HK1122531B - Card cleaning mechanism - Google Patents

Description

Card cleaning mechanism

Cross Reference to Related Applications

This application was filed in the form of PCT international application in the name of DataCard Corporation, claiming priority from U.S. provisional patent application serial No.60/735,636 entitled "card cleaning agency (CARD CLEANINGMECHANISM)" filed on 10.11.2005.

Technical Field

The present invention relates to a cleaning mechanism for cleaning one or both surfaces of a plastic card substrate prior to the card being subjected to a processing operation (e.g., personalization process occurring on the cleaned surface).

Background

Card personalization systems and methods for forming personalized cards and other personalized identity documents have been adopted by organizations issuing such documents. Identity documents that are typically personalized by such systems and methods include plastic and composite cards, such as financial (e.g., credit and debit) cards, drivers' licenses, national identity cards, and other cards and documents that are personalized with information unique to the holder of the document.

For large, mass-produced cards, various institutions often employ systems that use multiple processing modules to process multiple cards simultaneously and reduce the overall time per card process. Examples of such systems include the system disclosed in U.S. Pat. No.6,902,107, the DataCard MaxSys and 9000 series of systems available from data card Corporation of Minneapolis (Minneapolis), Minnesota, the system disclosed in U.S. Pat. No. 4,825,054, and the system disclosed in U.S. Pat. No. 5,266,781 and derivatives thereof.

Common to each of these types of systems is an input device capable of holding a relatively large number of required processing cards, a plurality of processing modules through which each card is directed to perform processing operations, and an output device which receives the resulting processed cards. Processing operations typically performed on the card include programming data onto the magnetic stripe of the card, monochrome and/or color printing, laser processing, changing the integrated circuit chip within the card, and applying various finishes and protective layers. Controllers are typically employed to transmit data information and instructions for operating the input devices, processing stations, and output devices.

In the case of cards, the processing operations are often performed on one or both of the generally flat sides of the card. The processing operations performed include processes such as applying data and/or graphic images to one or more sides using, for example, known printing processes. Other processing operations performed also include applying laminates and coatings to the card sides.

Oftentimes, the cards will contain contaminants on one or both of their substantially planar side surfaces. Examples of contaminants commonly found on the surface of cards include dust, particles, fibers, and grease. These contaminants can be caused by a variety of reasons, such as the card production technology used to produce the cards, or improper care and/or stacking of card storage. Contaminants on planar card surfaces are known to adversely affect many processing operations performed on the card surface, for example, monochrome and multi-color printing processes.

As a result, cards are typically cleaned prior to processing operations in order to remove contaminants. It is known to use a cleaning mechanism to clean one or more side surfaces of a card. Some conventional cleaning mechanisms include a pair of cleaning rollers having an adhesive outer surface between which the card passes to remove contaminants from each side surface of the card. Thereafter, the contaminants are removed from the cleaning roller using a cleaning belt in contact with the cleaning roller, thereby peeling or otherwise removing the contaminants from the roller. The cleaning tape is typically supplied from a supply roll and, after contaminants have been stripped from the tacky outer surface of the roll, the cleaning tape is wound onto a take-up roller. Various examples of known cleaning mechanisms are disclosed in U.S. Pat. Nos. 5,401,111 and 6,902,107.

Disclosure of Invention

The present invention relates to a cleaning mechanism for cleaning one or both sides of a card substrate prior to a processing operation on the cleaned surface of the card.

The cleaning mechanism may be part of a cleaning module that forms one module of a modular card processing system. Alternatively, the cleaning mechanism may be incorporated into a different processing module with other card processing equipment and may be used in a non-modular system.

The cleaning mechanism is designed so that two cleaning rollers, one cleaning roller located at a first cleaning station and the other cleaning roller located at a second cleaning station, can be cleaned simultaneously by a single cleaning tape assembly.

In one aspect of the invention, the card cleaning mechanism includes first and second cleaning roller assemblies. Each cleaning roller assembly includes a pair of cleaning rollers rotatably mounted on the turret body for rotation about respective longitudinal axes, each cleaning roller including a tacky outer surface. The turret body rotates about a central longitudinal axis extending parallel to the longitudinal axis of the cleaning roller. In addition, a cleaning tape assembly is disposed adjacent to the first and second cleaning roller assemblies, with the cleaning tape assembly being configured to remove contaminants from the tacky outer surfaces of the cleaning rollers in each of the first and second cleaning roller assemblies.

In another aspect of the present invention, there is provided a card cleaning module including: a card input device through which a card to be cleaned is input into the module; an input drive mechanism adjacent the card input device for receiving a card through the card input device and driving the card into the module; a card output device through which the cleaned card is output from the module; and an output drive mechanism adjacent the card output device for driving the cleaned card out of the module. The first and second cleaning stations are disposed between the card input device and the card output device. The first and second cleaning stations each include a pair of cleaning rollers rotatably mounted for rotation about respective longitudinal axes and defining a nip therebetween through which a card may pass. Each cleaning roller includes a tacky outer surface. In addition, a cleaning tape assembly is disposed adjacent to the first and second cleaning stations, with the cleaning tape assembly being configured to remove contaminants from the tacky outer surfaces of the cleaning rollers of each of the first and second cleaning stations.

In yet another aspect of the invention, a card cleaning mechanism is provided that includes a cleaning roller assembly having a pair of cleaning rollers rotatably mounted for rotation about respective longitudinal axes and defining a nip therebetween through which a card may pass for cleaning. Each cleaning roller includes a tacky outer surface. In addition, a cleaning tape assembly is disposed adjacent to the cleaning roller assembly and is configured to remove contaminants from the tacky outer surface of the cleaning roller. The cleaning tape assembly includes a backing roller having first and second ends, the backing roller being supported by bearings near a center of the backing roller between the first and second ends, the backing roller not being supported by bearings at the first and second ends.

This configuration of the backing roller enables the backing roller to maintain consistent contact along the entire length of the cleaning roller, which is necessary for complete cleaning of the cleaning roller. The backing roller is independently pivotable in two planes using angular play in the bearing. This gives the backing roller the freedom to match the angular position of the two cleaning rollers so that the backing roller can self-align with the two cleaning rollers independently. This reduces the need to use high tolerance parts at the cleaning station, saves assembly time and improves reliability of the cleaning function.

In yet another aspect of the invention, a card cleaning mechanism is provided that includes a cleaning roller assembly having a pair of cleaning rollers rotatably mounted for rotation about respective longitudinal axes and defining a nip therebetween through which a card may pass for cleaning. Each cleaning roller includes a tacky outer surface. In addition, a cleaning tape assembly is disposed adjacent to the cleaning roller assembly and is configured to remove contaminants from the tacky outer surface of the cleaning roller. The cleaning tape assembly includes a supply roll of cleaning tape, an idler roller riding against a surface of the supply roll, and an arm on which the idler roller is supported, the arm being pivotally mounted such that as the supply roll decreases in diameter, the idler roller is movable toward the supply roll, and the arm is biased in a direction away from the supply roll.

The idler roller causes the cleaning tape to be smoothly and consistently withdrawn from the supply spool as the drive roller pulls the cleaning tape from the supply spool. This reduces noise and erratic movement (jumping) of the supply roll which may cause unreliable sensor readings.

Drawings

FIG. 1 is a schematic diagram of a modular card processing system.

Figure 2 shows a card cleaning mechanism according to the present invention.

Figure 3 illustrates the structure of a backing roller in a cleaning tape assembly for a card cleaning mechanism.

Figure 4 shows the structure of the mechanism used to draw the cleaning tape from the supply roller in the cleaning tape assembly that controls the card cleaning mechanism.

Fig. 5 is a perspective view of the card cleaning mechanism.

Detailed Description

The present invention relates to a cleaning mechanism that cleans one or both side surfaces of a plastic card substrate prior to performing a processing operation on the cleaned surface. The cleaning mechanism will be described herein as part of a cleaning module that forms one module of a centrally issued modular card processing system. However, the cleaning mechanism may be incorporated into a different processing module with other card processing equipment and may be used in a non-modular system.

One example of a modular card processing system 10 is schematically illustrated in fig. 1. The system 10 is configured for mass, batch production of cards that simultaneously process multiple cards using multiple processing modules 12a, 12b, 12 c. Examples of processing modules 12a, 12b, 12c,. 12n that may be included within system 10 are the following various modules: a magnetic stripe module for writing data to and reading data from the magnetic stripe on the card; an embossing module for forming embossed characters on the card; the intelligent card programming module is used for programming the integrated circuit chip on the card; a printing module that performs monochromatic or polychromatic printing; the laser module is used for carrying out laser personalized processing on the card; a graphics module for applying monochrome data and images to the card; a cleaning module (described below) for cleaning the card; a surface layer module for coating a surface layer on the card; and a card punching module for punching or cutting the card and/or punching the card into a particular shape. The system 10 also typically includes an input module that receives a plurality of cards to be processed, and an output module that receives the processed cards. Additional information regarding the structural and operational aspects of modular card processing systems can be found in U.S. Pat. No.6,902,107.

One of the modules in the system 10 is a cleaning module 20, and in accordance with the present invention, the cleaning module 20 is designed to clean both sides of a card to remove contaminants from the side surfaces of the card. Contaminants such as foreign particles, dirt and oil on the side surfaces of the card can interfere with the task of processing. For example, in personalization processes performed by other modules, contaminants can degrade the quality of the generated personalization process. Cleaning module 20 is preferably located within system 10 before the graphics module (if used), the printing module (if used), and the laser module (if used), because the tasks performed by these modules are particularly affected by card contamination. However, the cleaning module 20 may be located anywhere within the system 10 downstream of the input module. In addition, the system 10 may employ more than one cleaning module.

Referring to fig. 2 and 5, the interior of the cleaning module 20 is shown as including a card cleaning mechanism 22. The cleaning mechanism module 20 includes a card input device 24 and a card output device 26, with a card to be cleaned being input into the cleaning module 20 via the input device 24 and a cleaned card being output from the cleaning module 20 via the output device 26.

The input drive mechanism 28 is in the form of a pair of input rollers 28a, 28b which are positioned adjacent the card-to-card input 24 to receive a card from an upstream module and drive the card into the cleaning mechanism 22. The upper and lower input guides 30a, 30b assist the card in entering the nip between the rollers 28a, 28b and create upper and lower card paths that form the card path to the cleaning mechanism 22. An output drive mechanism 32 in the form of a pair of output rollers 32a, 32b is provided adjacent the card output device 26 to drive a cleaned card from the cleaning module to the next module. The upper and lower card guides 34a, 34b guide the card as it exits the cleaning mechanism 22 and form a card path to the output 26 of the module 20. The input rollers 28a, 28b and output rollers 32a, 32b are driven by a motor 36, such as a motor, through a drive belt 37 and pulley 38 for the rollers 28a, 28b and similar drive belts and pulleys (not shown) for the rollers 32a, 32 b.

As shown in fig. 2 and 5, the illustrated cleaning mechanism 22 includes first and second card cleaning stations 40a, 40b disposed between the card input device 24 and the card output device 26. In the illustrated embodiment, each station 40a, 40b includes a cleaning roller assembly including a pair of cleaning rollers 42a, 42b forming a nip therebetween through which a card may pass for cleaning. The cleaning mechanism 22 may include additional cleaning stations, such as a third cleaning station or third and fourth cleaning stations, which may use the same cleaning belts discussed below and one or more additional backing rollers.

The stations 40a, 40b in the illustrated embodiment are generally similar to each other, with each station 40a, 40b being similar to the cleaning roller assembly described in U.S. Pat. No.6,902,107. It should be understood that station 40b is similar in construction and operation to station 40a and therefore only station 40a will be described in detail.

The card passes through the nip of the cleaning rollers 42a, 42b such that roller 42a contacts one side of the card and roller 42b contacts the other side of the card. The outer surfaces of the cleaning rollers 42a, 42b are tacky so that contaminants on the card surface are picked up and adhered to the cleaning rollers. The use of a cleaning roller having a tacky outer surface is described in U.S. Pat. No. 5,401,111. The circumference of each cleaning roller 42a, 42b should be selected to be approximately equal to or greater than the length of the card. For example, the cleaning rollers 42a, 42b may each have a circumference of about 3.14 inches (about 79.76mm) and the card may have a length of about 3.375 inches (about 85.725 mm). This minimizes or eliminates the possibility that the portion of the outer surface of the roller that contacts the card rolls one revolution and then contacts the card.

Referring to fig. 2 and 5, the cleaning rollers 42a, 42b may be mounted for rotation on a turret body comprising a lower turret plate 44 and an upper turret plate 46. Each turret plate forms a track for guiding the upper and lower edges of the card as it moves past the cleaning rollers 42a, 42 b. Suitable drive mechanisms are connected to the cleaning rollers 42a, 42b for synchronously driving the rollers in counter-rotation. Preferably, the cleaning rollers 42a, 42b rotate in synchronization with the rotation of the input rollers 28a, 28b and the output rollers 32a, 32b and at the same rotational speed. Thus, a smooth transition of the card is achieved as the card is driven by the input rollers 28a, 28b into the cleaning rollers 42a, 42b and from there into the output rollers 32a, 32 b.

The turret body comprises an upper turret plate 46 and a lower turret plate 44 and is rotatable about a central longitudinal axis through the centre of the turret plate, which axis extends parallel to the longitudinal axis of the cleaning rollers 42a, 42 b. The cleaning rollers 42a, 42b rotatably mounted on the turret plate rotate with the turret plate. As described in U.S. patent 6,902,107, rotation of the turret body plate serves to decouple the drive connection between the drive and driven wheels and positions the cleaning rollers 42a, 42b for subsequent engagement with the cleaning belt 48 to remove contaminants from the cleaning rollers. A motor (e.g., a stepper motor) rotates the turret body through a suitable transmission mechanism, such as a gear. An example of a mechanism for rotating the tower is disclosed in U.S. Pat. No. 5,401,111.

A sensor detects a tab positioned below the upper turret plate to determine the home position of the turret body. The initial position of the turret body of the station 40a is shown in fig. 2. Contaminants can be removed from the cleaning rollers 42a, 42b by rotating the turret body in a clockwise or counterclockwise direction away from the home position. Preferably, the turret body is rotated to a first cleaning station to remove contaminants from the cleaning roller 42a and rotated to a second cleaning station to remove contaminants from the cleaning roller 42 b.

The second station 40b is disposed downstream of the first station 40a and is generally similar in construction to the first station 40 a. The cleaning rollers 42a, 42b of the second station 40b are driven by the same drive mechanism that drives the cleaning rollers of the first station. Similarly, the turret body of the second station 40b is driven by the same motor and drive mechanism used to drive the turret body of the first station 40a, and the same detection mechanism used to detect the initial position of the turret body of the first station 40a is used to detect the initial position of the turret body of the second station 40 b. Therefore, no additional active components are required to support the operation of the second station 40 b.

Referring to fig. 2, a single cleaning tape assembly 50 including the cleaning tape 48 is positioned adjacent to both stations 40a, 40b to be shared between the two stations 40a, 40b, and the cleaning rollers of the stations 40a, 40b are cleaned using the same portion of the cleaning tape 48. The cleaning tape assembly 50 schematically illustrated in fig. 2 is substantially similar in construction and operation to the cleaning tape assembly disclosed in U.S. patent 6,902,107.

Referring to fig. 2 and 3, the cleaning rollers 42a, 42b can be cleaned to remove accumulated contaminant debris by moving the cleaning belt 48 against the outer surfaces of the cleaning rollers. During cleaning, the backing roller 52 of the cleaning tape assembly 50 presses the cleaning tape against the roller.

For complete cleaning, it is necessary to maintain consistent contact along the entire length of the cleaning roller. The gap between the cleaning roller and the backing roller 52 can cause debris to remain on the cleaning roller. The cleaning tape assembly 50 should be positioned such that: one of the two cleaning rollers is located at station 40a and the other cleaning roller is located at station 40b, which are cleaned simultaneously, and the backing roller 52 must remain in contact with each cleaning roller during the cleaning cycle. Because the backing roller is fixed in position (i.e., the backing roller does not move toward or away from the cleaning roller), all three rollers (two cleaning rollers and one backing roller) need to be substantially parallel to each other to allow the belt to continuously contact. Any change in the angle or shape of the rollers will result in a gap between the rollers.

As shown in fig. 3, the backing roller 52 is not supported by bearings at its top and bottom, but is supported by a single bearing 54 at about mid-height. This design allows the backing roller 52 to pivot independently in two planes with angular play in the bearings. This gives the backing roller 52 the freedom to match the angular position of the two cleaning rollers so that the backing roller is independently self-aligned to the two cleaning rollers. This reduces the requirement for high tolerance parts to be used at the stations 40a, 40b, saves assembly time and improves the reliability of the cleaning function.

Referring to fig. 4, and also to fig. 5, the cleaning tape assembly 50 further includes a supply spool 56 containing a supply of cleaning tape 48. The supply spool 56 is disposed on a non-driven but rotatable spindle 58, the spindle 58 being rotatable as the cleaning tape 48 is pulled from the spool 56. An encoder is coupled to the spindle for detecting rotation of the supply roll and predicting the amount of cleaning tape remaining on the roll. Because the cleaning tape 48 is sticky, the cleaning tape 48 has a tendency to peel off from the supply roll 56 in an uneven or jerky manner. This can cause the encoder to obtain unreliable readings of the rotation of the supply roll.

The cleaning tape assembly 50 includes a mechanism that smoothly or uniformly strips the cleaning tape from the supply roll at the tangent point of the roll, thereby reducing noise and erratic movement (jumping) of the supply roll that can cause unreliable sensor readings. In particular, the mechanism includes an idler roller 60 that rides against the surface of the supply roll 56, as shown in FIG. 4. As the cleaning tape 48 is stripped from the supply roll 56 at the tangent point, the cleaning tape 48 partially surrounds the idler roller 60 and then moves toward the knurled drive roller 62, which helps to advance the cleaning tape 48 through the cleaning roller during cleaning.

The idler roller 60 is supported on a pivoting arm 64 mounted to move the idler roller 60 toward the supply roll core as the supply roll diameter decreases. In addition, the pivot arm 64 is slightly spring loaded away from the supply spool 56. The tension in the cleaning tape and the manner in which the cleaning tape 48 is partially wrapped around the idler roller 60 maintain the idler roller in contact with the supply roll 56 during normal operation. The tab 66 is attached to the arm 64 and moves with the arm, and the sensor 68 detects the movement of the tab 66.

The idler roller 60 causes the cleaning tape 48 to peel smoothly and consistently from the roll 56 as the drive roller 62 pulls the tape. The tension of the belt maintains the idler roller 60 in contact with the supply roll 56. Once the tension in the belt is removed, for example, when the cleaning belt breaks, the spring load of the arm 64 will cause the idler roller 60 to move away from the spool 56. If the idler roller 60 and arm 64 move far enough away from the spool 56, the sensor 68 will no longer detect the tab 66. As a result, the arm 64 may also be used to detect breaks in the cleaning belt 48.

The operation of the cleaning module 20 and the cleaning mechanism 22 will now be described. The card is fed into the module 20 from an upstream module and then the feed rollers 28a, 28b drive the card into the first cleaning station 40 a. The card passes between the cleaning rollers 42a, 42b which pick up contaminants from the side surfaces of the card. The card then enters the second cleaning station 40b and passes between the cleaning rollers 42a, 42b, which pick up additional contaminants from the side surfaces of the card. The cleaned card is then picked up by the output rollers 32a, 32b, which drive the card from the cleaning module 20 to an adjacent downstream module for further processing.

After card cleaning, the turret body of the cleaning station 40a rotates in a clockwise direction and the turret body of the cleaning station 40b rotates in a counter-clockwise direction, which disengages the cleaning roller drive structure and brings the cleaning roller 42a of each cleaning station 40a, 40b into a position ready for cleaning.

The cleaning tape is then pulled across the outer surface of the cleaning roller 42a, and after the surface of the cleaning roller 42a has been cleaned, the cleaning station is reversed to its initial position and another card is passed over the roller for cleaning. After the second card is cleaned, the turret body of station 40a rotates counterclockwise and the turret body of cleaning station 40b rotates clockwise to position the cleaning roller 42b for cleaning. In this position the cleaning tape 48 contacts the outer surface of the cleaning roller 42b and is pulled across the outer surface of the cleaning roller 42b to clean the roller. The cleaning station then rotates back to its initial position in preparation for cleaning of another card.

It has been found that cleaning only one set of rollers (i.e., roller 42a or roller 42b) after each card is cleaned increases card throughput because it minimizes the amount of movement of each turret body between the cards. At the same time, acceptable card cleaning is achieved. The two sets of rollers 42a, 32b can be cleaned one after the other between the cards if desired.

The use of two cleaning stations can improve card cleaning even with an inexpensive cleaning belt, while eliminating the need for a second cleaning belt assembly.

Claims (12)

1. A card cleaning mechanism comprising:

first and second cleaning roller assemblies, each cleaning roller assembly comprising:

a pair of cleaning rollers rotatably mounted on a turret body for rotation about respective longitudinal axes, each cleaning roller including a tacky outer surface, the turret body rotating about a central longitudinal axis extending parallel to the cleaning roller longitudinal axes;

a cleaning tape assembly disposed adjacent to the first and second cleaning roller assemblies, the cleaning tape assembly configured to remove contaminants from the tacky outer surfaces of the cleaning rollers of each of the first and second cleaning roller assemblies, the cleaning tape assembly comprising a cleaning tape and a backing roller positioned adjacent to the first and second cleaning roller assemblies, wherein the backing roller is fixed in position so as not to move toward or away from the cleaning rollers of the first and second cleaning roller assemblies; and

the backing roller has a first end and a second end, and the backing roller is supported by a single bearing at an intermediate height between the first end and the second end, and the backing roller is not supported by bearings at the first end and the second end.

2. The card cleaning mechanism of claim 1, wherein each pair of cleaning rollers forms a nip therebetween through which a card being cleaned passes.

3. The card cleaning mechanism of claim 1, wherein a circumference of each cleaning roller is approximately equal to or greater than a length of a card being cleaned.

4. The card cleaning mechanism of claim 1, wherein the cleaning tape assembly is positioned relative to the first and second cleaning roller assemblies such that the cleaning tape assembly can simultaneously remove contaminants from the tacky outer surface of one of the cleaning rollers of each of the first and second cleaning roller assemblies.

5. The card cleaning mechanism of claim 1, wherein the cleaning tape assembly includes a supply roll that supplies the cleaning tape, and an idler roller that rides against a surface of the supply roll.

6. The card cleaning mechanism of claim 5, wherein the idler roller is supported on a pivotally mounted arm such that the idler roller is movable toward the supply roll as the supply roll diameter decreases; and the arm is biased away from the supply spool.

7. A card cleaning module, comprising:

a card input device through which a card to be cleaned is input into the module;

an input drive mechanism adjacent to the card input device and adapted to receive a card passing through the card input device and drive the card into the module;

a card output device through which cleaned cards are output from the module;

an output drive mechanism adjacent to the card output device for driving the cleaned card out of the module;

first and second cleaning stations disposed between the card input device and the card output device, the first and second cleaning stations each comprising:

a pair of cleaning rollers rotatably mounted for rotation about respective longitudinal axes and forming a nip therebetween through which the card passes, each cleaning roller including a tacky outer surface;

a cleaning tape assembly disposed adjacent to the first and second cleaning stations, the cleaning tape assembly configured to remove contaminants from the tacky outer surfaces of the cleaning rollers of each of the first and second cleaning stations, the cleaning tape assembly comprising a cleaning tape and a backing roller positioned adjacent to the first and second cleaning stations, wherein the backing roller is fixed in position so as not to move toward or away from the cleaning rollers of the first and second cleaning stations; and

the backing roller has a first end and a second end, and the backing roller is supported by a single bearing at an intermediate height between the first end and the second end, and the backing roller is not supported by bearings at the first end and the second end.

8. The card cleaning module of claim 7, wherein the circumferential length of each cleaning roller is approximately equal to or greater than the length of the card being cleaned.

9. The card cleaning module of claim 7, wherein the cleaning tape assembly is positioned relative to the first and second cleaning stations such that the cleaning tape can simultaneously remove contaminants from the tacky outer surface of one of the cleaning rollers of each of the first and second cleaning roller assemblies.

10. The card cleaning module of claim 7, wherein the cleaning tape assembly includes a supply roll that supplies the cleaning tape, and an idler roller that rides against a surface of the supply roll.

11. The card cleaning module of claim 10, wherein the idler roller is supported on a pivotally mounted arm such that the idler roller is movable toward the supply roll as the supply roll diameter decreases.

12. The card cleaning module of claim 10, wherein the idler roller is supported on a pivotally mounted arm, wherein the arm is biased away from the supply roll.