Embossing drive mechanism for an automatic embossing system

Claim 2

A drive mechanism for actuating a die element carried by a die wheel and a punch element carried by a punch wheel to emboss a document positioned between the punch element and the die element, comprising: a cam; means for driving said cam in constant rotation; a first bail arm mounted for pivotal movement in a plane transverse to said die wheel; a second bail arm mounted for pivotal movement in a plane transverse to said punch wheel; first and second cam followers, mounted on said first and second bail arms, respectively, said first and second cam followers biased in rolling contact with said cam and driven by rotation of said cam for in turn driving said first and second bail arms in complementary oscillatory movement; first interposer means adjustably mounted on said first bail arm and selectively actuable to be disposed between said first bail arm and the die element; second interposer means adjustably mounted on said second bail arm and selectively actuable to be disposed between said second bail arm and the punch element; said first and second interposer means driving the corresponding die and punch elements into and out of engagement with the document for embossing the document in response to the complementary oscillatory movement of said first and second bail arms, said first and second interposer means being adjustable relative to said first and second bail arms, respectively, to achieve a desired embossing height on the document.

Claim 3

A drive mechanism as set forth in claim 1, wherein said cam is a two lobed cam.

Claim 4

A drive mechanism as set forth in claim 2, wherein said cam followers engage said cam at substantially 180° spaced-apart positions, and wherein said cam is a two lobed cam and is shaped to produce, in a first 180° of revolution thereof, complementary travel of said first and second cam followers and corresponding said complementary oscillatory movement of said first and second bail arms for initially driving said die element forward to engage the adjacent surface of the document and dwell at that position and thereafter drive said punch element forward to engage and emboss the document and then retract from the document, said die element thereafter retracting from the document.

Claim 5

A drive mechanism as set forth in claim 3, wherein said two lobed cam is shaped such that a complete 360° revolution of said two lobed cam produces a 70° rise, a 40° dwell, a 70° fall, a 20° dwell, a 70° rise, a 70° fall, and a 20° dwell.

Claim 6

A drive mechanism as set forth in claim 1, wherein said first interposer means comprises: a first interposer bracket adjustably mounted on the end of said first bail arm; and a first interposer solenoid, carrying an interposer tip on its movable core, mounted on said first interposer bracket, said first interposer bracket being adjustable relative to said first bail arm to achieve the desired embossing height on the document; and wherein said second interposer means comprises: a second interposer bracket adjustably mounted on the end of said second bail arm; and a second interposer solenoid, carrying an interposer tip on its movable core, said second interposer bracket being adjustable relative to said second bail arm to achieve the desired embossing height on the document.

Claim 7

A drive mechanism as set forth in claim 1, wherein the document to be embossed is a metal card.

Claim 8

A drive mechanism for selectively actuating one of a plurality of associated pairs of first and second embossing elements, said plurality of associated pairs of first and second embossing elements carried by first and second embossing element carriers, said apparatus for embossing a document positioned between the selected one of the plurality of associated pairs of first and second embossing elements, comprising: a cam; means for driving said cam in constant rotation; first and second bail arms mounted for pivotal movement in a plane transverse to said first and second embossing element carriers; first and second cam followers, mounted on said first and second bail arms, respectively, and biased in rolling contact with said cam and driven by rotation of said cam for in turn driving said first and second bail arms in complementary oscillatory movement; first interposer means adjustably mounted on said first bail arm and selectively actuable to be disposed between said first bail arm and the selected first embossing element; and second interposer means adjustably mounted on said second bail arm and selectively actuable to be disposed between said second bail arm and the selected second embossing element; said first and second interposer means driving the selected pair of first and second embossing elements into and out of engagement with the document for embossing the document in response to the complementary oscillatory movement of said first and second bail arms, said first and second interposer means being adjustable relative to said first and second bail arms, respectively, to achieve a desired embossing height on the document.

Claim 9

A drive mechanism for selectively actuating one of a plurality of associated pairs of first and second embossing elements, said plurality of associated pairs of first and second embossing elements carried by first and second embossing element carriers, said apparatus for embossing a document positioned between the selected one of the plurality of associated pairs of first and second embossing elements, comprising: a cam; means for driving said cam in constant rotation; first and second bail arms mounted for pivotal movement in a plane transverse to said first and second embossing element carriers; first and second cam followers, mounted on said first and second bail arms, respectively, and biased in rolling contact with said cam and driven by rotation of said cam for in turn driving said first and second bail arms in complementary oscillatory movement; first interposer means adjustably mounted on said first bail arm and selectively actuable to be disposed between said first bail arm and the selected first embossing element; and second interposer means adjustably mounted on said second bail arm and selectively actuable to be disposed between said second bail arm and the selected second embossing element; said first and second interposer means driving the selected pair of first and second embossing elements into and out of engagement with the document for embossing the document in response to the complementary oscillatory movement of said first and second bail arms, said first and second interposer means being adjustable relative to said first and second bail arms, respectively, to achieve a desired embossing height on the document.

Claim 10

A drive mechanism as set forth in claim 7, wherein said first interposer means comprises: a first interposer bracket adjustably mounted on the end of said first bail arm; and a first interposer solenoid, carrying an interposer tip on its movable core, mounted on said first interposer bracket, said first interposer bracket being adjustable relative to said first bail arm to achieve the desired embossing height on the document; and wherein said second interposer means comprises: a second interposer bracket adjustably mounted on the end of said second bail arm; and a second interposer solenoid carrying an interposer tip on its movable core, said second interposer bracket being adjustable relative to said second bail arm to achieve the desired embossing height on the document.

Claim 11

A drive mechanism as set forth in claim 7 or 8 wherein said cam is a two lobed cam.

Claim 12

A drive mechanism as set forth in claim 9, wherein said cam followers engage said cam at substantially 180° spaced-apart positions, and wherein said cam is a two lobed cam and is shaped to produce, in a first 180° of revolution thereof, complementary travel of said first and second cam followers and corresponding said complementary oscillatory movement of said first and second bail arms for initially driving said first embossing element forward to engage the adjacent surface of the document and dwell at that position and thereafter to drive said second embossing element forward to engage and emboss the document and then retract from the document, said first embossing element thereafter retracting from the document.

Claim 13

A drive mechanism as set forth in claim 9, wherein said two lobed cam is shaped such that a complete 360° revolution of said two lobed cam produces a 70° rise, a 40° dwell, a 70° fall, a 20° dwell, a 70° rise, a 70° fall, and a 20° dwell.

Claim 14

A drive mechanism as set forth in claim 7, wherein the document to be embossed is a metal card.

Claim 15

A drive mechanism for selectively actuating one of a plurality of die elements carried by a die wheel and one of a plurality of punch elements carried by a punch wheel to emboss a document positioned between the selected punch and die elements, comprising: a cam; means for driving said cam in constant rotation; a first bail arm mounted for pivotal movement in a plane transverse to the die wheel; a second bail arm mounted for pivotal movement in a plane transverse to the punch wheel; first and second cam followers, mounted on said first and second bail arms, respectively, said first and second cam followers biased in rolling contact with said cam and driven by rotation of said cam for in turn driving said first and second bail arms in complementary oscillatory movement; first interposer means adjustably mounted on said first bail arm and selectively actuable to be disposed between said first bail arm and the selected die element; second interposer means adjustably mounted on said second bail arm and selectively actuable to be disposed between said second bail arm and the selected punch element; said first and second interposer means driving the selected die and punch elements, respectively, into and out of engagement with the document for embossing the document in response to the complementary oscillatory movement of said first and second bail arms, said first and second interposer means being adjustable relative to said first and second bail arms, respectively, to achieve a desired embossing height on the document.

Claim 16

A drive mechanism for selectively actuating one of a plurality of die elements carried by a die wheel and one of a plurality of punch elements carried by a punch wheel to emboss a document positioned between the selected punch and die elements, comprising: a cam; means for driving said cam in constant rotation; a first bail arm mounted for pivotal movement in a plane transverse to the die wheel; a second bail arm mounted for pivotal movement in a plane transverse to the punch wheel; first and second cam followers, mounted on said first and second bail arms, respectively, said first and second cam followers biased in rolling contact with said cam and driven by rotation of said cam for in turn driving said first and second bail arms in complementary oscillatory movement; first interposer means adjustably mounted on said first bail arm and selectively actuable to be disposed between said first bail arm and the selected die element; second interposer means adjustably mounted on said second bail arm and selectively actuable to be disposed between said second bail arm and the selected punch element; said first and second interposer means driving the selected die and punch elements, respectively, into and out of engagement with the document for embossing the document in response to the complementary oscillatory movement of said first and second bail arms, said first and second interposer means being adjustable relative to said first and second bail arms, respectively, to achieve a desired embossing height on the document.

Claim 17

A drive mechanism as set forth in claim 13, wherein said first interposer means comprises: a first interposer bracket adjustably mounted on the end of said first bail arm; and a first interposer solenoid, carrying an interposer tip on its movable core, mounted on said first interposer bracket, said first interposer bracket being adjustable relative to said first bail arm to achieve the desired embossing height on the document, and wherein said second interposer means comprises: a second interposer bracket adjustably mounted on the end of said bail arm; and a second interposer solenoid, carrying an interposer tip on its movable core, mounted on said second interposer bracket, said second interposer bracket being adjustable relative to said second bail arm to achieve the desired embossing height on the document.

Claim 18

A drive mechanism as set forth in claim 14, further comprising: a first intermediate driver mounted between the die element and the interposer tip of the first interposer solenoid, for transmitting the driving force of said first bail arm to the die element; and a second intermediate driver mounted between the punch element and the interposer tip of said second interposer solenoid, for transmitting the driving force of said second bail arm to the punch element.

Claim 19

A drive mechanism as set forth in claim 13 or 14 wherein said cam is a two lobed cam.

Claim 20

A drive mechanism as set forth in claim 16, wherein said cam followers engage said cam at substantially 180° spaced-apart positions, and wherein said cam is a two lobed cam and is shaped to produce, in a first 180° revolution thereof, complementary travel of said first and second cam followers and corresponding said complementary oscillatory movement of said bail arms for initially driving said die element forward to engage the adjacent surface of the document and dwell at that position and thereafter to drive said punch element forward to engage and emboss the document and then retract from the document, said die element thereafter retracting from the document.

Claim 21

A drive mechanism as set forth in claim 13, wherein the document to be embossed is a metal card.