Patent Description:
There are processing machines that are intended to process plastic cards, like bank cards. For example, such a processing machine consists of a printer which prints a pattern on the card. Printing is performed by thermal transfer and the processing machine includes:.

The printing module ensures the transfer of ink areas, corresponding to the patterns to be printed on the plastic card, onto a transfer film carrying a varnish.

The transfer film is positioned between the plastic card and the heating roll.

Printing a plastic card consists in firstly covering the varnish of the transfer film with ink areas representative of patterns to be printed, between the feeding roll and the heating roll.

Once the ink areas are on the transfer film, the latter passes at the level of the lamination module between the plastic card and the heating roll, which ensures the transfer of the ink areas and of the varnish onto the plastic card.

Gradually, the plastic card and the transfer film advance simultaneously under the heating roll in order to print the plastic card, and the transfer film gradually winds up on the recovery roll.

Heating the transfer film might cause a slight sticking of the transfer film onto the card, and when the transfer film separates from the card by pulling the film by the recovery roll, it might happen that peeling is not properly performed and traces might then appear on the card.

<CIT> discloses a lamination module and card processing machine according to the prior art.

An object of the present invention is to propose a lamination module for a card processing machine where the lamination module includes a system for assisting in peeling a transfer film from the card after lamination.

To this end, a lamination module is provided for a plastic card processing machine, said lamination module including:.

Advantageously, the movement of the peeling roll between the release position and the constraint position is a rotation about its axis.

Advantageously, the peeling system includes a return spring which tends to return the peeling roll from the constraint position to the release position when the peeling roll is brought away from the release position.

Advantageously, the lamination module includes a peeling anvil roll which faces the peeling roll so that the plastic card is pinched between the peeling anvil roll and the wedge when the peeling roll is in a constraint position.

Advantageously, the lamination module includes a lifting system ensuring the movement of the heating roll alternately from a lowered position in which the heating roll bears against the anvil roll to a raised position in which the heating roll is at distance from the anvil roll.

Advantageously, the lifting system includes:.

Advantageously, each cam has a second profile, the lamination module includes a third carrier frame mounted movable in rotation about the axis of rotation, and which, for each cam, has a second cam path cooperating with the corresponding second profile, and which carries at least one first gear section, for each first gear section, the peeling roll carries a second gear section cooperating with the first gear section, and the lamination module includes at least one third spring element which is mounted between the second carrier frame and the third carrier frame so as to raise said third carrier frame, where, in the first direction, the or each second profile cooperates with a second cam track to lower the third frame carrier and by cooperation between the gear sections move the peeling roll into the constraint position, and where, in the second direction, the or each second profile cooperates with the second cam track to release the third carrier frame and by cooperation between the gear sections move the peeling roll to the release position.

Advantageously, the third carrier frame carries a compression roll downstream of the heating roll, and the lamination module includes a compression anvil roll which faces the compression roll so that the plastic card is pinched between the compression roll and the compression anvil roll when the third carrier frame is lowered.

The invention also proposes a card processing machine including a feeding system for feeding the card processing machine with plastic cards to be processed, an ejection system which ejects each processed plastic card from the processing machine, and between the feeding system and the ejection system, a lamination module according to one of the preceding variants.

The above-mentioned features of the invention, as well as others, will appear more clearly upon reading the following description of one embodiment, said description being made with reference to the appended drawings, wherein:.

<FIG> shows a processing machine <NUM> which is used in the context of covering a plastic card <NUM> with a product with ink and varnish. The processing machine <NUM> is of the thermal transfer type and it includes:.

The feeding system <NUM> and the ejection system <NUM> are not described further, because all types of known systems using motorized drive rolls can be used.

The printing module <NUM> is schematically shown and it is also in the form of any type of printing module known to a person skilled in the art. The printing module <NUM> ensures the transfer of ink areas onto the varnish of a transfer film <NUM>.

The movement of the plastic card <NUM> is herein generally horizontal in the lamination module <NUM>.

<FIG> shows a particular embodiment of the lamination module <NUM> and <FIG> and <FIG> show sections of the lamination module <NUM> at different levels. <FIG> and <FIG> show sections of the lamination module <NUM> in two operating positions.

The lamination module <NUM> includes a frame <NUM> which is secured to a main frame of the processing machine <NUM>, and which may be a portion of the main frame of the processing machine <NUM> or an attached and fastened element. The frame <NUM> is herein in the form of two vertical walls opposite one another, but only one is visible in <FIG>.

The lamination module <NUM> includes a heating roll <NUM> mounted movable in rotation on the frame <NUM>. The heating roll <NUM> heats over its entire length. For example, heating of the heating roll <NUM> is carried out by a resistance embedded in the heating roll <NUM> and controlled by a control unit.

The lamination module <NUM> also includes two movement systems 160a-b arranged so as to move a plastic card <NUM> relative to the heating roll <NUM> according to a so-called lamination direction <NUM> which goes from the feeding system <NUM> to the ejection system <NUM> throughout the lamination module <NUM>.

All the rolls described hereinabove and hereinbelow have their axes parallel to one another and perpendicular to the lamination direction <NUM> and they extend between the walls forming the frame <NUM> where they are mounted movable in rotation.

In the embodiment of the invention presented herein, there is a movement system 160a upstream of the heating roll <NUM> with respect to the lamination direction <NUM> and a movement system 160b downstream of the heating roll <NUM> with respect to the lamination direction <NUM>. Each movement system 160a-b is herein in the form of a pair of rolls where each roll is mounted movable in rotation on the frame <NUM>, where there is a roll bearing against the upper face of the plastic card <NUM> and a roll bearing against the underside of the plastic card <NUM>. At least one roll of each pair is equipped with a motor intended to drive said roll.

These or some of these rolls may form part of the feeding system <NUM> and the ejection system <NUM> depending on their positions with respect to the heating roll <NUM>.

The lamination module <NUM> also includes an anvil roll <NUM> mounted movable in rotation on the frame <NUM> and arranged against the heating roll <NUM> and arranged so as to ensure pinching of the plastic card <NUM> between said anvil roll <NUM> and the heating roll <NUM>, and thus to press the plastic card <NUM> against the heating roll <NUM>.

In the embodiment of the invention presented herein, the anvil roll <NUM> is equipped with a motor which drives the anvil roll <NUM> in rotation to drive the plastic card <NUM> in the lamination direction <NUM>.

The lamination module <NUM> also includes a feeding and recovery system <NUM> which is arranged so as to move the transfer film <NUM> between the plastic card <NUM> and the heating roll <NUM> according to the lamination direction <NUM>.

The transfer film <NUM> is in the form of a strip covered with varnish and including areas covered with ink and as specified above, the ink areas have been deposited on the varnish of the transfer film <NUM> by the printing module <NUM>. The ink and the varnish are intended to be deposited over the plastic card <NUM>.

When the ink areas and the varnish should be deposited over the plastic card <NUM>, the heating roll <NUM> heats and the heat and the pressure exerted between the heating roll <NUM> and the anvil roll <NUM> ensure the transfer of the ink and of the varnish onto the plastic card <NUM> at the heating points. The varnish then covers the ink and the plastic card <NUM>.

The feeding and recovery system <NUM> herein includes a feeding roll <NUM> on which the transfer film <NUM> is wound and a recovery roll <NUM> on which the transfer film <NUM> is wound after the product (ink and varnish) has been deposited over the plastic card <NUM>.

On the path followed by the transfer film <NUM>, the heating roll <NUM> is arranged between the feeding roll <NUM> and the recovery roll <NUM>.

To ensure winding of the transfer film <NUM> on a recovery roll <NUM>, said recovery roll <NUM> is driven in rotation by a motor 110a. Thus, driving of the transfer film <NUM> during deposition is performed by the motor 110a which drives the recovery roll <NUM> in a direction <NUM> of winding the transfer film <NUM> on the recovery roll <NUM>.

The operation of the lamination module <NUM> includes receiving a plastic card <NUM> from the feeding system <NUM>. This plastic card <NUM> is handled by the movement systems 160a-b, and in particular the movement system 160a upstream of the heating roll <NUM> which moves the plastic card <NUM> between the heating roll <NUM> and the anvil roll <NUM> with the transfer film <NUM> between the heating roll <NUM> and the plastic card <NUM>.

At the same time as the plastic card <NUM> moves towards the movement system 160b downstream of the heating roll <NUM>, the feeding and recovery system <NUM> moves the transfer film <NUM> loaded with the ink areas to be deposited which thus follows the plastic card <NUM>. After passage of the plastic card <NUM> under the heating roll <NUM>, the movement system 160b downstream of the heating roll <NUM> takes over the plastic card <NUM> and sends it towards the ejection system <NUM>.

When the plastic card <NUM> passes under the heating roll <NUM>, the latter heats up to transfer the product from the transfer film <NUM> onto the plastic card <NUM>.

Downstream of the heating roll <NUM>, the transfer film <NUM> adheres to the plastic card <NUM> due to the heat and the pressure, and to more easily peel the transfer film <NUM> from the plastic card <NUM>, the lamination module <NUM> includes a peeling system <NUM> which is arranged downstream of the heating roll <NUM> with respect to the lamination direction <NUM>.

The peeling system <NUM> includes a peeling roll 150a and a wedge 150b secured to the peeling roll 150a and extending along said peeling roll 150a. The wedge 150b is arranged so as to be positioned between the heating roll <NUM> and the peeling roll 150a.

The wedge 150b extends at least over the width of the plastic card <NUM>, i.e., the dimension of the plastic card <NUM> that is perpendicular to the lamination direction <NUM>.

The peeling roll 150a is movably mounted on the frame <NUM> between a constraint position in which the wedge 150b pinches the transfer film <NUM> against the plastic card <NUM> and a release position in which the wedge 150b does not pinch the transfer film <NUM> against the plastic card <NUM>.

The peeling roll 150a serves as a guide for the transfer film <NUM> by ensuring a change of direction towards the recovery roll <NUM>. Thus, the transfer film <NUM> passes between the peeling roll 150a and the plastic card <NUM> without being clamped therebetween.

<FIG> shows the lamination module <NUM> when the peeling roll 150a is in the release position and <FIG> shows the lamination module <NUM> when the peeling roll 150a is in the constraint position.

In the release position, the wedge 150b is at a distance from the plastic card <NUM> and therefore does not compress the transfer film <NUM> against the plastic card <NUM>.

In the constraint position, the wedge 150b presses against the transfer film <NUM> and the plastic card <NUM>. The scraper-type wedge shape of the wedge 150b creates a pinching force at a pinch line on the transfer film <NUM>, which facilitates peeling of said transfer film <NUM>.

The movement of the peeling roll 150a between the release position and the constraint position and vice versa is herein a rotation about its axis relative to the frame <NUM>, and the movement is ensured by a drive system, such as a motor which is controlled by the control unit and which is arranged so as to move the peeling roll 150a from the release position to the constraint position and vice versa.

In some processing machines <NUM>, for double-sided printing, the plastic card <NUM> should pass under the heating roll <NUM>. To do so, the movement systems 160a-b should be arranged so as to move the card in the lamination direction <NUM> and in a reverse direction <NUM> which therefore goes from the ejection system <NUM> to the feeding system <NUM>.

To do so, the direction of rotation of each motor of the movement systems 160a-b can be reversed to change the direction of rotation and therefore the direction of movement of the plastic card <NUM>.

The passage of the peeling roll 150a from the constraint position into the release position allows clearing the passage for the plastic card <NUM> and thus avoiding the wedge 150b forming an obstacle to the passage of the plastic card <NUM>. In the release position, the wedge 150b is thus not in the passage of the plastic card <NUM> and in the constraint position, the wedge 150b is thus in the passage of the plastic card <NUM> to peel the transfer film <NUM>, and it is moved to the constraint position at the beginning of the plastic card <NUM>.

To relieve the pressure on the plastic card <NUM> at the level of the heating roll <NUM>, for example to ensure a passage of the plastic card <NUM> without printing or to facilitate its return in the opposite direction <NUM> where necessary, the lamination module <NUM> is equipped with a lifting system <NUM> which ensures the movement of the heating roll <NUM> alternately from a lowered position (<FIG>) corresponding to the position where the heating roll <NUM> bears against the anvil roll <NUM> and a raised position (<FIG>) where the heating roll <NUM> is at a distance from the anvil roll <NUM>.

In the embodiment of the invention presented herein, the lifting system <NUM> includes a first carrier frame <NUM> mounted movable in rotation on the frame <NUM> about an axis of rotation <NUM> perpendicular to the lamination direction <NUM> and where the heating roll <NUM> is secured to the first carrier frame <NUM>.

The lifting system <NUM> also includes a second carrier frame <NUM> also mounted movable in rotation on the frame <NUM> about the axis of rotation <NUM>. The second carrier frame <NUM> is herein above the first carrier frame <NUM>.

The lifting system <NUM> also includes at least one first spring element <NUM> which is mounted between the first carrier frame <NUM> and the second carrier frame <NUM> so as to separate them from each other, by pushing them back. Each first spring element <NUM> is herein a compression spring.

To limit the spacing between the first carrier frame <NUM> and the second carrier frame <NUM>, the lifting system <NUM> includes at least one blocking means <NUM> (herein two in number) which prevents the first carrier frame <NUM> from separating more than a maximum distance from the second carrier frame <NUM>. Each blocking means <NUM> is herein in the form of a window 320a formed in the second carrier frame <NUM> and of a finger 320b inserted into said window 320a and secured to the first carrier frame <NUM>. Thus, the movement of the finger 320b is limited by the edges of the window 320a.

The lifting system <NUM> also includes at least a second spring element <NUM> which is mounted between the frame <NUM>, herein via a shaft 302a, and the second carrier frame <NUM> so as to raise said second carrier frame <NUM>. Each second spring element <NUM> is herein a tension spring.

The lifting system <NUM> also includes at least one cam <NUM> mounted movable in rotation on the frame <NUM> about a cam axis <NUM> parallel to the axis of rotation <NUM>, where the cam <NUM> has a first profile 312a.

For each cam <NUM>, the second carrier frame <NUM> has a first cam track 306a which cooperates with the first profile 312a.

The cam <NUM> is herein mounted secured to the shaft 302a.

For balance-related reasons, there is a first spring element <NUM> at each end of the first carrier frame <NUM>, there is a second spring element <NUM> at each end of the second carrier frame <NUM> and there are two cams <NUM> at each end of the second carrier frame <NUM> which then includes a first cam track 306a for each cam <NUM>.

The lifting system <NUM> also includes a drive means, such as a motor, which is arranged so as to move the or each cam <NUM> in rotation about the cam axis <NUM>.

When the cam(s) <NUM> rotate(s) in a first direction, each first profile 312a cooperates with a first cam track 306a to lower the second carrier frame <NUM> and, due to the presence of the first spring elements <NUM>, the first carrier frame <NUM> and therefore the heating roll <NUM> against the anvil roll <NUM>.

Conversely, the rotation of the cam(s) <NUM> in a second direction opposite to the first direction, each first profile 312a cooperates with the first cam track 306a to release the second carrier frame <NUM> which, due to the presence of the second spring elements <NUM>, is raised while driving the first carrier frame <NUM> and therefore the heating roll <NUM> which moves away from the anvil roll <NUM>.

The first spring elements <NUM> also act as shock absorbers when the heating roll <NUM> rises upon passage of a plastic card <NUM>.

In the embodiment of the invention presented herein, the lamination module <NUM> also includes a third carrier frame <NUM> which is mounted movable in rotation on the frame <NUM> about the axis of rotation <NUM>, and which, for each cam <NUM>, has a second cam path 330a and each cam <NUM> has a second profile 312b which cooperates with a second cam path 330a.

The third carrier frame <NUM> also carries at least one first gear section 330b, herein two in number, namely one at each end of the third carrier frame <NUM>.

For each first gear section 330b, the peeling system <NUM> includes a second gear section 150c cooperating with the first gear section 330b. Each second gear section 150c is secured to the peeling roll 150a.

Each gear section 150c, 330b herein includes three teeth, but, depending on the desired angle of rotation, a different number of teeth is possible.

The lamination module <NUM> also includes at least one third spring element <NUM> which is mounted between the second carrier frame <NUM> and the third carrier frame <NUM> so as to raise said third carrier frame <NUM>. In this case, there is one single third spring element <NUM> arranged at a midplane of the lamination module <NUM> and which herein is a tension spring.

When the cam(s) <NUM> rotate(s) in the first direction, each second profile 312b cooperates with a second cam path 330a to lower the third carrier frame <NUM> and, due to the cooperation between the gear sections 150c and 330b, the peeling roll 150a pivots on its axis so as to bring the wedge 150b into the constraint position.

Conversely, the rotation of the cam(s) <NUM> in the second direction, each second profile 312b cooperates with the second cam path 330a to release the third carrier frame <NUM> which, due to the presence of the third spring element <NUM> is raised with each first gear section 330b and, due to the cooperation between the gear sections 150c and 330b, the peeling roll 150a pivots on its axis so as to bring the wedge 150b into the release position.

When the cam <NUM> rotates, the heating roll <NUM> is thus moved from the raised position to the lowered position and vice versa, and, at the same time, the peeling roll 150a is moved from the release position to the constraint position and vice versa.

The drive system which moves the peeling roll 150a is thus made up, inter alia, of cams <NUM>, of the drive means which moves the cams <NUM>, and of the third carrier frame <NUM>.

To improve the return of the peeling roll 150a into the release position when it rotates, the peeling system <NUM> includes a return spring 150d which tends to return the peeling roll 150a from the constraint position to the release position when the peeling roll 150a is brought away from the release position. The return spring 150d is herein a torsion spring mounted between the peeling roll 150a and the frame <NUM>.

In the embodiment of the invention presented herein, the lamination module <NUM> includes a peeling anvil roll <NUM> which faces the peeling roll 150a against the lower face of the plastic card <NUM> so that the plastic card <NUM> is pinched between the peeling anvil roll <NUM> and the wedge 150b when the peeling roll 150a is in the constraint position.

In the embodiment of the invention presented herein, the third carrier frame <NUM> also carries a compression roll <NUM> which is downstream of the heating roll <NUM> and which bears against the upper face of the plastic card <NUM> when the third carrier frame <NUM> is lowered.

The lamination module <NUM> also includes a compression anvil roll <NUM> which faces the compression roll <NUM> against the underside of the plastic card <NUM> so that the plastic card <NUM> is pinched between the compression roll <NUM> and the compression anvil roll <NUM> when the third carrier frame <NUM> is lowered. This pinching ensures a pressure force which clamps the transfer film <NUM> against the plastic card <NUM> for a better application of the product.

To visualize the different elements of the lamination module in <FIG> and <FIG>, the heating roll <NUM> and the first carrier frame <NUM> are shown in ghost lines, the second carrier frame <NUM> is shown in dotted lines, and the third carrier frame <NUM> is shown in chain lines.

When the second carrier frame <NUM> and the third carrier frame <NUM> are raised, each cam <NUM> forms a stop against which the second carrier frame <NUM> and the third carrier frame <NUM> bear to stop their upward movements.

Each motor driving a roll or a cam is controlled by the control unit.

According to a particular embodiment, the control unit includes, connected by a communication bus: a processor or CPU ("Central Processing Unit"); a random-access memory or RAM ("Read-Only Memory"); a read only memory, for example of the ROM type ("Read Only Memory") or EEPROM ("Electrically-Erasable Programmable ROM") or of the Flash type; a storage unit, such as an HDD hard disk type storage medium ("Hard Disk Drive"), or a storage medium reader, such as an SD card reader ("Secure Digital"); and an I/O input/output interface manager.

The I/O input/output manager enables the control unit to interact with the different motors.

The processor is capable of executing instructions loaded into the random-access memory from read-only memory, an external memory, a storage medium (such as an SD card), or a communication network (not shown). When the human-machine interface is powered on, the processor is able to read instructions from the random-access memory and execute them. These instructions form a computer program causing the processor to implement the above-described operating steps.

Claim 1:
A lamination module (<NUM>) for a plastic card (<NUM>) processing machine (<NUM>), the lamination module (<NUM>) comprising:
- a frame (<NUM>);
- a movement system (160a-b) arranged so as to move a plastic card (<NUM>) according to a lamination direction (<NUM>);
- a heating roll (<NUM>);
- an anvil roll (<NUM>) arranged so as to ensure pinching of a plastic card (<NUM>) between the anvil roll (<NUM>) and the heating roll (<NUM>);
- a transfer film (<NUM>) including areas covered with a product to be deposited over the plastic card (<NUM>);
- a feeding and recovery system (<NUM>) arranged so as to move the transfer film (<NUM>) between the plastic card (<NUM>) and the heating roll (<NUM>);
- a peeling system (<NUM>) arranged downstream of the heating roll (<NUM>) in the lamination direction (<NUM>) and including a peeling roll (150a), characterised in that
the peeling system further includes a wedge (150b) secured to the peeling roll (150a) and extending along the peeling roll (150a),
wherein the wedge (150b) is between the heating roll (<NUM>) and the peeling roll (150a) in the lamination direction (<NUM>), and wherein the peeling roll (150a) is movable between a constraint position in which the wedge (150a) pinches the transfer film (<NUM>) against the plastic card (<NUM>) and a release position in which the wedge (150b) does not pinch the transfer film (<NUM>) against the plastic card (<NUM>); and
in that the lamination module further includes
- a drive system arranged so as to move the peeling roll (150a) from the release position into the constraint position and vice versa.