Abstract: A system and method for personalizing cards and other secure identification documents. The card personalization system and method provide improved data integrity, system reliability, and system performance. Improvements to card handling and processing within the modules, improved card transfer between modules, improvements to control of the modules, and other improvements are set forth, all of which contribute, individually and collectively, to achieving these goals.

Abstract: A cutable topcoat composition and apparatus useful for preparing stable data carrying devices, such as multi-layered laminates, and methods for preparing and using the composition. The composition includes a polymerizable composition and a polymeric binder. The polymerizable composition includes hard and flexible polymerizable subunits in a ratio that optimizes flexibility while retaining good adhesion and plasticizer resistance. In a preferred embodiment, a polymerization initiator is also included in the composition. Optionally, a chain transfer agent may also be added to the composition. The composition is substantially plasticizer free. The methods of using the composition include incorporating the composition into a topcoat film useful for storing the topcoat composition prior to use in preparing data-carrying devices, such as cards.

Abstract: A curable topcoat composition and apparatus useful for preparing stable data carrying devices, such as multi-layered laminates, and methods for preparing and using the composition. The composition includes a polymerizable composition and a polymeric binder. The polymerizable composition includes hard and flexible polymerizable subunits in a ratio that optimizes flexibility while retaining good adhesion and plasticizer resistance. In a preferred embodiment, a polymerization initiator is also included in the composition. Optionally, a chain transfer agent may also be added to the composition. The composition is substantially plasticizer free. The methods of using the composition include incorporating the composition into a topcoat film useful for storing the topcoat composition prior to use in preparing data carrying devices, such as cards.

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: An input hopper (20) for inputting card members to card processing modules (14) includes a tray (22) for storing the cards which are maintained in a stack by a pusher mechanism (30) having a plate (23) biasing the card stack toward a first end of the tray (22). A notched cam (42) at the first end of the tray (22) rotates and engages the edge of a lead card to separate it from the stack. Rollers (50,52,54) engage the separated card and deliver the card from the input hopper (20). The cam (42) and main roller (50) are driven by a motor (60) and drive linkage (61) including a coiled spring (70) to provide an override to the drive linkage (61) in the event of jamming.

Abstract: A foil loading apparatus (12) includes a foil lift mechanism (14) and a guide plate (20) for advancing foil material (16) along a winding foil flow path. Foil material (16) is raised on lift arm (24) from a lower position up through a confined space between a heated platen (40) and a pressing block (42) to an upper position where the foil material (16) may be accessed and fed through a remaining portion of the foil flow path.

Abstract: A switching mechanism for use in a transit system employing vehicles (10) traveling on a guideway (12), the switching mechanism includes forward and rearward switching subassemblies each having upper (32) and lower (36) switch arms. The upper switch arms include switching wheels (34) which selectively engage switch channels (42) positioned on opposite sides of the guideway to cause the vehicle to follow a selected path on the guideway (12). A stabilizer mechanism (90) for biasing the switch arms into operating position is provided.