Patch lamination device and method

Patent metadata

Field	Value
Publication number	US-10828877-B2
Application number	US-201615065389-A
Country	US
Kind code	B2
Filing date	Mar 9, 2016
Priority date	Mar 9, 2016
Publication date	Nov 10, 2020
Grant date	Nov 10, 2020

Abstract

A patch lamination device includes a laminate feed roller, a laminating roller, and a laminate spreader. The laminate feed roller is configured to feed a patch laminate ribbon along a laminate path. The laminating roller is configured to laminate individual patch laminates of the ribbon to a surface of a card substrate. The laminate spreader is positioned between the laminate feed roller and the laminating roller. The laminate spreader is configured to reduce the formation of trough wrinkles in a patch laminate that is tensioned between the laminate feed roller and the laminating roller during lamination of the patch laminate to a card substrate using the laminating roller.

First claim

What is claimed is:

1. A patch lamination device comprising:
a laminate feed roller configured to feed a patch laminate ribbon along a laminate path;
a laminating roller configured to laminate individual patch laminates of the patch laminate ribbon to a surface of a card substrate; and
a first laminate spreader between the laminate feed roller and the laminating roller, the first laminate spreader configured to reduce the formation of trough wrinkles in a patch laminate caused by tension of the patch laminate generated between the laminate feed roller and the laminating roller, the tension configured to detach the patch laminate from the patch laminate ribbon during a lamination process of the patch laminate in which the patch laminate is detached from the patch laminate ribbon and laminated to a card substrate using the laminating roller;
wherein the first laminate spreader is configured to contact the patch laminate on both sides of a center line of the patch laminate that is parallel to the laminate path.

2. The device according to claim 1 , wherein the first laminate spreader has a length extending across a width of the web of patch laminates that is perpendicular to the laminate path.

3. The device according to claim 2 , wherein:
the first laminate spreader includes at least one patch engaging surface along its length that is perpendicular to the laminate path, the at least one patch engaging surface engaging a patch laminate that is tensioned between the laminate feed roller and the laminating roller during the lamination process of the patch laminate; and
the at least one patch engaging surface includes a central patch engaging surface between end patch engaging surfaces, the central patch engaging surface extends closer to a path of the card substrate than the end patch engaging surfaces.

4. The device according to claim 3 , wherein the patch engaging surface is concave in a lengthwise direction of the laminate spreader.

5. The device according to claim 2 , wherein the first laminate spreader comprises a deflector member having the patch engaging surface.

6. The device according to claim 2 , wherein the first laminate spreader comprises a roller having the patch engaging surface.

7. The device according to claim 1 , further comprising a second laminate spreader between the laminate feed roller and the first laminate spreader, the second laminate spreader configured to reduce the formation of trough wrinkles in the patch laminate between the laminate feed roller and the laminating roller during the lamination process of the patch laminate.

8. The device according to claim 1 , further comprising:
a card transport mechanism configured to transport individual card substrates along a card path; and
a patch sensor configured to detect a perforated line of reduced strength between individual patch laminates in the web.

9. The device according to claim 1 , further comprising a laminate feed mechanism including:
the laminate feed roller, which is configured to feed the patch laminate ribbon along the feed path in a feed direction;
a surface that defines a portion of the feed path and includes first and second adjoining portions, wherein the second portion is downstream of the first portion relative to feed direction, and the second portion is oriented at an angle relative the first portion, wherein the second portion deflects and flattens a leading portion of a leading patch laminate of the patch laminate ribbon as the patch laminate ribbon is fed along the feed path in a feed direction by the laminate feed roller; and
a sensor configured to detect a leading edge of the leading patch laminate that is supported on the second portion of the surface.

10. The device according to claim 9 , wherein the laminate feed mechanism includes a guide roller located along the feed path between the laminate feed roller and the sensor, the guide roller configured to move away from and toward the second portion of the surface and flatten the leading portion of the leading patch laminate that is supported on the second portion of the surface.

11. A patch lamination device comprising:
a laminate feed roller configured to feed a patch laminate ribbon along a laminate path in a feed direction;
a laminating roller configured to laminate individual patch laminates of the patch laminate ribbon to a surface of a card substrate; and
a first laminate spreader between the laminate feed roller and the laminating roller, the first laminate spreader configured to deflect and reduce trough wrinkles in a patch laminate that are caused by tension of the patch laminate generated between the laminate feed roller and the laminating roller, the tension configured to detach the patch laminate from the patch laminate ribbon during a lamination process of the patch laminate in which the patch laminate is detached from the patch laminate ribbon and laminated to a card substrate using the laminating roller;
wherein the first laminate spreader is configured to remain in contact with the patch laminate for at least substantially a duration of a detachment phase of the lamination process during which the tension is applied to the patch laminate to detach the patch laminate from the patch laminate ribbon.

12. The patch lamination device of claim 11 , further comprising:
first and second surface portions configured to support the patch laminate ribbon along the laminate path, wherein the second surface portion is downstream from the first surface portion relative to the feed direction, and the second surface portion is oriented at an angle relative the first surface portion, and wherein the second surface portion deflects a leading portion of a leading patch laminate of the patch laminate ribbon from a plane of the first surface portion as the patch laminate ribbon is fed along the laminate path in the feed direction by the laminate feed roller; and
a sensor configured to detect a leading edge of the leading patch laminate that is supported on the second surface portion.

13. The device of claim 11 , wherein the first laminate spreader has a length extending across a width of the web of patch laminates that is perpendicular to the laminate path.

14. The device of claim 13 , wherein:
the first laminate spreader includes at least one patch engaging surface that deflects a patch laminate that is tensioned between the laminate feed roller and the laminating roller during the lamination process of the patch laminate; and
the patch engaging surface includes a central patch engaging surface between end patch engaging surfaces, the central patch engaging surface extends closer to a path of the card substrate than the end patch engaging surfaces.

15. The device according to claim 14 , wherein the first laminate spreader comprises a deflector member between the second surface portion and the laminating roller, the deflector member including the patch engaging surface.

16. The device according to claim 14 , wherein the first laminate spreader comprises a roller having the patch engaging surface.

17. The device according to claim 13 , further comprising a second laminate spreader between the laminate feed roller and the first laminate spreader, the second laminate spreader configured to reduce the formation of trough wrinkles in a patch laminate between the laminate feed roller and the laminating roller during the lamination process of the patch laminate.

18. The device according to claim 17 , further comprising:
a card transport mechanism configured to transport individual card substrates along a card

Assignees

• Assa Abloy Ab

Inventors

• Skoglund John P
• Hoffman Ted M

Classifications

• B32B38/1825

  characterised by the control or constructional features of devices for tensioning, stretching or registration · CPC title

• B32B37/0007

  involving treatment or provisions in order to avoid deformation or air inclusion, e.g. to improve surface quality · CPC title

• B32B38/1875

  Tensioning · CPC title

• B32B38/1808

  characterised by the laying up of the layers · CPC title

• B32B38/0004

  Cutting, tearing or severing, e.g. bursting; Cutter details (cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence) · CPC title