Apparatus and system for preparing data cards and mailer forms and for attaching data cards to respectively associated mailer forms

• US 4,384,196 A
• Filed: 11/14/1980
• Issued: 05/17/1983
• Est. Priority Date: 11/14/1980
• Status: Expired due to Term

• Current Assignee: Data Card Corp.
• Original Assignee: Data Card Corp.
• Inventors: McCumber, Roger D., Gerlach, LeRoy E.
• Primary Examiner(s): YUSKO, DONALD
• Application Number:
  US06/206,840
• Time in Patent Office: 914 Days
• Field of Search: 235/375, 235/385, 235/454, 235/449, 235/474, 235/489, 270/58, 270/1, 270/4, 270/52, 270/54, 364/464, 364/478, 340/153, 355/1, 156/384, 156/442, 101/2, 101/45, 53/266 A
• US Class Current: 235/375
• CPC Class Codes: B65H 2301/4311 Making personalised books or mail packets according to personal, geographic or demographic data
• CPC Class Codes: B65H 2701/1914 Cards, e.g. telephone, credit and identity cards
• CPC Class Codes: B65H 39/14 Associating sheets with webs

Abstract

A system for attaching data cards to mailer forms including apparatus having a supply of serially connected mailer forms, a paper drive for the forms and a printer therefore, a card holding station for holding up to two data cards in position for pickup by a printed mailer form having divergent slots for receiving opposite end portions of the data cards, a burster for separating an individual card carrying printed mailer form from the serially connected forms, a folder, an output stacker and a form reject area. Electronic control circuitry is included for controlling the operation of the various stations in a cooperative manner and for assuring that the mailer forms are printed with information corresponding to the data cards which will be inserted therein.

Claims

1. A system for automatically attaching data cards authorized to be issued for predetermined accounts and coded with predetermined card account information, to respectively associated carrier forms having printed thereon corresponding, predetermined form account information, said system including means for operative connection to a common data base containing the account information for both the cards and the forms for a plurality of accounts, and comprising:

means for deriving the associated, predetermined card account information and predetermined form account information from the common data base in predetermined timed relationship for each account, and in individual succession for plural said accounts;

means for attaching data cards having card account information coded thereon to carrier forms having corresponding form account information printed thereon;

means for coding blank data cards in accordance with predetermined card account information supplied thereto;

means for printing predetermined account information on blank carrier forms, in individual succession corresponding to a succession of plural accounts for which data cards are authorized to be issued;

means for supplying coded data cards to said attaching means, in individual succession as to the data cards authorized to be issued for each of a succession of plural accounts;

said deriving means including means for supplying the predetermined card account information to said coding means in accordance with the number of data cards authorized to be issued for a given account, and for supplying, in timed relationship, synchronized with the supply of the predetermined card account information to said coding means, the predetermined form account information for the given account to said printing means; and

said printing means including means for supplying successive printed carrier forms to said attaching means in timed relationship synchronized with the successive supply of coded data cards for the respectively corresponding accounts, to said attaching means by said means for supplying coded data cards;

said attaching means including means for attaching the correct number of coded data cards to the respectively corresponding printed carrier form, in individual succession for the successive plural accounts.

2. The system as set forth in claim 1, wherein said common data base includes control data for indicating the authorized number of data cards for a given account and wherein said deriving means includes means for selectively deriving control data from the common data base in succession for plural accounts, said system further comprising means for supplying control data for a given account to said printing means, wherein said printing means includes means for sending a second card request signal to said coding means, in dependence upon said control data, after a first of the coded data cards for the given account is supplied to said attaching means, said coding means including means for generating an error signal if a second of the coded data cards for the given account is not available when the second card request signal is received by said coding means.

3. The system as set forth in claim 2, wherein:

said attaching means includes a card attachment station and means for transporting the coded data cards from said means for supplying coded data cards to said card attachment station,

said transporting means comprises first sensor means for providing a first sensor signal to said printing means when one of the coded data cards passes said transporting means,

said card attachment station comprises second sensor means for generating a second sensor signal when one of the coded data cards is received at said card attachment station, and

said printing means includes means for establishing a predetermined period of time for receiving said first and second sensor signals and for generating an error signal if the length of time between receipt of said first and second sensor signals exceeds the predetermined period of time.

4. The system as set forth in claim 3, wherein the carrier forms each have first and second divergent slots provided therein for holding a data card and wherein said card attachment station comprises:

means for receiving and releasably holding each of the coded data cards for the given account;

a guide member, having first and second guide slots, positioned parallel to the carrier forms;

a pivot rod connected to said guide member; and

first and second spring biased fingers pivotally connected to said pivot rod and positioned to protrude through said first and second guide slots, respectively, wherein said first and second spring biased fingers deflect a portion of the form adjacent to the first and second divergent slots, respectively, out of the form so that the printed carrier form picks up the corresponding coded data cards for the given account.

5. The system as set forth in claim 1, wherein the carrier forms are serially connected, said system further comprising burster means for separating a printed one of the serially connected carrier forms from the remaining blank serially connected carrier forms.

6. The system as set forth in claim 5, wherein the serially connected carrier forms are separated by a burst line and wherein said burster means comprises:

a U-shaped channel member having an open end positioned on one side of the serially connected carrier forms;

clamp means, positioned on the opposite side of the serially connected carrier forms, for selectively clamping the burst line, which separates the printed one of the serially connected carrier forms from the remaining blank serially connected carrier forms, against the open end of said U-shaped channel member; and

knife means movably positioned inside said clamp means, for cutting the printed one of the serially connected carrier forms from the remaining blank serially connected carrier forms at the burst line.

7. The system as set forth in claim 6, wherein said printing means generates a burst signal and wherein said knife means comprises:

a knife blade positioned inside said clamp means;

a first linkage member pivotally connected to said knife blade;

a second linkage member pivotally connected to said knife blade, said second linkage member longer than said first linkage member;

a triangular linkage member, having a first corner pivotally connected to said first linkage member, having a second corner pivotally connected to said second linkage member and having a third corner; and

a rotary solenoid connected to the third corner of said triangular linkage member and operatively connected to said electronic control means, wherein said rotary solenoid is actuated, upon receipt of the burst signal, to cause said triangular linkage member to move said first and second linkage members which in turn move said knife blade to engage and cut the burst line.

8. The system as set forth in claim 5, 6 or 7, further comprising means for folding the separated carrier forms.

9. The system as set forth in claim 8, further comprising means for stacking the folded carrier forms.

10. The system as set forth in claim 9, further comprising means for stuffing the folded carrier forms in envelopes.

11. A system for attaching data cards authorized to be issued for predetermined accounts and coded with predetermined card account information, to respectively associated carrier forms having corresponding predetermined form account information printed thereon, said system including means for operative connection to a common data base containing the account information for both the cards and the forms for a plurality of accounts, and comprising:

coding means for supplying predetermined card account information and predetermined form account information, said coding means including means for deriving the predetermined card account information and the predetermined form account information from the common data base and means for coding the predetermined card account information, for a given account, on first and second blank data cards;

means for supplying blank carrier forms in individual succession;

printing means, operatively connected to said coding means, for receiving the predetermined form account information for the given account and for printing the predetermined form account information for the given account on one of the blank carrier forms in timed relationship synchronized with the coding of the predetermined card account information for the given account on the first and second blank data cards;

a card attachment station;

means for transporting the coded first and second data cards from said coding means to said card attachment station; and

means for transporting the printed one of the carrier forms to said card attachment station in timed relationship synchronized with the transport of the coded first and second data cards to said card attachment station;

said card attachment station including means for receiving and releasably holding the first and second coded data cards in a desired pickup position, and means for attaching the first and second coded data cards for the given account to the corresponding printed one of the carrier forms.

12. The system as set forth in claim 11, wherein said printing means comprises electronic control means for generating a control signal and wherein said card attachment station further comprises means, operatively connected to said electronic control means, for moving said receiving and holding means to engage the printed one of the carrier forms in response to said control signal.

13. The system as set forth in claim 12, wherein said moving means comprises:

a linkage connected to said receiving and holding means; and

a rotary solenoid, connected to said linkage and operatively connected to said electronic control means, for moving said linkage in response to said control signal.

14. The system as set forth in claim 11 or 12, wherein the carrier forms each have first, second, third and fourth divergent slots provided therein for holding the first and second coded data cards for the given account and wherein said attaching means comprises:

a guide member, having first, second, third and fourth guide slots, positioned parallel to the carrier forms;

a pivot rod connected to said guide member; and

first, second, third and fourth spring biased fingers pivotally connected to said pivot rod and positioned to protrude through said first, second, third and fourth guide slots, respectively, wherein said first, second, third and fourth spring biased fingers deflect a portion of the form adjacent to the first, second, third and fourth divergent slots, respectively, out of the form so that the printed one of the carrier forms picks up the corresponding first and second coded data cards for the given account as the printed one of the carrier forms is transported past said card attachment station.

15. The system as set forth in claim 12, further comprising:

first sensor means, positioned adjacent said means for transporting the first and second coded data cards, for providing a first sensor signal to said electronic control means when one of the first and second coded data cards enters the transporting means; and

second sensor means, positioned adjacent said means for receiving and releasably holding the first and second coded data cards, for providing a second sensor signal to said electronic control means when one of the first and second coded data cards is received at said receiving and holding means,

wherein said electronic control means includes means for establishing a predetermined period of time for receiving said first and second sensor signals and means for generating an error signal if the length of time between receiving said first and second sensor signals exceeds the predetermined period of time.

16. The system as set forth in claim 15, wherein said first and second sensor means comprise photocells.

17. The system as set forth in claim 11, wherein said electronic control means generates a transport signal and wherein said means for transporting the first and second coded data cards comprises:

a transport motor, operatively connected to said electronic control means, driven in response to the transport signal;

a drive pulley driven by said transport motor;

a plurality of transport belts driven by said drive pulley, said plurality of transport belts for transporting the first and second coded data cards to said card attachment station; and

a plurality of idler rollers for supporting said plurality of transport belts.

18. The system as set forth in claim 11, wherein the carrier forms are serially connected, said system further comprising burster means for separating the printed one of the serially connected carrier forms from the remaining blank serially connected carrier forms.

19. The system as set forth in claim 18, wherein the serially connected carrier forms are separated by a burst line and wherein said burster means comprises:

a U-shaped channel member having an open end positioned on one side of the serially connected carrier forms;

clamp means, positioned on the opposite side of the serially connected carrier forms, for selectively clamping the burst line, which separates the printed one of the serially connected carrier forms from the remaining blank serially connected carrier forms, against the open end of said U-shaped channel member; and

knife means movably positioned inside said clamp means, for cutting the printed one of the serially connected carrier forms from the remaining blank serially connected carrier forms at the burst line.

20. The system as set forth in claim 19, wherein said electronic control means generates a burst signal and wherein said knife means comprises:

a knife blade positioned inside said clamp means;

a first linkage member pivotally connected to said knife blade;

a second linkage member pivotally connected to said knife blade, said second linkage member longer than said first linkage member;

a triangular linkage member, having a first corner pivotally connected to said first linkage member, having a second corner pivotally connected to said second linkage member and having a third corner; and

a rotary solenoid connected to the third corner of said triangular linkage member and operatively connected to said electronic control means, wherein said rotary solenoid is actuated, upon receipt of the burst signal, to cause said triangular linkage member to move said first and second linkage members which in turn move said knife blade to engage and cut the burst line.

21. The system as set forth in claim 18, further comprising means for folding the separated carrier forms.

22. The system as set forth in claim 21, further comprising means for stacking the folded carrier forms.

23. The system as set forth in claim 22, further comprising means for stuffing the folded carrier forms in envelopes.

24. A system for attaching data cards authorized to be issued for predetermined accounts and coded with predetermined card account information, to respectively associated carrier forms having predetermined form account information printed thereon, comprising:

means for supplying identifying information in synchronized timed relationship for each of a plurality of accounts, said identifying information including predetermined card account information and a print signal including number of cards per form data and predetermined form account information, said number of cards per form data indicating the required number of data cards to be attached to a respectively associated carrier form for a given account;

coding means for receiving the predetermined card account information from said means for supplying identifying information and for coding the predetermined card account information on the data cards;

a card attachment station;

means for transporting, in succession, the coded data cards to said card attachment station;

electronic control means, operatively connected to said means for supplying identifying information, for receiving the print signal, for providing, as an output, the predetermined form account information, and for sending a second card request signal to said coding means, in dependence upon the number of cards per form data, after a first of the coded data cards for a given account is received at said transporting means;

means for supplying blank carrier forms in individual succession;

means, operatively connected to said electronic control means, for receiving the predetermined form account information from said electronic control means and for printing, on one of the blank carrier forms, the predetermined form account information corresponding to the predetermined card account information coded on the data cards for the given account, said printing occurring in timed relationship synchronized with the coding of the predetermined card account information on the data cards by said coding means; and

means for transporting the printed one of the carrier forms past said card attachment station after the transport of the coded data cards for the given account to said card attachment station;

said card attachment station comprising means for receiving and releasably holding the coded data cards for the given account and means for attaching the coded data cards to the respectively associated printed carrier form for the given account;

said coding means including means for generating an error signal if the print signal is being generated when the second card request signal is received by said coding means.

25. The system as set forth in claim 24, wherein the carrier forms each have first and second divergent slots provided therein for holding a data card and wherein said attaching means comprises:

a guide member having first and second guide slots, positioned parallel to the carrier form;

a pivot rod connected to said guide member; and

first and second spring biased fingers pivotally connected to said pivot rod and positioned to protrude through said first and second guide slots, respectively, wherein said first and second spring biased fingers deflect a portion of the form adjacent to the first and second divergent slots, respectively, out of the form, so that the printed carrier form picks up the corresponding coded data cards for the given account as the printed carrier form is transported past said card attachment station.

26. The system as set forth in claim 24, wherein:

said means for transporting the coded data cards includes first sensor means for providing a first sensor signal to said electronic control means when one of the data cards passes through said transporting means,

said card attachment station further comprises second sensor means for generating a second sensor signal when one of the data cards is received at said receiving and holding means, and

said electronic control means includes means for establishing a predetermined period of time for receiving said first and second sensor signals and means for generating an error signal if the length of time exceeds the predetermined period of time.