U.S. patent application number 10/161286 was filed with the patent office on 2003-01-02 for identification card printer and laminator.
Invention is credited to Campion, Kevin R., Haugen, I. Tony, Klinefelter, Gary M., Upin, Jeffrey D..
Application Number | 20030000637 10/161286 |
Document ID | / |
Family ID | 22692966 |
Filed Date | 2003-01-02 |
United States Patent
Application |
20030000637 |
Kind Code |
A1 |
Campion, Kevin R. ; et
al. |
January 2, 2003 |
Identification card printer and laminator
Abstract
A laminator for laminating sheets of lamina onto substrates such
as cards uses a web of lamina material that preferably has a
bondable and printable layer on the reverse side and can then be
printed with information and laminated onto a blank card. The web
also preferably has a series of spaced transverse lines of reduced
strength so the web can be separated into individual sheets of
lamina by creating a tension in the web across the transverse line
of reduced strength.
Inventors: |
Campion, Kevin R.;
(Minnetonka, MN) ; Haugen, I. Tony; (Minnetonka,
MN) ; Klinefelter, Gary M.; (Eden Prairie, MN)
; Upin, Jeffrey D.; (Edina, MN) |
Correspondence
Address: |
Nickolas E. Westman
WESTMAN CHAMPLIN & KELLY
International Centre, Suite 1600
900 South Second Avenue
Minneapolis
MN
55402-3319
US
|
Family ID: |
22692966 |
Appl. No.: |
10/161286 |
Filed: |
May 31, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10161286 |
May 31, 2002 |
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09188396 |
Nov 6, 1998 |
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6409872 |
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Current U.S.
Class: |
156/264 ;
156/277; 156/387 |
Current CPC
Class: |
B65H 37/04 20130101;
B32B 2425/00 20130101; B65H 2701/1914 20130101; Y10T 156/1322
20150115; B32B 38/0004 20130101; B32B 37/182 20130101; B32B 38/145
20130101; Y10T 156/1339 20150115; B32B 38/185 20130101; Y10T
156/1075 20150115; B65H 35/10 20130101 |
Class at
Publication: |
156/264 ;
156/277; 156/387 |
International
Class: |
B32B 001/00 |
Claims
What is claimed is:
1. An apparatus for laminating a sheet of lamina onto a substrate
comprising a supply of lamina in the form of a continuous web and
having transverse lines of reduced strength to define a plurality
of sheets of lamina, guide rollers for controlling movement of the
web including a first and a second set of drive rollers that are
spaced apart, controllable drives to the sets of drive rollers to
provide differential drive speed, to create tension in the web
between the first and second sets of drive rollers and to cause
separation of a sheet of lamina from the web between the sets of
drive rollers, and a lamination station for receiving the separated
sheet of lamina and a substrate for laminating the separated sheet
to the substrate.
2. The apparatus of claim 1 wherein the web of lamina material has
a printable layer on a reverse side thereof that faces a substrate
when lamination occurs, and a printer to print information on the
reverse side thereof.
3. The apparatus of claim 2 wherein the lamina has a layer of vinyl
forming the reverse side thereof.
4. The apparatus of claim 1 including a supply of individual
substrates comprising cards, and a printer to print information on
a card prior to laminating the lamina sheet thereon.
5. The apparatus of claim 1 wherein the web has a pair of laterally
spaced, longitudinally extending side edges, and at least one pair
of scallops on the side edges, the pair of scallops being
transversely aligned on opposite edges to define a line of reduced
strength across the web.
6. The apparatus of claim 4 wherein a micropreforated line extends
across the web between the aligned scallops.
7. A web of lamina material for use in covering a substrate having
a length, said web having a longitudinal length and spaced apart
longitudinal edges, a series of scallops formed along each of the
longitudinal edges and arranged in transversely aligned pairs to
define a transverse line of reduced web strength.
8. The web of claim 7, wherein a length of the web between adjacent
transverse lines of reduced web strength is substantially equal to
a length of the substrate to be covered by the lamina material.
9. The web of claim 7, wherein the scallops form rounded corners
that are substantially the same configuration as corners of a
substrate on which the lamina material is applied.
10. A method of providing a protective lamina on a substrate
comprising providing a web of lamina material with a heat bondable
layer on a reverse side thereof, printing information on the
reverse side web in selected locations, separating the selected
locations into separate sheets of lamina, mating the separated
sheets with substrates, and laminating the separated sheets onto
separate substrates.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates to an apparatus for bonding a
heat bondable lamina onto a card that forms a substrate. The lamina
is separable into sheets that fit the cards closely. Informational
materials can be printed either on the cards or on the lamina.
[0002] Laminated cards are widely used as drivers licenses,
identification cards, and other types of cards on which information
is printed, and then a lamina is placed over the card to protect
the printing. Particularly, a card shaped substrate is made from a
suitable material such as a plastic, cardboard or the like, and
information such as photographs, personal data, text and graphics
are required to be carried on the card so that it can be used for
identification easily. In some instances, holographic images and
other optical or magnetically stored information will be present on
the card.
[0003] The present device permits selectively utilizing a lamina
that is provided from a web on supply roll and which can be
separated into sections without cutting. The lamina is made so
printing can be applied to the reverse side of the lamina, if
desired, and then laminated onto a face of a card or substrate.
Alternately, the card may be preprinted and the lamina bonded into
place with a heat sensitive layer.
[0004] Another problem that has arisen in the use of laminated
cards is the ability to lift the plastic lamina from the substrate
and alter or change the printed information and then subsequently
replace the lamina after the alteration has been completed. In
order to obviate that, it is important that the edges of the lamina
do not protrude from the card at any place, unlike the square
corner of standard lamina used on the rounded corners of standard
substrates as cards.
SUMMARY OF THE INVENTION
[0005] The present invention provides apparatus and methods for
placing lamina onto a substrate, such as a card, and heat bonding
the lamina in place with little waste of lamina material.
[0006] In one preferred form, the lamina is constructed with a
printable vinyl layer that will be placed to overlie the substrate
and used for heat bonding to the substrate. Since a vinyl layer
also can carry printed material, printing may be applied to the
reverse or inner side of the lamina, and then the lamina will be
bonded to a card that has no printing. The lamina may be provided
as an elongated web on a supply roll, and then separated into
individual substrate sized sheets. The sheets are brought into
registry with the substrates or cards and heat bonded in place.
[0007] A further preferred embodiment utilizes a roll having a web
of lamina material from which the successive of sheets are
separated from each other along micro perforated lines or
equivalent that extend transversely to the length of the web.
Scallops are formed at intervals along the edges of the web and
aligning scallops are joined by the micro perforated lines so that
by placing a snap-load on the web visually smooth end edges are
formed for the individual lamina sheets. The scalloped portions
along the edges of the roll of material are rounded to conform to
the corners of the cards or substrates. The lamina sheets are
precisely sized and configured to the corners of the substrates or
cards, so that the lamina can be of size to cover the entire area
of the card with no edges of the lamina extending beyond the card
at the rounded corners.
[0008] In this preferred embodiment, the printing can take place on
a reverse side of the lamina, or the cards can be preprinted and
then covered with the lamina sheets. The sheets are separated
without cutting, but by exerting a tensile load across the
microperforations which form a reduced strength line.
[0009] In all forms of the apparatus, the lamina can be multiple
layered and include a polyester outer layer, and a layer of
material such as a holographic imaging system layer bonded to the
polyester layer in a known manner, and then a layer of vinyl bonded
to the holographic image layer. The vinyl can be printed upon, and
is on the reverse side, of the laminate so it also is bonded to the
core or substrate forming the card. If the reverse side of the
laminate carries the needed printing, the card or substrate can be
blank. Alternatively, a vinyl layer may be used and printed upon on
the reverse side and bonded directly to a card or substrate without
using a polyester layer or a holographic layer.
[0010] The apparatus shown accurately places the laminate sheets
onto the cards. The web is either easily separated into sheet
segments with the printing either on the reverse side of the lamina
or on the card, depending on the configuration of the apparatus
desired.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a flow diagram showing the steps of operation of a
preferred form of the apparatus of the present invention;
[0012] FIG. 2 is a flow diagram of a method of separating sheets of
lamina from a web stored on a roll into individual sheets that
cover the individual substrates or cards;
[0013] FIG. 3 is a side part-schematic view of an apparatus made
according to the present invention in a first preferred form;
[0014] FIG. 4 is a modified form of the device of FIG. 3;
[0015] FIG. 5 is a further modified form of the invention including
a printer for printing cards prior to laminating to a
substrate;
[0016] FIG. 6 is a perspective view of a supply roll of a web of
lamina material illustrating the regions of reduced strength for
separating the lamina into individual sheets;
[0017] FIG. 7 is a perspective view of a card having a sheet of
lamina bonded thereto;
[0018] FIG. 8 is a schematic flat layout of a web of lamina
material;
[0019] FIG. 9 is an enlarged fragmentary sectional view of a first
form of lamina;
[0020] FIG. 10 is an enlarged fragmentary sectional view of a
second form of lamina; and
[0021] FIG. 11 is a schematic sectional view of a typical set of
snap drive rollers used for driving sheets of lamina.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Referring to FIGS. 1 and 2, box 200 is a step of providing a
web of lamina material on a roll with a heat sensitive layer on its
reverse side, that is the side that would not be exposed when the
lamina material is laminated to a substrate. The web of lamina is
moved from the roll through a printer for printing on the reverse
side of the lamina represented at 202. The layer of the web that is
heat sensitive also is a layer that can be printed upon. Then, the
lamina is separated into sheets, at step 204. The apparatus is used
to guide and the individual sheet segments to mate with a card as
indicated at step 205, and the substrate or card, and the lamina
sheet are laminated in place using heat as indicated by step
206.
[0023] Alternatively, the card can be printed as indicated by the
step 208, and in which instance, the lamina can be provided without
printing, as indicated by the step 210. The lamina web would be
merely separated into the card size sheets and mated with the
preprinted card at step 205 and laminated in place at step 206.
[0024] FIG. 2 shows details of the separating step 204 to separate
the web from a roll into individual lamina sheets, without using a
cutter. As shown at step 212, the lamina is provided with weakened
or reduced strength cross lines, preferably microperforations,
aligned with notches or scallops at the edges of the web. Then the
web is driven in a first set of drive or pinch rollers that will
drive the lamina web from the supply roll as indicated at 214. The
lamina web, before separating the sheets, is received by a second
set of pinch or drive rollers with the reduced strength or weakened
transverse line across the lamina web between the first and second
sets of pinch rollers as indicated in step 216, and then as
indicated at 218, a differential in speed between the first and
second sets of rollers is provided to introduce tension in the
lamina material that is sufficient to separate the sheets from the
roll supply across the weakened portion or perforated portion. The
tension preferably is a "snap" or sudden tension load. This can be
done by providing a sudden stop to the trailing set of rollers, or
a sudden acceleration to the leading rollers provides a "snap"
action, or in other ways. This avoids the need for providing a
cutter or a cutting mechanism of any sort. Microperforations for
the line of reduced strength leave a smooth edge that makes the
sheets easy to handle.
[0025] Referring to FIGS. 6, 7 and 8 to illustrate the reduced
strength transverse cross lines, a supply roll 220 of a web 230 of
lamina material, which will be explained in greater detail, but
which includes a sheet to protect information on a printed card,
and a heat sensitive bonding layer on the reverse side that would
laminate to a substrate or card. The web 231 is provided with a
plurality of evenly-spaced aligning scallops or notches indicated
at 224 along opposite edges, with the scallops 224 being rounded to
conform to the rounded corners of a typical card indicated at 226,
FIG. 7 showing rounded corners 228. The scallops 224 meet at a
junction, and a microperforated transverse line 230 of reduced
strength is provided laterally across the web 231. The web 231 is
thus divided into individual lamina sheets 232 of selected standard
card size and shape, such as CR80 type cards. The microperforations
are spaced so that the individual sheets will be the same size as a
card 226. When indexed appropriately and laminated onto the card
the sheets 232 will come all the way out to the edges and to the
corners of the cards or substrates without protruding at the corner
where the lamina could be grasped and lifted. The use of the
scallops 224 permits the close fit, and true edge to edge printing
on all of the card surface, if the reverse side printing is
used.
[0026] The web 231 of lamina can take several different forms, but
preferably, the lamina would be a sheet one of two layered forms
indicated in FIGS. 9 and 10, respectively. In FIG. 9, the lamina is
shown as having a polyester over layer or outer layer 236 that
would be exposed to the elements when laminated onto a card, which
is indicated at 226, a holographic system layer 238 which is
well-known in the field, and comprises a layer that can be bonded
to polyester using a suitable adhesive, and permit the holograms to
be put into place, and other information recorded. A vinyl layer
240 would then be bonded to the holographic layer 238, and would be
used for either printing or directly adhering to the substrate or
card illustrated at 226. When the reverse side of the lamina is
printed, the printing is indicated at 241.
[0027] Another embodiment could be a cartridge or housing of precut
sheets of lamina that can be fed individually, using a known
feeder.
[0028] A simplified form of the web that is provided as a lamina is
shown in FIG. 10, and includes a vinyl layer 242, that would be
directly laminated to the substrate 226, or a printing layer 244
can also be provided on the vinyl before laminating in accordance
with the subsequent disclosure.
[0029] In the discussion, when mention is made of printing on the
reverse side of the web or lamina, it is meant that this is the
side that would be in contact with the substrate, and the printing
would be so that it was readable when the lamina was laminated to
the substrate.
[0030] Referring to FIG. 3, apparatus is shown for laminating
substrates or cards. A printer assembly 1A is outlined in dotted
lines and is of the dye-sublimation type that utilizes a printer
ribbon actuated with a printing head assembly. The printer ribbon
1B is taken from a supply roll and is taken up by a take-up roll 2,
which is suitably driven from a motor 2A. The motor 2A is a stepper
motor that is controlled by a main control 1C, which is a logic
type controller that sequences operations of the overall laminating
assembly. The print ribbon 1B passing a sensor 4 which is used for
insuring that a ribbon is present so that the printing head 3 can
operate against a platen 6 as desired. Idler rollers 5 are used for
guiding the print ribbon 1B in its desired path over the platen
roller 6.
[0031] The lamina web supply roll 220 is illustrated schematically
and is rotatably mounted on the frame that is used for the printer.
The web 231 passes a sensor 10, and then passes up over the platen
roller 6, as guided by a guide roller 7. The reverse side, or the
vinyl side of the web 231, for example, that is shown in either
FIG. 9 or 10, is passed under the print head 3, so that the reverse
side of the lamina may be printed on to include the desired
message. The web 231 then passes through suitably rotatable mounted
guide rollers 11 and 12, and up over a further guide roller 13 for
the desired path of travel, and passes through a sensor 15 for
sensing presence of the web and providing desired information.
[0032] A pair of feed or pinch rollers 16 and 17 are rotatably
mounted on side frame plates and receive the web. The feed rollers
16 and 17 include a drive roller 16 that is driven from a stepper
motor 14. The roller 17 is a pinch roller or pressure roller that
is spring loaded against the drive roller 16 so that positive drive
of the web is achieved. The web is then fed into a second set of
feed rollers 18 and 19, which also includes a stepper motor 14A
driving roller 18. The stepper motor 14 and 14A are individually
controlled from the control 1C of the unit. The roller 19 is a
pinch roller constructed in a known manner for driving various
sheets of material as well as webs.
[0033] The speed of the first set of drive rollers 16 and 17 and
the speed of the second set of drive rollers 18 and 19 are
controlled by the respective stepper motors 14 and 14A. When the
web 231 is positioned with a reduced strength cross line between
the first and second sets of drive rollers, varying the speed of
the sets of rollers relative to each other will place a tension
load on the web and cause the separation across the region of
reduced strength. The split or separation of a sheet 20 is
indicated at 20A. An individual lamina sheet shown at 20 will be
held in the second set of drive rollers 18 and 19.
[0034] This individual sheet 20 is directed past a sensor 21 which
will provide a signal indicating when the leading edge of the
individual sheet that has been severed passes through, and also
when the leading edge of the next sheet, which remains attached to
the web, is received so that the motors 14 and 14A can be driven to
provide the tension on the web between the rollers 16 and 17 and
the rollers 18 and 19 to again break out or separate out a lamina
sheet 20. Lamina sheet 20 is then driven by the rollers 18 and 19
through the sensor 21 to a set of laminating rollers including a
heated roller 22, and a laminating platen roller 23 that are
suitably driven also through a stepper motor indicated at 23A. The
signal from the sensor 21 is used to bring a substrate and the
lamina sheet into registry.
[0035] A substrate or card supply hopper 24 has a card feeder of
conventional design indicated only schematically at 24A and feeds
cards, such as that shown at 29, past a first sensor 25 where they
are gripped by feed roller such as a drive rollers 26 driven with a
stepper motor 26A and an idler roller 27. The card 29 passes
through a sensor that senses the card presence, and then a second
sensor 28 which provides signals to the controls for determining
the card position just prior to entry into the laminating rollers.
The card 29 is then fed by stepper motor 26A to position it when
correlated with a signal from a sensor 21 for the lamina sheet 20,
so that the lamina sheet 20 and the leading edge of the card 29 are
precisely aligned as they go through the laminating rollers
including the heater roller 22 and the driven platen roller 23. The
laminated card, which is then covered with a lamina sheet 20 and
with the reverse side printing of the sheet printed, is moved as
indicated by the arrow 23B to a set of transport rollers 30 and 31
that are driven again by suitable stepper motor 30A. The laminated
cards are then deposited in a discharge hopper illustrated
schematically at 32.
[0036] In this form of the apparatus shown in FIG. 3, the steps of
the process illustrated in FIG. 1 are followed, with reverse side
printing on the web of lamina, that is, on the side which is
ultimately laminated to a substrate or card 29. The separation of
the web into individual lamina sheets 20 is done by using a line of
reduced strength across the web and providing a suitable tension
load on the web between the first and second sets of rollers to
cause the separation.
[0037] In FIG. 4, the apparatus is exactly the same as it is shown
in FIG. 3, except that in place of controlling the motors 14 and
14A to create a tension in the web and cause separation of
individual sheets 20 by lines of reduced strength across the web, a
web of lamina without the scallops and without the lines of reduced
strength is carried on the roll 220, and the web, indicated at 231A
passes through a cutter 33 that is positioned between the first set
of drive roller 16 and 17 and the second set of drive roller 19,
and in response to a signal from the sensor 21 and the controls 1C,
the cutter is operated to sever the web 231A into individual sheets
20A that would be laminated to cards 29 in exactly the same manner
as described in connection with FIG. 3.
[0038] The web 231A would be printed on the reverse side, as
previously stated, and then using the cutter 33 severed into the
individual sheets of lamina 20A and laminated onto a substrate or
card 29. If desired, the scallops could be used on the web 231A,
but there is no need for the microperforations. The use of the
scallops would enhance the ability to use the full surface of the
card for information by having the rounded corners that would match
with the rounded corners of the card, as shown in FIG. 7.
[0039] If desired in FIG. 4 the sensor 21 can be movably mounted so
that any size lamina, limited only by the range of movement of the
sensor, may be determined and separated at the time of cutting.
[0040] Again, the process shown in FIG. 1 is followed, but the
separation of lamina sheets is not carried out as shown in FIG. 2,
but separation is by using the cutter 33.
[0041] FIG. 5 is a modified form of the invention, in which the
cards are printed, and individual sheets of lamina are separated
using the cross microperforated lines of reduced strength across
the web from the supply. As shown in FIG. 5, a printer section 50
is the same as the printer section 1A shown in FIG. 3, but it is
used for printing onto cards in this form of the invention. The
printer ribbon is indicated at 51, and is provided from a supply
roll 52 to a take-up roll 53 which is driven from a motor 54. This
is a stepper motor again, that controls the feeding of the printer
ribbon for dye-sublimation printing. Again, any desired type of
printer can be used. A sensor 55 is provided to sense presence of
the ribbon, and the ribbon extends over guide rollers 56, 56 so
that it is guided across a print head 57 that is in registry with a
platen 58.
[0042] A card supply 60 has a card feeder 62 that feeds cards as
indicated by the arrow 63 past a sensor 64 and into a pair of card
drive rollers 65 and 66, which are used to drive the card shown at
67 in its path of travel. The roller 65 is driven from a suitable
stepper motor 68 from central controller indicated here at 70 which
controls the various functions including the printer 50, and the
stepper motors. The controller receive signals from the sensor 64
and a second sensor 72 that senses when a card is moved through the
card feed rollers 65 and 66.
[0043] As the card 67 passes over the platen 58, it is printed with
information controlled by the print head 57 using the ribbon 51,
and thus has information on its upper surface. The card 67 is fed
through further card feed rollers 74 and 75, and through a set of
transport rollers 76 and 77 that support and guide the card past a
sensor 78. The card shown at 67A has been printed on, and is passed
into the laminating rollers 80 and 81. The roller 81 is a heated
roller and the roller 80 is driven from a stepper motor 82
controlled by the controller 70.
[0044] A lamina supply roll 220 provides the web 231 that has the
crossed lines of reduced strength, and it is rotatably mounted on a
frame and is used for laminating onto the preprinted card 67. The
web 231 passes through a sensor 90 into a first set of feed rollers
91 and 92. The roll 92 is a driven roll, while the roll 91 is a
pressure roller. The roll 92 is driven from a stepper motor 94
under control of the control section 70.
[0045] A second set of drive rolls 96 and 98 are provided spaced
from the first set of drive rolls a selected distance. The second
set of drive rolls includes a driven roll 98 that is driven from a
stepper motor 100 that also is controlled by the control 70. A
sensor 102 is provided downstream from the second set of drive
rolls 96 and 98, and between the drive rolls 96 and 98 and the
laminating set of rolls 80 and 81.
[0046] A schematic side view of the rollers 96 and 98 is shown in
FIG. 11. The rollers are rotatably mounted on frame plates 99 in
brushing. The rollers 96 can be driven by a gear from roller 98, if
desired. A gear set can be used between the stepping motor and
roller 98. The sensor 102 will sense the leading edge of web 231,
and will provide a signal to the controller 70 so that the first
set of feed rolls 91 and 92 and the second set of feed rolls 96 and
98 will be differentially driven by their respective motors 94 and
91 to create a tension in the web and provide a separation of the
web to form individual sheets 104 of the lamina by breaking the
individual sheet 104 off from the rest of the web along a cross
line of reduced strength.
[0047] Then, the signal from the sensor 102 is used for ensuring
that the leading edge of the sheet 104 is properly aligned with the
leading edge of the card 67 as they are fed into the laminating
rollers 80 and 81 so that the lamination can take place with the
lamina sheet 104 precisely positioned relative to the card of
substrate 67. Transport rollers 110 and 112 will receive the card
after lamination, and will move the card into an output hopper 114
in a conventional manner. The roller 112 is drive with a suitable
stepper motor 116 as shown. All of the stepper motors are
coordinated in movement through the controller 70 in precise
positioning of the card as well as the lamina sheet 104 can be
achieved.
[0048] The use of the reduced strength cross line or
microperforated cross line on the web for separating out the
individual lamina sheets sized to be identical to the size of the
substrate or card being used eliminates the need for a separate
cutter, thereby reducing costs by eliminating parts and reducing
some complexity because of the need for normally quite precisely
operating the cutter so that the lamina sheet that will be
laminated onto the substrate is the right size.
[0049] Also as stated, the use of the scallops along the edges of
the web of lamina material makes the lamina sheets that are formed
to be the exact configuration and size of the card so that a
greater area of the card is available for having printing displayed
thereon. This printing can either be on the reverse side of the
lamina itself, or on the card as disclosed herein.
[0050] Although the present invention has been described with
reference to preferred embodiments, workers skilled in the art will
recognize that changes may be made in form and detail without
departing from the spirit and scope of the invention.
* * * * *