Input hopper apparatus and method

• US 4,921,237 A
• Filed: 10/07/1988
• Issued: 05/01/1990
• Est. Priority Date: 09/05/1986
• Status: Expired due to Term

• Current Assignee: Datacard Corp. (Entrust Corp.)
• Original Assignee: Datacard Corp. (Entrust Corp.)
• Inventors: Mattila, Gary P., Nubson, Richard C.
• Primary Examiner(s): SCHACHER, RICHARD
• Application Number:
  US07/256,091
• Time in Patent Office: 571 Days
• Field of Search: 271/11-13, 271/99, 271/102, 271/104, 271/105, 271/106, 271/31.1, 271/161
• US Class Current: 271/11
• CPC Class Codes: B65H 1/02 adapted to support articles on edge
• CPC Class Codes: B65H 3/0808 Suction grippers
• CPC Class Codes: B65H 3/54 Pressing or holding devices

Abstract

An input hopper apparatus (40) including input hopper receptacle (42) for receiving a stack of cards (44). A pick mechanism (60) is disposed proximate a second end of the input hopper receptacle (42) for individually picking a card from the stack of cards (44) by use of a suction cup assembly (62). A transfer mechanism (70) is included for transferring the picked card to a card transfer path (59).

Claims

1. A method for receiving a stack of cards and for individually feeding the cards into a card transfer path, the method comprising the steps of:

(a) receiving a stack of cards in input hopper receptacle means having a first end and a second end;

(b) exerting a force on the stack of cards in a direction toward the second end of the input hopper receptacle means;

(c) pinching opposing edges of at least a first card closest the second end of the input hopper so as to force the opposing edges of at least the first card toward each other, the pinching step being accomplished by reciprocally moving pinch means between a first position wherein the pinch means is pinching opposing edges of at least the first card and a second position wherein the pinch means is not pinching opposing edges of at least the first card;

(d) fanning at least the first card closest the second end of the input hopper receptacle means by forcing suction means into engagement with a major surface of the first card facing away from the stack of cards such that the first card is bowed between its opposing edges in a direction toward the first end of the input hopper receptacle means and such that a suction force is created between the suction means and the first card;

(e) individually separating the first card from the stack of cards by retracting the suction means away from the stack of cards while the suction means is engaged to the first card; and

(f) transferring the card to a card transfer path.

2. A method in accordance with claim 1, wherein the step of removing the first card includes the step of forcing a flexible suction cup against the major surface of the first card at the second end of the input hopper receptacle means so as to deform the suction cup.

3. A method in accordance with claim 1, wherein the step of transferring includes the steps of first transferring the card to a staged position and subsequently transferring the card to a transfer position on the card transfer path.

4. An input hopper apparatus for receiving a stack of cards and for individually feeding cards to a card transfer path, individual cards of the stack of cards having first and second major surfaces, the apparatus comprising:

(a) input hopper receptacle means for receiving the stack of cards, the input hopper receptacle means having first and second ends and comprising;

(i) support means for supporting the stack of cards;

(ii) guide rail means for guiding movement of the stack of cards;

(iii) force means for forcing the stack of cards toward the second end;

(b) pick means disposed proximate the second end of the hopper receiving means for individually picking a card from the stack of cards, the pick means comprising pinch means for pinching opposing edges of at least a first card of the stack of cards so as to force opposing edges of at least the first card toward each other and suction means for engaging a major surface of the first card and bowing the first card in a direction generally toward the first end of the input hopper receptacle while the first card is pinched by the pinch means whereby the opposing edges of the first card are separated from those of the other cards in the stack of cards and removing the first card from the stack of cards at the second end of the input hopper receptacle means, the pinch means being reciprocally moveable between a pinching position wherein the pinch means is pinching opposing edges of at least the first card so as to force the opposing edges toward each other and a second position; and

(c) transfer means for transferring the card removed from the stack of cards to a card transfer path, whereby the card can then be transferred elsewhere.

5. An apparatus in accordance with claim 4, wherein a single DC motor is used to drive the pick means and the transfer means, control means is provided for reversing the direction of the motor between picking the card and transferring the card.

6. An apparatus in accordance with claim 4, including a drive arrangement including a first one way clutch means for driving the pick means and a second one way clutch means for driving the transfer means.

7. An apparatus in accordance with claim 4, wherein the suction means includes passive suction means having a deformable suction cup, wherein no vacuum source is required to create a partial vacuum between the deformable suction cup and the first card.

8. An apparatus in accordance with claim 4, wherein the pinch means is moved into the pinching position prior to the suction means engaging the first card.

9. An apparatus in accordance with claim 4, wherein the suction means bows the first card partially beyond a plane containing the opposing edges of the first card.

10. An apparatus in accordance with claim 4, wherein the stack of cards has a horizontal orientation.

11. An input hopper apparatus for receiving a stack of cards and for individually feeding cards to a card transfer path, individual cards of the stack of cards having first and second major surfaces, the apparatus comprising:

(a) input hopper receptacle means for receiving the stack of cards, the input hopper receptacle means having first and second ends and comprising;

(i) support means for supporting the stack of cards;

(ii) guide rail means for guiding movement of the stack of cards; and

(iii) first force means for forcing the stack of cards toward the second end;

(b) pick means disposed proximate the second end of the hopper receptacle means for individually picking a card from the stack of cards, the pick means comprising;

(i) means for bowing at least a first card at the second end of the input hopper receptacle means in a direction toward the second end of the input hopper receptacle means, the means for bowing including card pinch means proximate the second end of the input hopper receptacle means for forcing toward each other opposing edges of at least the first card; and

(ii) suction means reciprocally movable toward and away the stack of cards for engaging a first major surface of the first card facing away from the stack of cards and removing the first card so engaged from the stack of cards, the suction means including a deformable suction cup member and second force means for forcing the suction cup member against the first card and in a direction toward the first end of the input hopper receptacle means so as to bow the first card in a direction toward the first end of the input hopper receptacle means and deform the suction cup member, thereby creating a suction force without necessitating actively withdrawing air from the cavity formed by the suction cup member and the card it engages, the force required to displace the stack of cards toward the first end of the input hopper receptacle means being greater than the force required to deform the suction cup member, the means for bowing including means for activating the card pinch means prior to the suction cup member engaging the surface of the first card at the second end of the input hopper receptacle means, the suction cup cooperating with the card pinch means to fan at least the first card from the stack of cards as the first card is bowed toward the first end of the input hopper receptacle means; and

(c) transfer means for transferring the card to the card transfer path, whereby the card can then be transferred elsewhere.

12. An apparatus in accordance with the claim 11, wherein the stack of cards has a substantially horizontal orientation.

13. An apparatus in accordance with claim 11, wherein the guide rail means includes trailing and leading side guide rail members projecting inwardly toward the stack of cards so as to restrict movement of the stack of cards toward the second end of the input hopper receptacle means, the trailing side guide rail member being located on a side of the rail means in a direction away from the card transfer path and providing greater resistance to movement of the stack of cards than the leading side member, thereby allowing a leading edge of the first card to be pulled beyond the leading side guide rail member before a trailing edge of the first card is pulled beyond the trailing side guide rail member.

14. An apparatus in accordance with claim 11, wherein the pick means includes means for placing the card picked from the stack of cards in a staged position for subsequent transfer to the card transfer path.

15. An apparatus in accordance with claim 14, wherein the input hopper apparatus includes means for transferring the card picked from the staged position to the card transfer path.

16. An apparatus in accordance with claim 11, wherein the force means for forcing the cards toward the second end of input hopper receptacle means includes a cooperating mass and spring arrangement.

17. An apparatus in accordance with claim 16, wherein the suction means is reciprocally mounted for movement toward and away from the second end of the input hopper assembly in a direction substantially perpendicular to a major surface of the card at the second end of the input hopper receptacle means.

18. An apparatus in accordance with claim 11, wherein the input hopper means includes force opposing means for limiting the rate of movement of the stack of cards to less than the rate of movement of the suction means away from the second end.