Abstract: A solenoid plunger for use in solenoid driven multi-line embossing systems is constructed of magnetic steel laminations that are attached to a center block which is machined to mount a solenoid shaft and anti-rotate pins. The laminations are attached to the center block with screws and vacuum epoxy glued for a very high cycle life. The laminated steel construction dramatically reduces eddy currents, which allows the magnetic field to rise and fall much more quickly than a conventional steel plunger. It also increases the magnetic force in the solenoid. This reduction in solenoid plunger eddy currents and increase of magnetic force in the solenoid structure itself operates to increase embosser throughput. The laminated steel construction further reduces embosser solenoid heating which also contributes to improved embossing control.

Abstract: A solenoid plunger for use in solenoid driven multi-line embossing systems is constructed of magnetic steel laminations that are attached to a center block which is machined to mount a solenoid shaft and anti-rotate pins. The laminations are attached to the center block with screws and vacuum epoxy glued for a very high cycle life. The laminated steel construction dramatically reduces eddy currents, which allows the magnetic field to rise and fall much more quickly than a conventional steel plunger. It also increases the magnetic force in the solenoid. This reduction in solenoid plunger eddy currents and increase of magnetic force in the solenoid structure itself operates to increase embosser throughput. The laminated steel construction further reduces embosser solenoid heating which also contributes to improved embossing control.

Abstract: A system and method for personalizing cards and other secure identification documents. The card personalizing system and method have 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 label affixer shoe, having an application blade with an edge, a first surface, and second surface, and a pivot. The shoe pivots between first and second orientations. The first surface, edge, said second surface separate a label from a liner when the label and liner are moved from the first surface of the shoe past the edge toward the second surface. The shoe may be incorporated into an affixer carriage, also including a pivot actuator. The shoe may be incorporated into an affixer module, with a translation actuator, a card feed mechanism, and a label feed mechanism. When the blade is in the first orientation, the shoe does not obstruct the feeding of the card to or from the label receiving position. The translation of the shoe from the first position to the second position while the blade is in the second orientation applies the label to the card.

Abstract: A label affixer shoe, having an application blade with an edge, a first surface, and a second surface, and a pivot connected to said blade. The pivot is arranged such that at the shoe is pivotable between a first orientation and a second orientation. The first surface, edge, said second surface are configured to separate a label from a liner at the shoe edge when the label and liner are moved from the first surface of the shoe past the edge toward the second surface. The shoe may be incorporated into an affixer carriage, also including a pivot actuator for pivoting the shoe. The shoe may be incorporated into an affixer module, also including a translation actuator for translating the shoe between first and second positions, a card feed mechanism for delivering a card to a label receiving position near the shoe, a label feed mechanism for delivering a label to a applying position near the shoe. The shoe, label receiving position, and applying position are arranged as follows.

Abstract: The invention relates to the programming of integrated circuit cards. More particularly, the invention concerns systems and methods for integrated circuit card programming, as well as modules used for integrated circuit card programming. Each module includes a movable cassette mechanism having a plurality of card programming stations thereon. The use of multiple card programming stations permits simultaneous programming of a plurality of cards. Further, the use of a single cassette in the module permits the size of the module to be reduced significantly. A modular concept is more readily adaptable to customer needs and requirements. For instance, if a customer requires more card production than that provided by a single module, a second module that is identical to the first module can be connected to the first module so that the two modules working together provide two cassettes. Additional modules can be added to further increase card production capacity.

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 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: An integrated card programming device for programming an integrated circuit card. The integrated circuit card programming device has a base, a card input platform, and a transport. The transport is operably connected to the base and rotatably mounted about a rotational axis. The transport includes a transport arm radially disposed about the rotational axis. A card picker carriage is mounted on the transport arm. The card picker carriage has two picker arms. One or more personalization stations for programming an integrated circuit card are radially disposed about the transport. The personalization stations can program the cards to the French or ISO standards and are rotatable 180.degree..

Abstract: An inserter module for attaching processed cards to associated card carrier forms having cardholder information printed thereon is provided. The inserter module includes a chassis, printer for printing cardholder information on serially connected card carrier forms, takeup means for maintaining proper takeup of the serially connected carrier forms as they exit the printer, burster for separating the serially connected carrier forms after printing, and inserter for attaching the processed cards to associated printed carrier forms.

Abstract: An integrated card programming device for programing an integrated circuit card. The integrated circuit card programing device has a base, a card input platform, and a transport. The transport is operably connected to the base and rotatably mounted about a rotational axis. The transport includes a transport arm radially disposed about the rotational axis. A card picker carriage is mounted on the transport arm. The card picker carriage has two picker arms. One or more personalization stations for programming an integrated circuit card are radially disposed about the transport. The personalization stations can program the cards to the French or ISO standards and are rotatable 180.degree..

Abstract: An integrated card programming device for programming an integrated circuit card. The integrated circuit card programming device has a base, a card input platform, and a transport. The transport is operably connected to the base and rotatably mounted about a rotational axis. The transport includes a transport arm radially disposed about the rotational axis. A card picker carriage is mounted on the transport arm. The card picker carriage has two picker arms. One or more personalization stations for programming an integrated circuit card are radially disposed about the transport. The personalization stations can program the cards to the French or ISO standards and are rotatable 180.degree..

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: 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 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 solenoid bumper mechanism wherein a resilient means absorbs a proportion of the kinetic energy of a shaft moving within the solenoid, and a nonresilient means which causes the shaft to terminate its movement at a fixed point. The mechanism provides shaft movement of repeatable precise distances and also does not interfere with the magnetic field created by the solenoid body.

Abstract: A processor for processing undeveloped photographic film discs mounted on a spindle assembly has a conveyor to intermittently convey the spindle assembly from a first end to a second end of the processor along a generally horizontal conveyor path. The spindle assembly is conveyed to a plurality of processing stations along the conveyor path, with each processing station having a processing tank. During processing, the processing tanks move between an upward process position and a downward dump and transport position. A fluid dispenser at each processing station dispenses processing fluid to the processing tank at that processing station when a spindle assembly is positioned at that processing station. A spindle sensor at the first end of the processor provides a signal indicative of the presence of the spindle assembly in the processor. The operations of the conveyor, processing tank movement and fluid dispensers are controlled by a control apparatus as a function of the spindle sensor signal.