Patent Description:
Card products include, for example, credit cards, identification cards, driver's licenses, passports, and other card products. Such card products generally include printed information, such as a photo, account numbers, identification numbers, and other personal information. Credentials can also include data that is encoded in a smartcard chip, a magnetic stripe, or a barcode, for example.

Card production devices include processing devices that process card substrates to form the final card product. Such processes generally include a printing process, a laminating or transfer process, a data reading process, a data writing process, and/or other process used to form the desired credential. Credential production devices typically include a collection unit, such as a hopper or other container, for collecting the processed card products. <CIT> describes a device for arranging and recovering cards. <CIT> describes a device for assorting and accommodating cards. From <CIT>, a card transport mechanism is known.

Embodiments of the present disclosure are directed to a card stacker for use with a card production device, a card stacker assembly that includes a plurality of the card stackers, and methods of using the card stacker to add a card substrate to a bottom of a stack of card substrates. One embodiment of the card stacker is configured to deliver a card substrate to a bottom of a stack of card substrates and includes a stack support, a card lift mechanism, a card feed mechanism, and a retraction mechanism. The stack support is configured to hold the stack of card substrates on a top side of the stack support that is opposite a bottom side of the stack support. The card lift mechanism is configured to support the card substrate in a lowered position on the bottom side of the stack support, and drive the card substrate to a raised position, in which the card substrate is positioned at the bottom of the stack of card substrates and is supported by the top side of the stack support. The card feed mechanism includes a first transport roller having a feed position when the card substrate is in the lowered position, and a retracted position when the card substrate is in the raised position. The first transport roller engages a top surface of the card substrate that faces the bottom side of the stack support when in the feed position. The first transport roller is on the bottom side of the stack support when in the retracted position. The retraction mechanism is configured to move the first transport roller between the feed and retracted positions.

One embodiment of the card stacker assembly includes a plurality of card stackers, each card stacker configured to deliver a card substrate to a bottom of a stack of card substrates. Each of the card stackers includes a stack support, a card lift mechanism, and a card feed mechanism. The stack support includes a top side configured to hold the stack of card substrates. The card lift mechanism is configured to drive the card substrate from a lowered position on a bottom side of the stack support that is opposite the top side to a raised position, in which the card substrate is positioned at the bottom of the stack of card substrates and is supported by the top side of the stack support. The card feed mechanism includes first and second pinch roller pairs that are respectively configured to receive or discharge individual card substrates along a card path through first and second ports positioned on opposing sides of the card lift mechanism. The plurality of card stackers are positioned in a side-by-side arrangement. A card substrate discharged through the second port of one of the card stackers is received through the first port of an adjoining card stacker.

In one embodiment of a method of adding a card substrate to a bottom of a stack of card substrates supported on a top side of a stack support of a card stacker, the card substrate is received with a card feed mechanism of the card stacker. The card feed mechanism includes a transport roller. The card substrate is supported in a lowered position on a bottom side of the stack support, which includes engaging a top surface of the card substrate that faces the bottom side of the stack support with the transport roller in a feed position. The card substrate is raised from the lowered position to a raised position, in which the card substrate is positioned on the bottom of the stack of card substrates and is supported on the top side of the stack support using a card lift mechanism of the card stacker. The transport roller is moved from the feed position to a retracted position, in which the transport roller is positioned and on the bottom side of the stack support during the raising of the card substrate.

The claimed subject matter is not limited to implementations that solve any or all disadvantages noted in the Background.

Embodiments of the present disclosure are directed to a card stacker that may be used with a card production device to deliver card substrates to a bottom of a stack of card substrates contained in the card stacker. In some embodiments, the card stacker is a modular device that may be combined with other card stackers to increase the card stacking capacity of the card production system.

These and other embodiments of the present disclosure are described more fully hereinafter with reference to the accompanying drawings. Elements that are identified using the same or similar reference characters refer to the same or similar elements. The various embodiments of the present disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the present disclosure to those skilled in the art.

<FIG> is a simplified illustration of a card production system <NUM> that includes a card production device <NUM> and one or more card stackers <NUM> formed in accordance with embodiments of the present disclosure. While the system <NUM> is shown as including a card stacker assembly <NUM> formed of three card stackers 104A-C, it is understood that embodiments of the present disclosure include systems <NUM> that include a single card stacker <NUM>, or a card stacker assembly <NUM> comprising two or more card stackers <NUM>.

The system <NUM> also includes a controller <NUM> and one or more card processing devices <NUM>. The controller <NUM> represents one or more distinct controllers of the system <NUM> each including at least one processor that is configured to execute program instructions stored in a computer-readable media or memory of the device <NUM>, which may also be represented by the controller <NUM>, or another location. Any suitable patent subject matter eligible computer readable media or memory may be utilized including, for example, hard disks, CD-ROMs, optical storage devices, flash memory, magnetic storage devices, or other suitable computer readable media or memory. Such computer readable media or memory do not include transitory waves or signals. The execution of the instructions by the controller <NUM> controls components of the system <NUM> to perform functions and method steps described herein.

The one or more card processing devices <NUM> are each configured to perform a process on a card substrate <NUM>. The card processing devices may include conventional card processing devices, such as a printing device configured to print an image to a surface of the card substrate <NUM> through a direct or transfer printing process, a laminating device configured to apply an overlaminate to a surface of the substrate <NUM>, a data reading and/or writing device (e.g., a chip encoder, a magnetic stripe encoder, etc.) configured to read data from, and/or write data to, the substrate <NUM>, a card flipper configured to invert the substrate <NUM>, and/or another conventional card processing device.

In some embodiments, individual substrates <NUM> may be received at an input <NUM> by the card production device <NUM> from a card substrate supply <NUM>, as shown in <FIG>, or another device of the system <NUM>. A transport mechanism <NUM> feeds individual substrates <NUM> along a processing path <NUM> to the one or more processing devices <NUM>. The transport mechanism <NUM> may include conventional motorized feed rollers and pinch roller pairs <NUM>, as shown in <FIG>. The card stackers <NUM> may be positioned to receive individual card substrates <NUM> discharged through an output <NUM> of the card production device <NUM> by the transport mechanism <NUM>, as shown in <FIG>.

Embodiments of the card stacker <NUM> will be described with reference to the <FIG>. <FIG> is a simplified side view of an exemplary card stacker <NUM>, and <FIG> are isometric assembled and exploded views of an exemplary card stacker <NUM>. As discussed in greater detail below, each of the card stackers <NUM> includes a stack support <NUM>, a card feed mechanism <NUM>, and a card lift mechanism <NUM>, as shown in <FIG>. The card feed mechanism <NUM> of each card stacker <NUM> is generally configured to feed individual card substrates <NUM> along a card feed path <NUM>, which may be aligned with the processing path <NUM> (<FIG>) of the card production device <NUM>, to a lift position <NUM> within the card stacker <NUM> or to handoff the substrate to the next card stacker <NUM>. Each lift mechanism <NUM> is configured to perform a lift operation on individual substrates <NUM> that are positioned in the lift position <NUM> within the card stacker <NUM>. The lift operation, which is illustrated as being performed by the card lift mechanism <NUM> of the card stacker 104C, delivers the substrate <NUM> from the lift position <NUM> in the card feed path <NUM> to the bottom of a card stack <NUM> of substrates <NUM> supported on the stack support <NUM>.

In some embodiments, each card stacker <NUM> includes a stack housing <NUM> that is removably supported within a receptacle <NUM> of a base <NUM>, which includes the card lift mechanism <NUM> and the card feed mechanism <NUM>. The stack housing <NUM> defines an interior cavity <NUM> that is configured to contain the card stack <NUM>, as shown in <FIG>. The housing <NUM> may include an access to the interior cavity <NUM>, such as a hinged door <NUM> (<FIG>) or other suitable access, for removal of the card stack <NUM>. The door <NUM> may be locked using a suitable locking mechanism <NUM>.

The stack support <NUM> is supported at a bottom <NUM> of the stack housing <NUM> adjacent an opening <NUM> in the housing <NUM>, and is configured to support the substrate stack <NUM> in a vertical column within the interior cavity <NUM> that is generally aligned with an axis <NUM>. During a substrate lifting operation, a substrate <NUM> is delivered through the opening <NUM> in the bottom <NUM> of the housing <NUM> adjacent the stack support <NUM> to the bottom of the substrate stack <NUM> and on the stack support <NUM>.

The stack support <NUM> may take on any suitable form. In one example, the stack support <NUM> includes multiple catch pawls <NUM> that may be pivoted in the direction indicated by arrows <NUM> (<FIG>) during a lift operation, but are restricted from pivoting in the direction opposite the arrows <NUM> past a support position, which is shown in <FIG>. The stack support <NUM> may include, for example, three or four catch pawls <NUM> that support the bottom surface <NUM> of the bottom substrate <NUM> of the stack <NUM> in a substantially perpendicular orientation to the axis <NUM>, as shown in <FIG>.

Each card feed mechanism <NUM> is configured to receive substrates <NUM> through a port <NUM>, feed the individual substrates <NUM> along the card feed path <NUM> to the lift position <NUM>, in which the substrate <NUM> is positioned for a lifting operation using the corresponding lift mechanism <NUM>, or deliver the substrates to an adjoining card stacker <NUM> through a port <NUM> on the opposing side of the axis <NUM> from the port <NUM>. For example, with reference to <FIG>, the card feed mechanism <NUM> of the card stacker 104A is configured to receive individual card substrates <NUM> discharged through the output <NUM> of the card production device <NUM> at the port <NUM> and feed the substrate <NUM> along the card feed path <NUM> to the lifting position <NUM>, in which the lift mechanism <NUM> may perform a lift operation, or discharge the substrate <NUM> through the port <NUM> where it is received by the card feed mechanism <NUM> of the card stacker 104B through the port <NUM>. Likewise, the card feed mechanism <NUM> of the card stacker 104B may feed the substrate <NUM> received from the card stacker 104A to position it for a lift operation or handoff the substrate <NUM> to the card feed mechanism <NUM> of the card stacker 104C, such as indicated by the substrate <NUM> drawn in phantom lines. The card stacker 104C, which is the last card stacker of the assembly <NUM> in the exemplary system <NUM> of <FIG>, may use its card feed mechanism <NUM> to position the card substrate <NUM> for a lift operation using its lift mechanism <NUM> to deliver the substrate <NUM> to the bottom of the card stack <NUM> supported by the stack support <NUM>, as indicated in <FIG>, or discharge the card substrate <NUM> through the port <NUM>, for example.

The card feed mechanism <NUM> of each card stacker <NUM> has a suitable form. In some embodiments, the card feed mechanism <NUM> includes pinch roller pairs <NUM>, such as pinch roller pairs 168A and 168B, which are respectively positioned on opposing sides of the axis <NUM> adjacent the ports <NUM> and <NUM>. Each of the pinch roller pairs <NUM> include upper and lower transport rollers <NUM> and <NUM>, respectively, such as upper transport rollers 170A and 170B, and lower transport rollers 172A and 172B. While the card feed mechanism <NUM> is illustrated as having two pinch roller pairs 168A and 168B, embodiments of the present disclosure include the use of the single pinch roller pair or other configurations.

The pinch roller pairs <NUM> are configured to drive a received substrate <NUM> along the card feed path <NUM> when in a feed position, such as shown in <FIG>. When in the feed position, one or both of the pinch roller pairs 168A and 168B pinch a received substrate <NUM> between the upper and lower transport rollers <NUM> and <NUM> and support the substrate <NUM> in substantial alignment with the card feed path <NUM>.

A motor <NUM> is configured to drive the pinch roller pairs <NUM>, such as through a conventional mechanical linkage, to feed a received card substrate <NUM> along the card feed path <NUM>. In some embodiments, the motor <NUM> is configured to drive the lower transport rollers <NUM>, and the upper transport rollers <NUM> are idler motors that are not directly driven by the motor <NUM>.

In some embodiments, the card feed mechanism <NUM> includes a card sensor <NUM> that is configured to detect reception of a card substrate <NUM> fed along the card feed path <NUM>, such as from the card production device <NUM> or an adjoining card stacker <NUM>, for example. In some embodiments, the card sensor <NUM> is used to detect a leading or trailing edge of the substrate <NUM> to establish a position of the substrate <NUM> relative to the card feed mechanism <NUM> along the card feed path <NUM>. This allows the controller <NUM> to control the card feed mechanism <NUM> to position the substrate <NUM> in the lift position <NUM> along the card feed path <NUM>, or handoff the substrate <NUM> to an adjoining card stacker <NUM>. In some embodiments, the motor <NUM> is a stepper motor, and the detection of the leading or trailing edge of the substrate <NUM> using the card sensor <NUM> allows the controller <NUM> to position the substrate <NUM> in a desired location along the card feed path <NUM> relative to the card feed mechanism <NUM> by driving the motor <NUM> a predetermined number of steps.

As discussed above, the card feed mechanism <NUM> is configured to position a received substrate <NUM> in a lift position <NUM> (<FIG>) along the card feed path <NUM> for a lifting operation. In some embodiments, the pinch roller pairs 168A and 168B simultaneously support the substrate <NUM> when it is in the lift position <NUM>. Thus, in some embodiments, the upper transport rollers <NUM> of the pinch roller pairs 168A and 168B each engage a top surface <NUM> of the card substrate <NUM> when it is in the lift position <NUM>, and the bottom transport rollers <NUM> each engage a bottom surface <NUM> of the substrate <NUM> when it is in the lift position <NUM>.

Some embodiments of the lift mechanism <NUM> include a card support member <NUM> and a drive mechanism <NUM>, which is driven by a motor <NUM> (<FIG>), such as through a conventional mechanical linkage. The card support member <NUM> has a lowered position, shown in <FIG>, that corresponds to the feed position of the pinch roller pairs 168A and 168B and the lift or lowered position <NUM> of the card substrate <NUM>, in which the substrate <NUM> is aligned with the card feed path <NUM>, as shown in <FIG>. In some embodiments, the card support member <NUM> includes a top surface <NUM> that can support the substrate <NUM> as it is fed along the card feed path <NUM>. For example, when a card substrate <NUM> is received by the pinch roller pair 168A, the leading edge of the substrate <NUM> may be supported by the top surface <NUM> of the card support member <NUM> as the leading edge of the card substrate <NUM> as it is fed to the pinch roller pair 168B.

During a lift operation, the lift mechanism <NUM> delivers a card substrate <NUM> supported on the card support member <NUM> from the lift position <NUM> (<FIG>) along the axis <NUM> through the opening <NUM> of the stack housing <NUM> to the bottom of the card stack <NUM> using the drive mechanism <NUM>, as generally illustrated by the card stacker 104C in <FIG>. The drive mechanism <NUM> may take on any suitable form. In some embodiments, the drive mechanism <NUM> includes a threaded rod <NUM> that is received within a threaded bore <NUM> of the card support member <NUM>, as indicated in <FIG>. The rod <NUM> may be substantially coaxial to the axis <NUM>. The motor <NUM> drives rotation of the rod <NUM> about the axis <NUM>, and the threaded engagement with the card support member <NUM> drives the card support member <NUM> along the axis <NUM> either toward or away from the card stack <NUM>.

When the card substrate <NUM> is in the lift position <NUM> within a card stacker <NUM>, one or more components of the card feed mechanism <NUM> block the desired lifting path of the substrate <NUM> to the bottom of the card stack <NUM>. For example, when the substrate <NUM> is supported between the pinch roller pairs 168A and 168B, and the upper transport rollers <NUM> engage the top surface <NUM> of the substrate <NUM>. As a result, the position of the upper transport rollers <NUM> between the substrate <NUM> and the opening <NUM> to the housing <NUM> prevent the delivery of the substrate <NUM> to the bottom of the card stack <NUM>.

Each card stacker <NUM> includes a retraction mechanism, which is generally indicated by box <NUM> in <FIG>. The retraction mechanism <NUM> is configured to facilitate a lift or stacking operation by clearing the one or more components of the card feed mechanism <NUM> from the desired lifting path for substrate <NUM>, which allows the lift mechanism <NUM> to deliver the substrate <NUM> to the bottom of the card stack <NUM> supported on the stack support <NUM>. In some embodiments, the retraction mechanism <NUM> is configured to move the upper transport rollers 170A and 170B of the pinch roller pairs 168A and 168B from the lifting path of the card substrate <NUM> to facilitate a lifting operation.

Exemplary embodiments of the retraction mechanism <NUM> will be described along with an exemplary lift or stacking operation with reference to <FIG> and <FIG>, which are each simplified side views of an exemplary card stacker <NUM> during various stages of the lift or stacking operation. Initially, with the pinch roller pairs 168A and 168B in the feed position and the lift mechanism <NUM> in its lowered position, the substrate <NUM> is fed along the card feed path <NUM> to the lift position <NUM> shown in <FIG>. Here, the card stack <NUM> is supported on a top side <NUM> of the stack support <NUM>, and the substrate <NUM>, the pinch roller pairs 168A and 168B and the top surface <NUM> of the card support member <NUM> are each positioned on a bottom side <NUM> of the stack support <NUM>, as shown in <FIG>. Thus, as used herein, the terms "top" and "bottom" refer to relative positions along the axis <NUM>, in which the top side or position is located along the axis <NUM> in an upward direction, which is indicated by arrow <NUM>, from the bottom side or position.

With the substrate <NUM> supported in the lift position <NUM> (<FIG>), the lift mechanism <NUM> raises the card support member <NUM> using the drive mechanism <NUM> in the upward direction <NUM>. In some embodiments, the retraction mechanism <NUM> moves the upper transport rollers <NUM> from their feed position, which is indicated in phantom lines, away from the axis <NUM> as indicated by arrows <NUM>. This movement of the upper transport rollers <NUM> may also involve an upward movement of the upper transport rollers <NUM> from their feed positions along the axis <NUM>. In some embodiments, this movement of the upper transport rollers <NUM> by the retraction mechanism <NUM> is driven in response to the upward movement of the card support member <NUM> by the lift mechanism <NUM>. Thus, in some embodiments, the retraction mechanism <NUM> is driven by the drive mechanism <NUM> of the lift mechanism <NUM> using the motor <NUM>.

Following this initial movement of the upper transport rollers <NUM> from their feed positions, the upper transport rollers <NUM> reach a position in which they remain engaged with the card substrate <NUM>, such as the top surface <NUM> or the side edges of the substrate <NUM>, as shown in <FIG>. As a result, the upper transport rollers <NUM> continue to hold the substrate <NUM> in the lift position <NUM> relative to the axis <NUM> following this initial raising of the substrate <NUM> toward the card stack <NUM>.

As the lift mechanism <NUM> continues to raise the substrate <NUM> along the axis <NUM>, the upper transport rollers <NUM> continue to be moved further from the axis <NUM> from their position in <FIG> (shown in phantom lines) by the retraction mechanism <NUM> until they are outside a projection of the substrate <NUM> along the axis <NUM>, as shown in <FIG>. Further movement of the upper transport rollers from their position in <FIG> (shown in phantom lines) allows the lift mechanism <NUM> to continue to deliver the substrate <NUM> along the axis <NUM> toward the opening <NUM> in the stack housing <NUM> to the stack support <NUM> (e.g., catch pawls <NUM>), as shown in <FIG>. Thus, the retraction mechanism <NUM> moves the upper transport rollers <NUM> from their feed position (<FIG>), in which the upper transport rollers <NUM> engage the top surface <NUM> of the substrate <NUM>, to a retracted position (<FIG>), in which the upper transport rollers <NUM> are displaced from the lifting path of the substrate <NUM> and are positioned below the substrate <NUM>, in response to the raising of the substrate <NUM> by the lift mechanism <NUM>.

Next, the card support member <NUM> is driven by the drive mechanism <NUM> to raise the substrate <NUM> along the axis <NUM> to the top side <NUM> of the stack support <NUM> and in engagement with the bottom of the stack <NUM>, as shown in <FIG>. For example, the drive mechanism <NUM> delivers the substrate <NUM> through the catch pawls <NUM>, which rotate in the direction <NUM> (<FIG>), and in engagement with the bottom substrate <NUM> of the stack <NUM>. This positions the substrate <NUM> on the top side <NUM> of the stack support <NUM>.

The card support member <NUM> is then lowered along the axis <NUM> by the drive mechanism <NUM> to the lowered position, as shown in <FIG>. The catch pawls <NUM> rotate in the direction opposite the arrows <NUM> (<FIG>) to their support position, in which they support the substrate <NUM> and the rest of the card stack <NUM>. Additionally, during the lowering of the card support member <NUM>, the retraction mechanism <NUM> pivots the upper transport rollers 170A and 170B of the pinch roller pairs 168A and 168B from their retracted position (shown in phantom lines) to their feed position, as indicated by the arrows in <FIG>, to complete the card stacking operation. Thus, the card feed mechanism <NUM> and the lift mechanism <NUM> are positioned to receive a new substrate <NUM>' fed along the card feed path <NUM>, as indicated in <FIG>.

The retraction mechanism <NUM> can take on any suitable form while driving movement of the upper transport rollers <NUM> from their feed position (<FIG>) to their retracted position (e.g., <FIG>). Exemplary embodiments of the retraction mechanism <NUM> will be described with reference to <FIG>. <FIG> is an isometric view of an exemplary base <NUM> of a card stacker <NUM>, in accordance with embodiments of the present disclosure. <FIG> are side cross-sectional views of the base <NUM> of <FIG> taken generally along line <NUM>-<NUM>, during various stages of a substrate lifting or stacking operation. The upper transport roller 170A and the bottom transport roller 172A are shown in phantom lines in order to show features of the retraction mechanism <NUM>.

In some embodiments, the retraction mechanism <NUM> includes pivotable supports 200A and 200B, which are respectively attached to the card support member <NUM> through suitable pivotable connections 202A and 202B, such as hinges, for example. The pivotable connections 202A and 202B allow the supports 200A and 200B to respectively pivot about axes 204A and 204B, which are generally perpendicular to the direction the substrates <NUM> are fed along the card feed path and the axis <NUM>. The upper transport roller 170A is connected to the support 200A and the upper roller 170B is connected to the support 200B. Thus, the transport rollers 170A and 170B move with movement of the corresponding support 200A and 200B. In some embodiments, the transport rollers 170A and 170B have a fixed position relative to the corresponding support 200A and 200B.

The support 200A may be biased to pivot about the axis 204A in the direction indicated by arrow 206A, and the support 200B may be biased to pivot about the axis 204B in the direction indicated by arrow 206B. In some embodiments, this biasing of the supports 200A and 200B is facilitated using conventional techniques, such as a coil spring or another suitable biasing mechanism. The biasing of the supports 200A and 200B about the corresponding axes 204A and 204B, also biases the upper transport rollers 170A and 170B in the same manner. As a result, when the pinch rollers 168A and 168B are in their feed position (<FIG> and <FIG>), the upper transport rollers 170A and 170B are generally biased toward the top surface <NUM> of the card substrate <NUM> and pinch the card substrate <NUM> against the corresponding lower transport rollers 172A and 172B, which engage the bottom surface <NUM> of the card substrate <NUM>. In some embodiments, the pinch roller pair 168A is configured to pinch the card substrate <NUM> in the lift position <NUM> adjacent a first edge <NUM> of the card substrate <NUM>, and the pinch roller pair 168B is configured to pinch the substrate <NUM> in the lift position <NUM> adjacent a second edge <NUM> of the substrate <NUM> that is opposite the first edge <NUM>, as best shown in <FIG>.

As discussed above, in some embodiments, the movement of the transport rollers 170A and 170B from the feed position to the retracted position is driven in response to movement of the card support member <NUM> from the lowered position (<FIG>) to the raised position (<FIG>) during a substrate lifting or stacking operation. In some embodiments, the movement of the card support member <NUM> from the lowered position to the raised position drives each of the supports 200A and 200B to respectively pivot about the axes 204A and 204B, and transitions the transport rollers 170A and 170B from the feed position (<FIG>) to the retracted position (<FIG>). This can be accomplished using any suitable technique.

In one exemplary embodiment, the transport rollers 170A and 170B are driven from the feed position to the retracted position through engagement between the supports 200A and 200B and the bottom transport rollers 172A and 172B. For example, the supports 200A and 200B may respectively include a slot 210A and 210B through which shafts <NUM> of the corresponding bottom rollers 172A extend. In some embodiments, the shafts <NUM> are supported by a frame <NUM> of the base <NUM> and have a fixed position relative to the frame <NUM>. As a result, the card support member <NUM>, the supports 200A and 200B, and the transport rollers 170A and 170B move relative to the shafts <NUM> during movement of the card support member <NUM> along the axis <NUM>. Accordingly, as the card support member <NUM> moves along the axis <NUM> during a substrate lifting or stacking operation, the shafts <NUM> slide within the slots 210A and 210B relative to the supports 200A and 200B. The slots 210A and 210B are shaped to pivot the supports 200A and 200B and drive the transport rollers 170A and 170B from the feed position to the retracted position along a desired path in response to the relative movement between the shafts <NUM> and the supports 200A and 200B.

When the card support member <NUM> of the lift mechanism <NUM> is in its lowered position and the transport rollers 170A and 170B are in their feed position, a card substrate <NUM> may be fed along the card feed path <NUM> to the lift position <NUM>, as shown in <FIG> and <FIG>. When in this position, the upper transport rollers 170A and 170B are biased toward the top surface <NUM> of the substrate <NUM> and pinch the substrate <NUM> against the bottom rollers 172A and 172B. At the beginning of the lifting operation, the card support member <NUM> engages the bottom surface <NUM> of the substrate <NUM> as the card support member <NUM> is raised from its lowered position along the axis <NUM>, as shown in <FIG> and <FIG>. During this initial movement of the card support member <NUM>, the upper transport rollers 170A and 170B are displaced from the corresponding bottom rollers 172A and 172B and may be rotated slightly about the corresponding axes 204A and 204B away from the central axis <NUM> in response to the engagement between the shafts <NUM> and the corresponding slots 210A and 210B, as shown in <FIG> and <FIG>.

As the card support member <NUM> continues to raise the substrate along the axis <NUM> toward the raised position, the supports 200A and 200B and the attached transport rollers 170A and 170B are driven to pivot about the corresponding axes 204A and 204B in response to the engagement between the shafts <NUM> and the slots 210A and 210B in the direction indicated by arrows <NUM> in <FIG>, to the retracted positions shown in <FIG> illustrates the card support member <NUM> driving the substrate <NUM> through the opening <NUM> in the bottom of the stack housing <NUM>, and <FIG> illustrates the card support member <NUM> positioning the substrate <NUM> in the fully raised position, in which the substrate <NUM> is positioned on the top side <NUM> of the stack support <NUM>, which is also shown in <FIG>. The retracted positions (e.g., <FIG> and <FIG>) of the upper transport rollers 170A and 170B position the rollers 170A and 170B on the bottom side <NUM> of the stack support <NUM> and outside of the lifting path of the substrate corresponding to a projection of the substrate <NUM> along the axis <NUM>.

The card support member <NUM> is then lowered along the axis <NUM> through the opening <NUM> in the housing <NUM> and back to its lowered position shown in <FIG> and <FIG> using the lift mechanism <NUM>. This movement of the card support member <NUM> pivots the supports 200A and 200B about the axes 204A and 204B and drives the upper transport rollers from the retracted position (<FIG> and <FIG>) to the feed position (<FIG> and <FIG>), to prepare the base <NUM> for receiving another card substrate <NUM>.

In some embodiments, the card stacker <NUM> includes a card stack sensor <NUM> (<FIG> and <FIG>) that is configured to detect when the stack housing reaches a full condition, such as illustrated by card stacker 104B in <FIG>, in which it no longer accepts additional substrates in the card stack <NUM>. In some embodiments, the card stack sensor <NUM> is configured to detect a position of the top substrate 112T in the stack <NUM> that indicates the full condition. This may be accomplished using any suitable sensor arrangement.

In some embodiments, the card stack sensor <NUM> includes a passive or mechanical sensing element <NUM> in the stack housing <NUM> and an active or electronic sensor <NUM> in the base <NUM>, as shown in <FIG>, which are simplified partial side views of a card stacker <NUM> in accordance with embodiments of the present disclosure. This allows the card stacker <NUM> to provide the desired full stack sensing feature without electrical connections between the stack housing <NUM> and the base <NUM>.

In some embodiment, the passive sensing element <NUM> includes a mechanical switch <NUM> positioned at the top end <NUM> of the interior cavity <NUM> of the stack housing <NUM>. The active sensor <NUM> may be any suitable active sensor, such as an optical or capacitive sensor, that is supported in the base <NUM> adjacent the receptacle <NUM> that receives the bottom <NUM> of the housing <NUM>. Before the stack <NUM> reaches a full condition, the top substrate 112T in the stack <NUM> does not trigger the mechanical switch <NUM>, as shown in <FIG>. However, as substrates <NUM> are added to the bottom of the stack <NUM>, the top substrate 112T rises relative to the mechanical switch <NUM> and transitions the switch <NUM> from the first (not full) position (<FIG>), to a second position indicating a full condition, as shown in <FIG>.

The mechanical switch <NUM> may take on any suitable form. For example, the mechanical switch <NUM> may comprise a lever arm <NUM> that is configured to pivot about an axis <NUM> from the first position to the second position in response to the rising stack of substrates <NUM>. A rod <NUM> is attached to an end <NUM> of the lever arm <NUM> and generally moves along the axis <NUM> in response to movement of the lever arm <NUM> from the first position to the second position. An end <NUM> of the rod <NUM> may initially be positioned for detection by the active sensor <NUM> when the lever arm <NUM> is in the first position, as shown in <FIG>. When the lever arm <NUM> transitions to the second position, the end <NUM> of the rod <NUM> is lowered and moved out of the detection zone of the active sensor <NUM>. This lack of detection of the end <NUM> of the rod <NUM> by the active sensor <NUM> may be used by the controller <NUM> to detect the full condition of the substrate stack <NUM>. Alternatively, the mechanical switch <NUM> may be arranged to position the end <NUM> outside the detection zone of the active sensor <NUM> when the card stack <NUM> has not reached the full condition, and position the end <NUM> within the detection zone of the active sensor <NUM> when the card stack <NUM> has reached the full condition. Other card stack sensing arrangements may also be used to provide the desired detection of the full card stack condition within the stack housing <NUM>.

In some embodiments, the active sensor <NUM> may also be used to detect whether the stack housing <NUM> is properly installed on the base <NUM>. For instance, when the stack housing <NUM> is properly installed on the base <NUM> and the card stack <NUM> is not full, the lever arm <NUM> is in the first position and the end <NUM> of the rod <NUM> is positioned within the detection zone of the active sensor <NUM>, as shown in <FIG>. However, if the housing <NUM> is not properly seated within the receptacle <NUM> of the base <NUM>, the active sensor <NUM> will not detect the end <NUM> of the rod <NUM>. Thus, the controller <NUM> can use the detection of the end <NUM> of the rod <NUM> by the active sensor <NUM> to determine that the stack housing <NUM> is properly installed within the receptacle <NUM> of the base <NUM>.

Thus, the controller <NUM> may enable substrate lifting or stacking operations to be performed by the card stacker <NUM>, when the active sensor <NUM> detects the end <NUM> of the rod <NUM>, and disable substrate lifting or stacking operations when the active sensor <NUM> does not detect the end <NUM> of the rod <NUM>, as this may indicate that the stack housing <NUM> is either not installed on the base <NUM>, is improperly installed on the base <NUM>, or the card stack <NUM> has reached a full condition. However, the controller <NUM> may still use the base <NUM> to receive and pass substrates <NUM> to an adjoining card stacker <NUM> when card lifting or stacking operations are disabled. This is generally illustrated in <FIG>, in which card stacker 104B has reached a full condition, but is able to pass a substrate <NUM> (shown in phantom lines) to the card stacker 104C.

In accordance with the above discussion, embodiments of the present disclosure include a card stacker <NUM> that is configured to deliver a card substrate <NUM> to a bottom of a stack <NUM> of card substrates <NUM>. In some embodiments, the card stacker <NUM> includes a stack support <NUM>, a card feed mechanism <NUM>, a card lift mechanism <NUM>, and a retraction mechanism <NUM>, as shown in <FIG>. The stack support <NUM> is configured to hold the stack <NUM> of card substrates <NUM> on a top side <NUM> of the stack support <NUM> that is opposite a bottom side <NUM> of the stack support <NUM>. The card lift mechanism <NUM> is configured to support the card substrate <NUM> in a lowered position (<FIG>) on the bottom side <NUM> of the stack support <NUM>, and drive the card substrate <NUM> to a raised position (<FIG>), in which the card substrate <NUM> is positioned at the bottom of the stack of card substrates <NUM> and is supported on the top side <NUM> of the stack support <NUM>.

Embodiments of the card feed mechanism <NUM> include an upper transport roller 170A having a feed position (<FIG>) when the card substrate <NUM> is in the lowered position, and a retracted position (<FIG>) when the card substrate <NUM> is in the raised position. The upper transport roller 170A engages a top surface <NUM> of the card substrate <NUM> that faces the bottom side <NUM> of the stack support <NUM> when in the feed position (<FIG>). The upper transport roller 170A is positioned on the bottom side <NUM> of the stack support <NUM> when in the retracted position (<FIG>). The retraction mechanism <NUM> is configured to move the upper transport roller 170A between the feed and retracted positions, as discussed above with reference to <FIG> and <FIG>.

In some embodiments, the card lift mechanism <NUM> includes a card support member <NUM> and a drive mechanism <NUM>. The drive mechanism <NUM> is driven by a motor <NUM> and drives the card support member <NUM> between a lowered position (<FIG> and <FIG>) corresponding to the lowered position of the card substrate <NUM>, and a raised position (<FIG> and <FIG>) corresponding to the raised position of the card substrate <NUM>.

In some embodiments, the retraction mechanism <NUM> includes a first pivotable support 200A that is attached to the card support member <NUM> and is configured to pivot the upper transport roller 170A about a support axis 204A to the retracted position in response to movement of the card support member <NUM> from the lowered position to the raised position, as discussed above with reference to <FIG>.

In some embodiments, the card feed mechanism <NUM> includes a lower transport roller 172A, and the card substrate <NUM> is pinched between the transport rollers 170A and 172A when the card substrate <NUM> is in the lowered position, such as shown in <FIG> and <FIG>. In some embodiments, the pivotable support 200A of the retraction mechanism <NUM> is biased to pivot the upper transport roller 170A about the first support axis 204A toward the top surface <NUM> of the card substrate <NUM> when the card substrate <NUM>. In some embodiments, the transport rollers 170A and 172A form a first pinch roller pair 168A that is configured to pinch the card substrate <NUM> in the lowered position adjacent a first edge <NUM> of the card substrate <NUM>.

In some embodiments, the card feed mechanism <NUM> includes a second pinch roller pair 168B that includes upper and lower transport rollers 170B and 172B, which pinch the card substrate <NUM> in the lowered position at a second edge <NUM> of the card substrate <NUM> that is opposite the first edge <NUM>, as shown in <FIG>.

In some embodiments, the upper transport roller 170B includes a feed position when the card substrate <NUM> is in the lowered position, as shown in <FIG> and <FIG>, and a retracted position when the card substrate is in the raised position, as shown in <FIG> and <FIG>. The upper transport roller 170B engages the top surface <NUM> of the card substrate <NUM> when in the feed position, and the upper transport roller 170B is on the bottom side of the stack support <NUM> when in the retracted position, as shown in <FIG> and <FIG>.

The retraction mechanism <NUM> is configured to move the upper transport roller 170B between the feed and retracted positions, as discussed above with reference to <FIG> and <FIG>. In some embodiments, the retraction mechanism <NUM> includes a second pivotable support 200B that is attached to the card support member <NUM> and is configured to pivot the upper transport roller 170B about a second support axis 204B to the retracted position in response to movement of the card support member <NUM> from the lowered position to the raised position.

Additional embodiments are directed to a method of performing a substrate stacking operation using the card stacker <NUM> formed in accordance with one or more embodiments described herein. In one embodiment of the method, a card substrate <NUM> is received using a card feed mechanism <NUM> of the card stacker <NUM> that includes a transport roller <NUM>, such as shown in <FIG> and <FIG>. The card substrate <NUM> is supported in a lift position (<FIG>) in a card path <NUM> on a bottom side <NUM> of the stack support <NUM>. In some embodiments, a top surface <NUM> of the card substrate <NUM> that faces the bottom side <NUM> of the stack support <NUM> is engaged with the upper transport roller <NUM> (e.g., roller 170A), in a feed position, as shown in <FIG>. The card substrate <NUM> is then raised from the lift position to a raised position, in which the card substrate <NUM> is positioned on the bottom of the stack of card substrates <NUM> and supported on the top side <NUM> of the stack support <NUM> using a card lift mechanism <NUM>, as discussed above with reference to <FIG> and <FIG>. During the lifting or stacking operation, the transport roller <NUM> is moved from the feed position to a retracted position, in which the transport roller is positioned on the bottom side <NUM> of the stack support <NUM>.

It is appreciated that certain features of the present disclosure, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the present disclosure, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable subcombination or as suitable in any other described embodiment of the present disclosure.

Claim 1:
A card stacker (<NUM>) for use with a card production device (<NUM>) and configured to deliver a card substrate (<NUM>) to a bottom of a stack (<NUM>) of card substrates (<NUM>), the card stacker (<NUM>) comprising:
a stack support (<NUM>) configured to hold the stack (<NUM>) of card substrates (<NUM>) on a top side (<NUM>) of the stack support (<NUM>) that is opposite a bottom side (<NUM>) of the stack support (<NUM>);
a card lift mechanism (<NUM>) configured to support the card substrate (<NUM>) in a lift position (<NUM>) on the bottom side (<NUM>) of the stack support (<NUM>), and drive the card substrate (<NUM>) to a raised position, in which the card substrate (<NUM>) is positioned at the bottom of the stack (<NUM>) of card substrates (<NUM>) and is supported by the top side (<NUM>) of the stack support (<NUM>);
a card feed mechanism (<NUM>) comprising a first transport roller (170A) having a feed position when the card substrate (<NUM>) is in the lift position (<NUM>), and a retracted position when the card substrate (<NUM>) is in the raised position, wherein:
the first transport roller (170A) engages a top surface of the card substrate (<NUM>) that faces the bottom side (<NUM>) of the stack support (<NUM>) when in the feed position; and
when in the retracted position, the first transport roller (170A) is displaced from a lifting path of the card substrate (<NUM>) defined between the lift and raised positions; and
a retraction mechanism (<NUM>) configured to move the first transport roller (170A) between the feed and retracted positions.