supply 212 b. The laminate webs are fed from the supplies 212 a and 212 b via guide rolls 210 a and 210 b, respectively. The laminate webs are preheated with upper and lower preheating rollers 208 a and 208 b. An adhesive side of the laminate preferably faces (and contacts) the preheating rollers 208. The preheating rollers 208 a and 208 b heat their respective laminates so as to bring the temperature of the laminate adhesive slightly below an activation temperature (around 170�X F.) of the adhesive (e.g., between about 5-20�X F. below the activation temperature). The preheating temperature is preferably such that the laminate material (e.g., amorphous polyester) does not soften to a point where it would unduly stretch from the preheating rollers 208 to the laminator roller 206. Laminator rolls 206 a and 206 b provide heat to activate the laminate adhesive, and press the upper and lower laminate onto respective upper and lower sides of the printed substrate sheet. In one implementation the laminator rollers 206 raise the laminate temperature from the activation temperature to about 230-240�X F. In another implementation, we maintain our preheating rollers 208 between 150-180�X F., and our laminator rollers 206 between 250-330�X F. Since the speed of lamination is proportional to the lamination temperature (e.g., hotter is faster), in some implementations we raise the laminator rolls 206 above 330�X F.
(It should be understood that, to simplify the discussion we have taken some liberty with the use of the term ��roller�� and ��roll.�� Conventionally the term ��roller�� is used to specifically imply a metal or anodized metal surface, while the term ��roll�� is used to specifically imply a rubber coated roll that fits over or otherwise surrounds the metal roller. Such distinctions are not critical to the understanding of the present invention. Accordingly we use the terms roller and roll interchangeable herein.).
One or more dryers (not shown in FIG. 5) can be added to the system 200 to dry the printed substrate after and/or during printing. For example a dryer can be positioned along the 203 path and/or along a path 204 b from the second printer 204 to the laminator 205. While a dryer may include radiant heating or the like, we prefer a forced hot air dryer. Forced drying has at least two advantages. First, forced drying produces ��hardening�� of the ink so that it can withstand rough handling between printing passes. Second, the drying of the sheet after final printing (e.g., after printing by the second printer 204) may also be useful in preventing moisture bubbles. Moisture bubbles occur during lamination and often produce visual defects in a finished card. In one embodiment, air drying for a predetermined time (such as by delaying the substrate along the path 203 and/or the path between the front printer 204 and the laminator 205) can be used in place of forced drying.
Embodiment 3�XDual Ink jet Printing Process with Alternate Printer Configurations While the FIG. 5 embodiment (and various alternative embodiments related to FIG. 5) describe a first ink jet printer positioned directly over, and positioned in an opposite direction of, a second ink jet printer, the present invention is not so limited.
For example, the printers 202 and 204 can be arranged one above the other, but both facing in the same direction and positioned on opposite sides of a substrate sheet such that the first printer prints one side of the sheet, and the sheet travels in a straight path into the second printer where the other side of the sheet is printed. Since the second printer is positioned ��upside down,�� the ink droplets travel horizontally (or vertically, depending on printer positioning) to the sheet without the normal assistance of gravity. Our experiments reveal satisfactory printing under such upside down printing conditions.
Another implementation, shown in FIG. 7, prints both substrate sides at substantially the same time. Referring to FIG. 7, an ink jet printer 201 is configured with two print heads 202��, 204��, each to respectively perform printing on a respective side of a substrate. A substrate is printed as it travels between the two print heads. Since the print cycle time is a major time factor in an ID document manufacture, and since a dual print head configuration significantly reduces the overall size of the processing unit, a simultaneous or substantially simultaneous printing configuration is an attractive embodiment. Although not shown in FIG. 7, a one or more dryers could be positioned along path 211 to dry one or more sides of the substrate. The dryer or dryers can, of course, be configured to dry both sides of the substrate at the same time.
Embodiment 4�XDual Ink Jet Printing Process with Alternate Laminator In this embodiment, platen lamination is used in alternative embodiments instead of a roll laminator 205 describe in the previous systems. A platen lamination process basically involves placing a platen (e.g., metal, glass or ceramic surface) in contact with a laminate to impart heat and/or pressure, so as to activate the laminate adhesives. Some laminates (e.g., amorphous polyester laminates) soften during a lamination process, and as a result the laminate may take on a finish of the laminating or cooling surfaces (e.g., rollers or platen).
Embodiment 5�XSingle Ink Jet Printing Process The FIG. 5 embodiment can be modified to include a single printer system 300, instead of the dual printer system 200, as shown in FIG. 8. A single ink jet printer 302 is used to print both sides of an ID document substrate. A substrate sheet 219 (e.g., a TESLIN sheet) is placed in print tray 302 a. Printer 302 prints a first side of the sheet. A first sheet conveyor 303 (e.g., a conveyor belt, guide rollers, vacuum, or etc.) is provided to return the printed sheet 219 to the print tray 302 a. The first sheet conveyor 303 preferably returns the printed sheet 219 to the print tray 302 in an orientation that allows printing of a second side of the substrate sheet by printer 302. Optionally, the system 300 can include a dryer 305 to dry the first printed side of the substrate 219 along the path 303. Optionally, the system 300 can include a dryer 305�� to dry the other printed substrate along the path 304. Optionally, a dryer 305�� can be configured to dry both sides of the substrate simultaneously along the path 304 (not shown in FIG. 8). Optionally, the system 300 can include a ��flipper�� 305��, which can assist the first sheet conveyor 303 in returning the printed sheet 219 in an orientation that allows printing of a second side of the substrate by printer 202 by automatically turning the substrate 219 over. Such ��flipping�� can, of course, also be accommodated manually.
One advantage of system 300 over system 200 is that one printer 302 accomplishes the work of two printers 202 and 204�Xsaving hardware cost and size. We note that system 300 does not experience a significant increase in printing time over system 200 since system 200 sequentially prints the front and back of a substrate sheet.
Embodiment 6�XInk Jet Printing with Carrier Supported Laminates We note that a substrate sheet is typically much shorter than the assembling path that the laminate web travels (e.g., referring to FIG. 5, starting at the guide rollers 210 a and 210 b, past the preheating rollers 208 a and 208 b, through the pressure (or ��nip��) rolls 206 a and 206 b, cooler 214, through the pull roller 216 to the cutter 218). Thus the amount of laminate that is consumed in processing one substrate sheet is often 4 or 5 times the amount of substrate used, resulting in a laminate design yield of no more than 20% to 25%. We can improve the yield with our following inventive techniques.
Any or all of the systems of FIGS. 4-8 are modified to reduce the amount of laminate required to manufacture an ID document by using patches or discrete card-sized sheets of laminate. The laminate patches are bonded to or otherwise carried by a carrier web. We space the laminate patches along the carrier web such that the carrier web�Xand not laminate�Xspans the majority of the assembling path. This configuration significantly raises the laminate yield, while reducing overall costs.
FIG. 9 is an illustration of a carrier web 600 usable with at least one embodiment of the invention, and FIG. 10 is an illustration showing laminate patches on the carrier web 600 of FIG. 9 (it should be understood that in FIGS. 9 and 10, the dimensions shown are not limiting and provided by way of illustration only). Referring to FIGS. 9 and 10, the carrier 600 preferably has ��windows�� 602 throughout the web (e.g., with no carrier material in the windows). In one Embodiment, the carrier 600 is made from 2 mil liner paper. In this example, the carrier web 600 is constructed for use in form feeding (as described further herein) and includes a plurality of form feed holes 604, but the invention does not, of course, require that the carrier web 600 be used in a form feeding type environment. The laminate patches 606 are bonded to the carrier web 600 at (or over) these carrier windows 602. In one embodiment, one or more heat seals 608 bond the laminate patches 606 to the carrier web 600. The windows 602 help prevent carrier material from being introduced into a final ID) card. Referring again to FIG. 5, the laminate patches 606 (and carrier windows 602) can be spaced so as to enter the laminator 205 (e.g., enter the preheating rollers 208 a and 208 b or laminator rollers 206 a and 206 b) when a previous laminate patch is in the cutter 218.
(In one implementation, by way of example, the laminate patch is about ¼ inch larger in all four directions than the substrate sheet. This over-sizing allows a buffer for, e.g., sufficient laminate overlap, extra material to be handled by the rollers, cutting imprecision, and even a so-called ��dead zone,�� if desired, to buffer the lamination roller 206 from riding up over the laminate on the carrier web.).
Embodiment 7�XAdditional Alternative Implementation While using a carrier web is an attractive solution to improve lamination yield, excess carrier web waste may be an unintended byproduct. We have developed an implementation to significantly reduce subsequent carrier web waste. Instead of using a carrier web as a ��continuous�� web that is controlled by maintaining down web tension (e.g., by puller roller 216) a discrete piece or sheet of carrier can be used for each individual laminate piece. Similar to the embodiments shown in FIGS. 9 and 10, a single piece of laminate is ��picture framed�� on and then bonded to (or otherwise carried by) each carrier sheet. These individual carrier sheets can be provided from a roll or fan folded box of continuous carrier with laminate patches. The carrier pieces are then cut into the single pieces prior to entering the laminator 205, or are separated from the roll by fracturing the carrier along a cross web perforation line 605 (FIG. 9). Or a carrier sheet can be obtained from a stack of carrier sheets. As with the carrier web above, the carrier sheet includes and opening or window 602 over which the laminate piece 606 is placed (or bound). Form feed holes 604 along the edge(s) of a carrier sheet are used to convey the individual carrier sheet through the laminator 205, cooler 214 and cutter 218. Pin feed mechanisms control the carrier sheet/laminate motion and alignment by transferring forces through engagement of the carrier web form feed holes.
Several alternative methods can be used to generate a force required to blank die cut a card in the processes described above. Since a blanking die can be fashioned with a shear angle or double shear angle on the face of a punch without sacrificing dimensional accuracy of the card product, only a small portion of the total card perimeter is cut at a given instant in a cutting cycle. This greatly reduces the force required to cut the card. Therefore a small electric motor driving a high mechanical advantage screw or other drive mechanism would be sufficient to slowly cut the cards. Faster cycle times would be possible with an energy storage system like a spring or flywheel device that becomes ��charged�� during the relatively long off-duty cycle time and is discharged during the brief cutting cycle.
Embodiment 8�XRotary Table or Linear Carriage Using Platen Lamination Platen lamination is ideally suited for a rotary table or a linear carriage. Rotary tables and linear carriages comprise dedicated stations that are respectively devoted to a specific processing step, and ID document parts (e.g., front laminate, substrate sheet, and back laminate) are fed into or unloaded from each station.
(The printed substrate is preferably conveyed to the first station around a sharp or otherwise pronounced bend in order to break the precut, final-sized chip or piece from its surrounding substrate material. This technique is similar to a method of applying pressure sensitive adhesive labels from a release liner. The separated chip or piece is provided to a first station of the rotary table. Alternatively, the ��breaking�� can be accomplished in a pre-station.).
While this approach has multiple steps, it does have the advantage of eliminating a cutter. An alternative might be to introduce precut laminate pieces from a carrier web where the laminate pieces are attached to the carrier with low bond strength adhesive such that the pieces could be ��label fed�� from the carrier onto the table. We also note that some of the above mentioned stations can be combined, such as stations 1 and 2, and 5 and 6.
Embodiment9�XSemi-Automated Process Manual intervention can be used to simplify our inventive processes. Such semi-automated systems with typically use one or two ink jet printers, a belt laminator, a manual die cutter and, optionally, a magnetic stripe encoder. Consider the following inventive process.
Embodiment 10�XInjection Molding Process An injection molding process is used as an alternative to the above described lamination processes.
�M�Q�ޥ� �ޥΪ��M�Q�ӽФ���o�G��� �ӽЪ��M�Q�W��US10945931913�~3��12��1914�~4��28��John W. 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