Patent Grant
7985316
The present invention is related to adhesive applicators, and more particularly, to systems and methods for applying adhesive attachments to transaction cards.
Transaction cards, such as credit cards, debit cards, membership cards, stored value cards, and the like, are widely used. Such cards may include a variety of different indicia to identify the card and other features, such as the card issuer, the customer, terms and conditions of use, or the like, depending in part on the type of card. The information may be printed on the card using alphanumeric characters, graphics, or the like, or may be embossed into the card. Alternatively, some or all the information may be encoded on the card, such as in a magnetic strip attached to the card.
Often, it is desirable to couple transaction cards to a carrier having additional information printed thereon. For example, when a credit card is mailed to a consumer, the cards is typically affixed with a carrier such as a paper sheet or other statement containing account information and the like. Similarly, stored value cards sold in retail locations may have a carrier containing terms and conditions of use, promotional information, and other inducements to buy the card. The card may be attached to the carrier, often with an adhesive strip or some type of bonding material. In an alternative process, some have devised methods whereby two or more corners of the card are slotted into punch holes of the carrier. Yet current approaches for coupling cards with carriers often suffer from certain drawbacks. For example, systems for punching D-holes into carrier sheets can be expensive and difficult to operate. Relatedly, it has been found that cards often become dislodged from carrier punch holes as a result of post office handling procedures. Some have proposed the use of gummy glue or other removable low melt adhesives for attaching cards with carriers. However, known adhesive applicators such as these are often prohibitively expensive. Accordingly, improved systems and methods are needed for affixing cards and other articles to carriers. The present invention provides such a solution to such needs.
According to one exemplary embodiment, the present invention provides systems and methods for affixing an attachment, for example a double sided adhesive strip, to an article such as a credit card or other presentation instrument. Advantageously, the present invention provides less expensive approaches that are easier to implement than other known techniques. Further, the present invention is well suited for applying such as clear or transparent adhesive slips to presentation instruments, which has heretofore been difficult to achieve in an economically feasible manner.
In a first aspect, the present invention provides an applicator system for applying an attachment to an article. The system can include a conveyor configured to transport the article along an article processing path, and an attachment assembly. The attachment assembly may include an advance motor configured to advance an attachment web along a web path, a peeler disposed along the web path and configured to separate an anchor portion of the attachment away from the attachment web, and a positioner disposed along the web path and configured to adjust the position of the web path relative to the article processing path, such that the anchor portion of the attachment is contacted with the article when the positioner moves the web path within sufficient proximity of the article processing path. In a related embodiment, the applicator system includes a staging sensor aligned to detect the presence of the anchor portion of the attachment when the anchor portion is separated from the attachment web. In some cases, the staging sensor can be an RF sensor.
The positioner can include an activatable solenoid, such that the solenoid when activated is adapted to induce the positioner to move the web path toward the article processing path, and when deactivated is adapted to allow the positioner to move the web path away from the article processing path. In a related aspect, the web path can extend from a source spool to a take-up spool. The system can also include a take-up spool motor configured to modulate rotation of the take-up spool to adjust slack in the attachment web. In some aspects, the attachment includes a double-sided adhesive slip. In other aspects, the article includes a card body having machine readable account information stored thereon, and the attachment includes a protective device that prevents the account information from being read by a machine when the protective device is placed over the account information.
In another aspect, the present invention provides a method of applying an attachment to an article. The method can include transporting the article along an article processing path, advancing an attachment web along a web path, separating an anchor portion of the attachment away from the attachment web, and moving the web path within sufficient proximity of the article processing path to cause the anchor portion of the attachment to contact the article. The method may also include detecting the presence of the anchor portion of the attachment when the anchor portion is separated from the attachment web, using a staging sensor. In some cases, the presence of the anchor potion of the attachment is detected using an RF sensor. In a related aspect, the step of moving the web path includes activating a solenoid to induce a positioner to move the web path toward the article processing path. The step of moving the web path can also include deactivating the solenoid to allow the positioner to move the web path away from the article processing path. In another related aspect, the step of advancing the attachment web along a web path includes advancing the attachment web from a source spool to a take-up spool. Similarly, methods of the present invention may include adjusting slack in the attachment web by modulating rotation of the take-up spool with a take-up spool motor. In some aspects, the present methods include affixing a double-sided adhesive slip to an article. In related aspects, the present methods include affixing a protective device to a card body having machine readable account information stored thereon, and the protective device prevents the account information from being read by a machine when the protective device is placed over the account information.
In still another aspect, the present invention provides a method for constructing an applicator system for applying an attachment to an article. The method can include coupling a system frame with a conveyor configured to transport the article along an article processing path, and coupling the system frame with an attachment assembly. The attachment assembly can include an advance motor configured to advance an attachment web along a web path, a peeler disposed along the web path and configured to separate an anchor portion of the attachment away from the attachment web, and a positioner disposed along the web path and configured to adjust the position of the web path relative to the article processing path, such that the anchor portion of the attachment is contacted with the article when the positioner moves the web path within sufficient proximity of the article processing path. The method can also include coupling the system frame with a staging sensor and aligning the staging sensor to detect the presence of the anchor portion of the attachment when the anchor portion is separated from the attachment web. In a related aspect, the positioner can include an activatable solenoid, such that the solenoid when activated is adapted to induce the positioner to move the web path toward the article processing path, and when deactivated is adapted to allow the positioner to move the web path away from the article processing path when in an inactive state.
The present invention provides systems and method for affixing attachments such as double-sided adhesive strips to presentation instruments and other articles. These techniques provide, for example, an economical and efficient approach to firmly securing credit cards to statements or other carriers, such that the card and the carrier do not become separated during mailing or other handling procedures. Turning now to the drawings,
In many embodiments, applicator system 100 also includes a staging sensor 970 (shown in
In some cases, article 400 is affixed with attachment 910, and then prepared for distribution. In other cases, attachment 910 operates as an intermediate coupling between article 400 and another item (not shown), and the resulting combination is then prepared for distribution. Attachment web 900 typically includes a plurality of attachments 910, which can be, for example, single-sided or double-sided adhesive slips. Relatedly, attachments 910 can be either transparent or opaque.
It is appreciated that article 400 can be any of a variety of transaction instruments, such as credit cards, debit cards such as ATM cards, bank cards, prepaid phone cards, airline cards, frequent buyer cards, casino cards, hotel room door access cards, insurance cards, library cards, discount cards, membership cards, entertainment cards, travel cards, supermarket check-out cards, retail store charge cards, gift cards, calendar cards, restaurant tip cards, driver's licenses or other identification cards, various stored-value cards, or any other type of financial, healthcare, or transaction presentation instrument, or the like. Exemplary articles are further discussed in U.S. patent application Ser. No. 09/971,303 filed Oct. 3, 2001; Ser. No. 10/421,604 filed Apr. 22, 2003; Ser. No. 10/922,815 filed Aug. 19, 2004; and Ser. No. 11/155,323 filed Jun. 17, 2005; the entire contents of which are incorporated herein by reference. In some embodiments, article 400 is a card body having machine readable account information stored thereon, and attachment 910 is a protective device that prevents the account information from being read by a machine when the protective device is placed over the account information. Exemplary protective devices are discussed in U.S. patent application Ser. No. 11/117,606 filed Apr. 27, 2005, the entire contents of which are incorporated herein by reference. Article 400 may also be a business card, a mailing insert, a coupon, an address label, a product sample, a key, a calendar, a coin, or the like.
Where attachment 910 operates as an intermediate coupling between article 400 and another item, the other item may be, for example, a continuous form, a cut form, a paper sheet, a financial statement, a brochure or other sales literature, a promotional advertisement, a solicitation, an inducement, a carrier, or the like. Exemplary carriers are discussed in U.S. patent application Ser. No. 11/155,323 filed Jun. 17, 2005 the entire contents of which are incorporated herein by reference.
In operation, system 100 can affix attachment 910 with article 400 according to exemplary method 1000 (shown in
Article 400 is received onto and advanced along article processing path 410. Typically, an article input sensor 430 is configured to detect the presence of article 400 at an upstream location (shown in
Before, during, or even after the staging process of anchor portion 912, article output sensor 420 (shown in
When article output sensor 420 detects article 400, solenoid 850 is activated and thereby operates to rotate positioner 800 about pivot 890, in a clockwise direction, as indicated by step 1035. Such activation of solenoid 850 may be under the control of smart motor 300. This rotation of positioner 800 moves a portion of web path 920 toward article processing path 410, and thereby moves anchor portion 912 toward and in contact with article 400, as depicted by step 1040. As anchor portion 912 is affixed with article 400, smart motor 300 instructs conveyor 200 to advance article 400 further along article processing path 410, and in a simultaneous or otherwise coordinated fashion instructs advance motor 600 to advance attachment web 900 along web path 920, as indicated by step 1045. In this way, attachment 910 and article 400 are transported together, and the remainder of attachment 910 is smoothly affixed with article 400.
Article 400 continues to advance along conveyor 200 past article output sensor 420. When article output sensor 420 no longer detects article 400, smart motor 300 operates to deactivate solenoid 850. Alternatively, deactivation of solenoid 850 can be independent of a signal from article output sensor 420, and instead can be accomplished via timing specifications dictated by smart motor 300. As depicted by step 1050, when deactivated, solenoid 850 causes or allows positioner 800 to rotate about pivot 890 in a counterclockwise direction. This rotation of positioner 800 moves a portion of web path 920 away from article processing path 410, and toward its original position. Conveyor 200 can transport article 400 further along article processing path and toward a downstream processing location as indicted by step 1055. In some embodiments, conveyor 200 includes accelerated conveyor friction wheels 220′ which are configured to rotate at an accelerated rate as compared with the other friction wheels 220.
It is appreciated that web path 920 is usually defined by attachment web 900, and extends from a source spool 940 to a take-up spool 950. System 100 typically can provide means whereby slack in attachment web 900 can be reduced or otherwise adjusted. For example, take-up spool motor 960 operates to modulate rotation of take-up spool 950 so as to adjust slack in attachment web 900. Toward this end, system 100 includes a slack sensor 965 disposed along web path 920 and in operative association with take-up spool motor 960. If slack sensor 965 detects excessive slack in attachment web 900, take-up spool motor 960 can initiate or increase rotation of take-up spool 950 in a counterclockwise direction, thereby providing more tension in attachment web 900. In some embodiments, slack sensor 965 and take-up spool motor 960 operate on a continuous basis, such that as soon as slack is generated in attachment web 900, it is detected by slack sensor 965 and consequently reduced due to activation of take-up spool motor 960. System 100 is then poised to repeat the procedure as describe above for any desired number of times. In brief, advance motor 600 advances attachment web 900 to stage anchor portion 912, and conveyor 200 transports article 400 along article processing path 410. Anchor portion 912 is affixed with article 400, and slack is removed from web 900.
Often, article processing path 410 is defined at least in part by conveyor tract 415. System 100 may also include a magnetic strip reader 440 or other means for reading identification information from article 400. Magnetic strip reader 440 may be disposed along article processing path 410, and typically is situated beneath a conveyor friction wheel 220. Often, such identification information can be used in other article-processing steps. For example, the identification information can be used to match article 400 with a particular carrier to which it is affixed with at a downstream processing location. More particularly, the identification information can be used to match article 400 with a particular customer financial statement or other carrier, so as to insure that article 400 is sent to the intended recipient. Exemplary magnetic strip readers are discussed in U.S. patent application Ser. No. 11/153,218 filed Jun. 14, 2005 the entire contents of which are incorporated herein by reference.
Relatedly, each of the steps described herein may be performed using a computer or other processor having hardware, software, and/or firmware. The various method steps may be performed by modules, and the modules may comprise any of a wide variety of digital and/or analog data processing hardware and/or software arranged to perform the method steps. The modules may optionally include data processing hardware adapted to perform one or more of these steps by having appropriate machine programming code associated therewith. Modules for two or more steps (or portions of two or more steps) may be integrated into a single processor board or separated into different processor boards in any of a wide variety of integrated and/or distributed processing architectures. These methods and systems will often employ a tangible media embodying machine-readable code with instructions for performing the method steps. Suitable tangible media may comprise a memory (including a volatile memory and/or a non-volatile memory), a storage media (such as a magnetic recording on a floppy disk, a hard disk, a tape, or the like; on an optical memory such as a CD, a CD-R/W, a CD-ROM, a DVD, or the like; or any other digital or analog storage media), or the like.
It will be apparent that substantial variations may be used in accordance with specific requirements. For example, customized hardware might also be used and/or particular elements might be implemented in hardware, software (including portable software, such as applets), or both. Further, system 100 can include or be in operative association with other computing devices such as a network input/output device, a computer terminal, a personal computer, a portable computer, a workstation, a network computer, or any other data processing system. Likewise, many of the hardware and software components discussed herein can be integrated with or configured to interface with other components of system 100 or with other non-system components.
While the above provides a full and complete disclosure of certain embodiments of the present invention, various modifications, alternate constructions and equivalents may be employed as desired. Therefore, the above description and illustrations should not be construed as limiting the invention, which is defined by the appended claims.
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