Abstract: Techniques are described herein for reducing bowing effects on a substrate while the substrate is being transported, for example in an elevator mechanism, from a first travel path to a second travel path, where the first travel path is offset from the second travel path so that the first travel path is not collinear with the second travel path. The substrate can be any substrate that is bowed and for which one wishes to eliminate or reduce the bow. One specific substrate that can benefit from the techniques described herein are personalized documents such as plastic cards including but not limited to financial (e.g. credit and debit) cards, drivers' licenses, national identification cards, gift cards, loyalty cards, employee badges, and other plastic cards which bear personalized data unique to the card holder and/or which bear other card or document information.

Abstract: Techniques are described herein for reducing bowing effects on a substrate while the substrate is being transported, for example in an elevator mechanism, from a first travel path to a second travel path, where the first travel path is offset from the second travel path so that the first travel path is not collinear with the second travel path. The substrate can be any substrate that is bowed and for which one wishes to eliminate or reduce the bow. One specific substrate that can benefit from the techniques described herein are personalized documents such as plastic cards including but not limited to financial (e.g. credit and debit) cards, drivers' licenses, national identification cards, gift cards, loyalty cards, employee badges, and other plastic cards which bear personalized data unique to the card holder and/or which bear other card or document information.

Abstract: Techniques are described herein for reducing bowing effects on a substrate while the substrate is being transported, for example in an elevator mechanism, from a first travel path to a second travel path, where the first travel path is offset from the second travel path so that the first travel path is not collinear with the second travel path. The substrate can be any substrate that is bowed and for which one wishes to eliminate or reduce the bow. One specific substrate that can benefit from the techniques described herein are personalized documents such as plastic cards including but not limited to financial (e.g. credit and debit) cards, drivers' licenses, national identification cards, gift cards, loyalty cards, employee badges, and other plastic cards which bear personalized data unique to the card holder and/or which bear other card or document information.

Abstract: Techniques are described herein for reducing bowing effects on a substrate while the substrate is being transported, for example in an elevator mechanism, from a first travel path to a second travel path, where the first travel path is offset from the second travel path so that the first travel path is not collinear with the second travel path. The substrate can be any substrate that is bowed and for which one wishes to eliminate or reduce the bow. One specific substrate that can benefit from the techniques described herein are personalized documents such as plastic cards including but not limited to financial (e.g. credit and debit) cards, drivers' licenses, national identification cards, gift cards, loyalty cards, employee badges, and other plastic cards which bear personalized data unique to the card holder and/or which bear other card or document information.

Abstract: A modular apparatus for processing printed sheets that are output from a high speed printer of a card processing system. The modular apparatus is capable of buffering or storing the sheets that are in progress in the printer when the system is stopped or paused, flips them so that they face upward, folds the sheets if necessary, and reorientates the sheets so that all sheets exit the module in the same orientation for further processing by the next module.

Abstract: A system for affixing cards to a form and folding the form with the cards attached. The system includes a card affixer for affixing cards to any location on a form having a form transporting mechanism for moving the form, a carriage for receiving and holding a card, a carriage translating mechanism for moving the carriage across the width of the form transporting mechanism and a pressing mechanism for pressing the card against the form. The system also includes a form folder for precisely folding forms with the cards already attached. The form folder includes a form guide structure having at least one scoring edge, a form transfer mechanism, a roller unit, a roller translating mechanism and a roller rotating mechanism.

Abstract: A system for affixing cards to a form and folding the form with the cards attached. The system includes a card affixer for affixing cards to any location on a form having a form transporting mechanism for moving the form, a carriage for receiving and holding a card, a carriage translating mechanism for moving the carriage across the width of the form transporting mechanism and a pressing mechanism for pressing the card against the form. The system also includes a form folder for precisely folding forms with the cards already attached. The form folder includes a form guide structure having at least one scoring edge, a form transfer mechanism, a roller unit, a roller translating mechanism and a roller rotating mechanism.

Abstract: A magnetically encoded plastic card production system is provided which includes a supply mechanism for supplying a series of blank plastic cards. An encoder is operatively coupled to the supply mechanism which encodes a magnetic strip on each card. A separating mechanism is operatively coupled following the encoder which has a roller surface for adhesively attracting loose particles from a surface of each card. A design placing mechanism is operatively coupled immediately following the separating mechanism which places a graphic design on each card. In this arrangement, the loose particles are separated from each card subsequent to encoding the magnetic strip on each card and prior to placing the graphic design on each card. A collecting mechanism is operatively coupled to the design placing mechanism which collects each card after each card has passed through the encoder, separating mechanism, and design placing mechanism. A method for producing magnetically encoded plastic cards is also provided.

Abstract: An apparatus and method are described for removing particulate matter from one or more surfaces of a workpiece, such as a credit card blank, prior to printing a graphic design thereon. The apparatus includes a pair of cleaning rollers which engage both sides of the card, the cleaning rollers having an adhesive coating for removing loose particulate matter from the surfaces of the card. The apparatus also includes a stripper system for stripping collected particulate matter away from the cleaning rollers after a predetermined number of cards have been cleaned.

Abstract: Standardized card processing modules are mechanically and electrically interconnected to form an application specific card personalization machine. A controller is coupled to a communication bus which permits the controller to download card data to the card processing modules and to upload status information from the card processing modules. Each one of the card processing modules performs a different encoding or personalization function under the control of a local processor.

Abstract: A card transport apparatus (12) carries cards along a card transport path through card processing stations (14, 74, 76). The transport apparatus (14) includes a vertically adjustable card carriage (16) for retaining cards along a card transport path throughout the entire card processing operation through the card processing stations (14, 74, 76). The card carriage (16) grips the cards with independently pivoting gripping arms (52, 54), actuated open by push solenoids (18, 20, 22) for picking up and releasing cards.

Abstract: An embossing apparatus (22) includes an embossing wheel (28) having a punch side (30) and a die side (32). The embossing wheel (28) has punch blocks (50) and die blocks (52) spaced around its periphery. A card (20) is carried to an embossing position by card transport (24) and aligned by a guide plate (36). The embossing is done by pushing the punch blocks (50) and die blocks (52) against the card (20) by a hammer (42, 42a) driven by a solenoid (38, 38a). Character return plates (46, 46a), located on the outer sides of the embossing wheel (28) engaging the inside of character blocks (35), spring the character blocks (35) and solenoid shaft (40, 40a) back to a home at rest position when the embossing stroke is completed. The solenoids (38, 38a) have bumpers (54, 54a) mounted thereon for controlling the motion of the shaft (40, 40 a).

Abstract: An apparatus and method for printing a graphic design on a hard plastic workpiece such as a credit card blank includes a thermal printing element which is supported by a head assembly that has been designed a single link, to have low mechanical compliance in a horizontal plane and yet to allow the print head to align with a print roller. A cleaning assembly is further provided which includes a pair of cleaning rollers having an adhesive coating; and a novel arrangement for stripping particulate matter away from the cleaning rollers after a predetermined number of cards have been cleaned. A number of stepper motors are provided to perform the cleaning and printing functions. The stepper motors are controlled by a local control system which monitors a number of sensors provided on the cleaning and printing stations and is subservient to an overall system controller. The invention further includes a novel method of operation, a cassette for use with the printing station and a novel thermal printing foil.

Abstract: A card output hopper apparatus (20) receives cards (82) and delivers them to a preselected card tray (42). The output hopper rotatable deflector (52). The deflector (52) is situated in a recieving position to deflect a delivered card (82) toward a card tray (42). The deflector (52) rotates as the card is delivered to drive the card past a retainer (64) and onto a card stack in the card tray (42). The deflector (52) is also rotatable to a receiving position to deflect the card toward an opposing card tray (44).

Abstract: A card transport apparatus (12) carries cards along a card transport path through card processing stations (14, 74, 76). The transport apparatus (14) includes a vertically adjustable card carriage (16) for retaining cards along a card transport path throughout the entire card processing operation through the card processing stations (14, 74, 76). The card carriage (16) grips the cards with independently pivoting gripping arms (52, 54), actuated open by push solenoids (18, 20, 22) for picking up and releasing cards.

Abstract: A processor for use in processing sheets of photosensitive material has a plurality of processing stations. A plurality of drive rollers define a sheet processing path through the processing stations and are driven to transport a sheet of photosensitive material along that path. The drive rollers at the processing station at the end of the path are driven at a faster rate of rotation than the drive rollers at previous processing stations along the path. The drive rollers of those previous processing stations, however, are mounted to permit said rollers to overrun their driven slower rate of rotation and permit those rollers to rotate at the faster rate of rotation.

Abstract: A processor for processing undeveloped photographic film discs mounted on a spindle assembly has a conveyor to intermittently convey the spindle assembly along a generally horizontal conveyor path. The spindle assembly is conveyed to a plurality of processing stations on the conveyor path, with each processing station having a processing tank. During processing, the processing tanks pivot between an upward process position and a downward dump/transport position. In their upward process position, selected processing tanks are filled with processing fluids. When the spindle assembly is positioned at one of the selected processing tanks and that tank is in its upward process position and filled with processing fluid, portions of the film discs on the spindle assembly are contacted by the procesing fluid. The spindle and discs are then rotated to uniformly contact the photographic images on the film discs with the processing solution.

Abstract: A compact inexpensive dryer unit for photographic processors which includes a liquid removing squeegee unit, transport rollers and guiding means for moving photographic sheet material through the drying area, a pair of opposed tapered air distribution manifolds to uniformly distribute warm drying air against both sides of the sheet material in close proximity thereto as it travels through the dryer with provision for recirculating substantial portions of the warmed air after it travels through the drying area of the unit, one of said manifolds being hinged to facilitate access to said drying area for servicing.