WO1992003289A1

WO1992003289A1 - Card assembly apparatus

Info

Publication number: WO1992003289A1
Application number: PCT/US1990/007465
Authority: WO
Inventors: Jaime Bonomi
Original assignee: Bostec Systems, Inc.
Priority date: 1990-08-21
Filing date: 1990-12-17
Publication date: 1992-03-05
Also published as: AU7046991A; US5080748A

Abstract

A current assembly apparatus and associated method for producing laminated cards (20) such as credit cards including providing means for feeding printed card sheets (10) to a laminating station and at the same time feeding top and bottom overlay webs (28, 30) also to the laminating station. The top overlay web (28) is provided with a series of parallel-disposed magnetic stripes (36). Means are provided for controlling the feeding of the top overlay web and the card sheets so as to feed them concurrently to form a lamination. Means (60, 62) are also provided for controlling the inter-positional relationship or registration between the card sheet and the overlay web to maintain a predetermined positional arrangement between the magnetic stripe and a predetermined position on the card sheet. Means (100) are also provided for continually loading new supplies of printed card sheets (102, 104) without interrupting the ongoing process.

Description

CARD ASSEMBLY APPARATUS

BACKGROUND OF THE INVENTION

The present invention relates in general to a card assembly apparatus, and pertains more particularly, to a card stock assembly machine that may be employed in the manufacture of, for example, laminated credit cards.

At the present time, in the manufacture of laminated cards, such as laminated credit cards, there are multiple steps that have to be carried out in constructing these cards. The production of the card can in general be separated into at least two steps including the use of a first machine that provides a laminated card comprised of a printed core material with top and bottom overlays for protecting the core material. Subsequently, with the use of a separate machine, a magnetic stripe is individually applied to the previously laminated card. This magnetic stripe may be applied with the use of a rolling die, typically referred to in the art as with the use of a roll-on machine. Alternatively, the stripe may be individually applied with the use of other types of machines for individually applying what is commonly referred to as the "signature panel".

It is further desirable that a machine to manufacture laminated cards have the ability to operate continuously. As such, the loading of new card stock sheets into the machine should not interfere with the ongoing process of manufacture.

It is an object of the present invention to simplify this card assembly procedure so that it can be carried out essentially with a single machine thus realizing an advantageous reduction in capital expenditure and associated operating costs.

Another object of the present invention is to provide a ^■card stock assembly machine that is characterized by the capability to automatically register and secure the different layers employed in the construction of the laminated credit card.

Another object of the present invention is to provide a card stock assembly machine that may be continuously loaded with new card stock sheets without interrupting the ongoing manufacturing process. A further object of the present invention is to provide a card assembly apparatus and associated method of card assembly in which the method can be carried out more simply, requiring fewer steps and requiring far less expenditure as far as capital equipment is concerned.

SUMMARY OF THE INVENTION

To accomplish the foregoing and other objects, features and advantages of the invention, there is provided a card assembly apparatus. This card assembly apparatus may be in the form of a machine that is adapted to construct a laminated card assembly. This laminated card assembly may then be sectioned so as to provide individual laminated cards such as credit cards. In accordance with the invention there is provided a stock of printed card sheets. These are typically provided in flat sheet form and are adapted to be printed in separate individual card formats. Means are provided for feeding the sheets one at a time to a laminating station of the machine. There is also a source of an overlay web having arranged thereon a series of parallel-disposed magnetic stripes and means are provided for feeding this overlay web to the laminating station also. The feeding of both the card sheets and the overlay web is carried out concurrently so as both are coupled at the same time at the laminating station so as to form a laminate structure. There is also preferably provided a second overlay web and means for also feeding this second web to the laminating station. One overlay web is for covering one side of the card sheet and the second overlay web is for covering the opposite side of the card sheet. In the making of credit cards, it is desired to maintain the printing on both sides of the card covered. The second overlay web is preferably a plain transparent web whereas, as mentioned previously, the first overlay web has the magnetic stripes disposed thereon in a parallel array. Means are provided for controlling the inter-positional relationship between the card sheet and the overlay web so as to maintain a predetermined positional arrangement between the magnetic stripe and a predetermined position on the card sheet. In this regard, the card sheet preferably has multiple lengthwise card segments with each card segment being a series of individual cards. The overlay web is preferably provided in a continuous roll. The means for controlling the inter-positional relationship between the card sheet and the overlay web, comprises registration means which in turn includes means for detecting the web position and also means for adjusting the card sheet position in the event of a misalignment of the magnetic stripe and the card sheet. With this registration arrangement, the overlay sheet that has the magnetic stripe on it can be properly oriented so that the magnetic stripe falls on the proper position of the card sheet with each magnetic stripe overlaying a predetermined position on the card segments. More particularly, the magnetic stripe is adapted to be positioned on an individual credit card basis so that it is in the proper position in a side-to-side relationship relative to the card. The aforementioned means for detecting web position may comprise a magnetic stripe detector. Other features of the present invention include a means for at least temporarily affixing the web and card sheet together. This may be referred to as a tacking mechanism that introduces a series of intermittent welded spots to securely affix preferably both overlay materials to the card sheet in preparation for subsequent processing. The subsequent processing is basically carried out by a device that die cuts into individual cards such as credit cards. In accordance with another feature of the present invention, there is provided means for cutting the web to a length comparable to each sheet length so that at the output of the machine there is a series of sheets that are outputted each laminated in accordance with the concepts of the invention.

The means for feeding the card stock sheets one at a time to the laminating station may alternatively be constructed to allow continuous reloading thereof without interrupting the feed of cards. Such a feeding device could include a track- mounted pair of feeding stacks having base supports displaceable in a direction transverse to the card feeding direction. A card on top of either of the stacks, when positioned in line with the remainder of the system, would be lifted from the top of the stack by means of a vacuum cup that lowers upon the card top and raises it. The card is then carried by means of a group of chain-mounted feed rollers to a set of pinch rollers leading into the feeding means. Once a sheet is fed, the chain driven feed rollers displace out of interfering contact with the top of the stack so that the next sheet in the stack may be lifted by the vacuum cup. The stack support bases may be shifted into position by means of an air cylinder mounted proximate to the tracks that responds to the detection of an empty stack to shift to a newly loaded stack while placing the empty stack aside to be refilled.

BRIEF DESCRIPTION OF THE DRAWINGS

Numerous other objects, features and advantages of the invention should now become apparent upon a reading of the following detailed description taken in conjunction with the accompanying drawing, in which:

FIG. 1 is a perspective view showing the overall cabinetry used with the machine of the present invention;

FIG. 2 is a more detailed perspective view illustrating the machine of this invention as employed with both a top overlay material with the magnetic stripe thereon and a bottom plain overlay material;

FIG. 3 is a view of the laminate construction illustrating the materials comprising the construction and also illustrating the inter-positional relationship or registration in particular of the top overlay material with its magnetic stripe and the printed card sheet or core material;

FIG. 4 is a perspective view of a continuous loading and feeding device for use with the machine of the present invention; and

FIG. 5 is a side view of the continuous loading and feeding device of FIG. 4 in conjunction with part of the machine of the present invention.

DETAILED DESCRIPTION

Referring now to the drawings, there is shown in FIG. 1 the general cabinetry that is used with the card assembly apparatus or machine of the present invention. FIG. 2 is a perspective view showing the internal mechanisms that are used in the machine. There is provided a stock of printed card sheets 10 arranged in a stack. This stack of sheets 10 is contained within cabinet 12 shown in FIG. 1. The cabinet 12 is preferably provided with doors 14 which provide access to the interior of the cabinet 12. A conventional support mechanism 16 is shown for supporting the stack of printed card sheets 10. FIG. 2 also illustrates a means for feeding the sheets one at a time to a laminating station. The laminating station may be considered as simply the area at which the various materials are joined together to form a lamination. In FIG. 2 the finely laminated sheet is shown at 20. Subsequent operations are carried out on the sheet 20 as to be described in further details hereinafter.

The means for feeding the sheets 10 one at a time includes a support table 22 and belt-type feed mechanisms 24. The card sheet feed mechanisms illustrated in detail in FIG. 2 are for the most part conventional, and operate in a conventional manner to feed individual sheets to the laminating station. The laminating station is indicated in general by the reference character 25.

The card assembly apparatus of the present invention also includes means for feeding both a top overlay material and a bottom overlay material to the laminating station. In this regard in FIG. 2 there is illustrated a top overlay material roll 28 and a bottom overlay material roll 30. With regard to FIG. 1, the area of the machine including the rolls 28 and 30 is contained within the cabinetry 27. As illustrated in FIG. 1 the cabinetry 27 is provided access thereto by means of the large front doors 29. At the output to the machine there is also provided an output cabinetry 31 having an output slot 33 through which the laminate card 20 shown in FIG. 2 couples. Also illustrated in FIG. 1 is a control panel 35 having associated therewith, means for controlling various aspects of the operation of the machine, some of which are discussed in more detail hereinafter.

The top overlay material roll 28 feeds an overlay web 34 having arranged thereon a series of parallel disposed magnetic stripes 36, each extending longitudinally of the web and spaced evenly along the transverse width of the web.

The bottom overlay material role 30 also is in the form of a web 38. This is preferably a plain transparent thin plastic material. The overlay web 34 is also of a clear plastic material. The magnetic stripes may be deposited thereon using known techniques .

In FIG. 2, for the sake of simplicity, much of the support structure is not illustrated. However, there are illustrated a series of rollers which are each of course supported for proper rotation. The support mechanisms are not illustrated for the sake of maintaining the drawing more simplified. Thus, for example, with respect to the feeding means for the web 34, there are provided in sequence, rollers 41, 42, 43, 44, 45, 46, and 47. Similarly, there is a feed means associated with the overlay material roller 30. This includes properly supported rollers 50, 51, 52, 53, 54, 55, and 56. It is noted that the rollers 47 and 56 are in juxtaposition and the individual core material sheets 10 are essentially fed therebetween with the top overlay material web 34 being directed to the top of the card sheet and the bottom plain overlay material web 38 being directed to the underside of the card sheet 10.

The web feeding mechanisms, as indicated previously, comprise a series of rolls. These individual rolls are adapted to provide for constant tension feed from each of the individual supply rolls. In this connection, there are a series of guiding rollers, turnover rollers, slack take-up rollers and nip rollers. These various roller mechanisms may for the most part, be of conventional design and provide mechanisms for supplying the two overlay material. The top overlay material with the magnetic stripe applied, is wrapped about the final roller 47 and is conveyed about that roller and onto the top of the card sheet. Similarly, the final roller 56 associated with the bottom overlay material feeds this material to the underside of the card sheet.

In accordance with the present invention, there is furthermore provided for registration or proper positioning of, in particular, the top overlay web 34, relative to the side-to-side position of the printed card sheets that are being fed to the laminating station. The registration system may comprise guide rails, registration edge bars, and motor driven mechanisms to advance the card sheets on demand.

It is noted that the registration mechanism receives the material from the stock feeder via the table 22 and the registration system is adapted to align each and every sheet to a lateral position in accordance with command signals generated from the magnetic stripe detector 60.

Thus, as each of the individual sheets 10 are fed toward the laminating station, they are driven in a linear direction by virtue of some of the feed mechanisms illustrated, such as the mechanisms 24. In addition, the feed tables that support these sheets are adapted to be controlled for certain side translational movement. In this regard, note the registration motors or mechanisms 62 which are adapted to move the tables 22 and 23 in the direction of arrows 63 and.64, respectively. The mechanisms 62 may include motors and associated lead screws for altering the side-to-side position of the tables and correspondingly of the individual printed card sheets 10. The control by means of the mechanisms 62, is for aligning the printed card sheets properly with the magnetic stripes so that the alignment occurs as substantially illustrated in FIG. 3.

FIG. 3 illustrates the positional inter-relationship that is desired in particular, between the web 34 and the card sheet 10. FIG. 3 also illustrates the magnetic stripe 38. In FIG. 3 there is shown the outline of the individual credit cards by virtue of the phantom perimeter outline 65. The magnetic stripe 36 is to be arranged so that the edge 67 thereof is within a predetermined distance of the edge 69 at the perimeter 65 of one of the individual credit cards. In operation, the web 34 and the card 10 may be adjusted relative to each other so that the magnetic stripe 38 is in the proper position. The magnetic stripe detector 60 is then positioned appropriately so as to be in registry with one of the magnetic stripes. If during the operating sequence, the magnetic stripe detector 60 indicates the magnetic stripe becoming out of registry, then a feedback signal is coupled to the mechanisms 62 so as to orient the printed card sheets being inputted to the laminating station to compensate for this out of alignment condition. In this way in a positive and negative feedback arrangement, the magnetic stripe detector is instrumental in maintaining the card sheets in the proper position for proper aligning with the web 34 and the magnetic stripes 36 thereon. In this regard, it is noted that the card sheets are registered with the web 34 instead of the web 34 being registered to the card sheets. This approach resolves many difficulties encountered when a slow speed and/or intermittent web has to be kept in precise alignment. It has been found in accordance with the present invention that it is much more easy to align the sheets rather than to try to control the alignment of the web, particularly with all of the different rollers that are used for web control.

There is preferably also included as part of the system, two pairs of overlay web nip rollers, one on each side of the sheet 10 for performing delivery of the materials at the output of the mechanism. Under control of the registration mechanism, these rollers are moved in the direction of the sheet 10 for conveying it and may later be retracted to stop operation. In accordance with the operation of the machine, it is preferred that registration occur and then once the sheets are registered, the drive can be engaged so as to feed the sheet and the two overlays concurrently and in synchronism. In this regard in FIG. 2, it is noted that there is shown at 70, one of the laminates that has now been fabricated. Also associated therewith are feed mechanisms 72, essentially at the output of the device for feeding the graphic assembly.

Although not described in detail herein, it is understood that in a later step in forming the individual credit cards, a die arrangement is used for cutting the individual cards. This cutting would occur basically along the perimeter of the card as indicated by the phantom perimeter line 65 in FIG. 3. As indicated in FIG. 2, it is noted that there is a preferred gap between each of the individually fed card sheets or card stock. This gap is provided so as to enable cutting of both of the overlay webs so that the end product is separated into separate individual sheets such as the laminated sheet 20 illustrated in FIG. 2.

This cutting may be carried out by basically one of two different methods. For example, a standard guillotine may be activated for cutting the overlay webs. Alternatively, an electrically heated resistance wire or rod may be activated for cutting the overlay materials. One such cutting mechanism 75 is illustrated in FIG. 2.

Also, in accordance with the machine illustrated in FIG. 2, there is provided a tacking mechanism so that the overlay materials are at^' least temporarily secured on either side of the card stock or card sheet. As the card sheet laminate advances through the machine, there are a series of heated rollers 76 which are preferably synchronized for speed and displacement. These rollers introduce a series of spaced weld spots shown as spots 78 in FIG. 2. These welded spots which are actually simply a fusing of the plastic overlays securely affix both overlay materials to the card stock in readiness for subsequent processing.

To complete the manufacturing process and previous to the die cutting step, there may be provided a standard process for completing the laminating of the three layers comprising the basic card. This standard laminating process includes heating, the application of pressure and subsequent cooling to provide proper laminating interlocking of the three layers comprising the card. Thereafter, the cards may then be cut into separate cards as illustrated in FIG. 3. This cutting into separate cards may be carried out by a standard die cutting machine.

In summary, in accordance with the apparatus and associated method of the present invention, there is provided for a stock of printed? card sheets which are fed, preferably one at a time to a laminating station. Both top and bottom overlay rolls feed respective overlay webs also to the laminating station where a bamina1:ion is formed comprised of the sheet covered on oppositecsides by the top and bottom overlay materials. The bottom overlay material is preferably transparent and plain and the top overlay material may be similar but is provided with a series of-.par.allel disposed magnetic stripes. These magnetic stripesImay be deposited on the web by a deposition technique that is ik own- and the top overlay web is simply provided on a roll and is fed with the magnetic stripes affixed thereto to the laminating station. The card sheet along with the overlay webs are fed concurrently to the laminating station to form the lamination. Means are provided for registering, in particular, the toμ--overl-ay material with the card sheet so as to maintain a predetermined positional arrangement between the magnetic stripe and a ^'predetermined position on the card sheet such as illustrated in FIG. 3.

An^additional feature of this invention is a stack feeder 100 that; al o-ws- reloading of the supply of card stock sheets without-rany need to stop the process in between loadings . FIGS. 43and 5 depict such a stack feeder 100 according to this invention. Continuous feeding is particularly enabled by means of twαeindependent supply stacks 102, 104 positioned aside one anotheέ;- In^"- his example, the first stack 102 is in a feeding position 106 with a card stock sheet 108 shown undergoing feeding into the assembly machine of this invention.

This first stack 102 remains positioned in the feeding position 106 with sheets drawn into the process upon demand while a second adjacent stack 104 remains or is reloaded to be full of card stock sheets for reserve use.

According to this invention the first stack 102 in the feeding position 106 remains in this position until all its card stock sheets are fed into the process. When a sensor (not shown) then determines that the last card stock sheet is in the process of feeding (thus, no more sheets remain in the stack), a control signal to engage the second reserve stack is transmitted. In response to this signal, an air cylinder 112 actuates, moving the first stack 102 rightwardly (arrow 114) out of a feeding position while simultaneously moving the interconnected second reserve stack 104 into feeding position 106.

As depicted in the figures, the stacks are easily movable rightwardly (114) and leftwardly (arrow 120) transversely relative to the direction of feeding due to the tracks 124 upon which each stack support base 116, 118 is mounted. The stack support bases 116, 118 may further include ball bearing blocks (123) or other antifriction bushings in conjunction with the tracks 124 to facilitate easy movement despite heavy stack weight.

As the first stack 102 is moved rightwardly (114) out of a

feeding position (106) it is now ready to be loaded with a new supply of card stock sheets. As long as the second reserve stack 104 is quickly moved to a feeding position 106, the overall feeding process may remain uninterrupted despite the full emptying of the first stack 102. In particular, the second reserve stack 104 must be ready to present its sheets to the process as soon as a new sheet is requested by the assembly machine. To this end, the air cylinder 112 must be sufficiently powerful to facilitate rapid movement of the stacks 102, 104 rightwardly (114) and leftwardly (120).

Once the second stack is placed in the feeding position, its sheets are continually fed into the assembly machine until the second stack 104 is also exhausted. At this point the sensor again signals the presence of an empty stack in the feeding position 106 causing the air cylinder 112 to move the pair of stacks leftwardly (120), thus positioning the now reloaded first stack 102 back in the feeding position 106.

The reloading of each empty stack once it is moved out of the feeding position 106 into a reserve position may be accomplished manually by simply hand loading new sheets onto the support base 116, 118 or reloading may be accomplished by means of further automation, e.g. conveyor belts, etc., positioned proximate to each stack support base reserve position (i.e. to the left and right of feeding position).

Since stacks 102, 104 are disposed to move from side-to-side relative to the machine feeding direction (122), the feeding mechanism 125 for placing each top sheet in the stack into the assembly machine for processing must not interfere with the side-to-side (leftward 120 and rightward 114) movement of stacks 102, 104. Thus, a retractable vacuum cup 126, placed upon the end of an air cylinder 128, is disposed over the stack in the feeding position 106. As stacks move from side-to-side, the air cylinder 128 and vacuum cup 126 arrangement is signalled to remain in a retracted position that prevents interference with the side-to-side movement. Once the stacks are repositioned and a new full stack presents itself in the feeding position 106, the air cylinder 128 places the vacuum cup 126 proximate the top surface of a top card stock sheet in the stack near the card's trailing edge 130 (taken in a processing direction) . A vacuum is subsequently produced at the cup 126 which secures the top card stock sheet to the cup 126. The air cylinder 128 is then retracted upwardly carrying the card stock trailing edge 130 therewith.

This action of the cup 126 separates the lifted top card stock sheet 132 from the stack 134 as depicted in FIG. 5. Note that the card 132 is angled with the trailing edge 130 substantially above the level of the stack 134. It is important that the air cylinder 128 raise the vacuum cup 126 carrying the card stock sheet to a sufficient height. At this height, a series of rollers 136 disposed between roller drive chains 138 running upon opposite sides of the stack in the feeding position move from a position (140) behind the stack upwardly and into the feeding direction (122) to a position beneath the lifted card 132. As the roller arrangement 136 moves forwardly on the chains 138, it lifts the leading edge 141 of the card 132 to a height parallel with that of the trailing edge 130 (which is still supported by the vacuum cup 126). Simultaneously, a grooved feeding finger 142 disposed upon the chains 138 at the rear (downstream) end of the roller arrangement 136 moves proximate to the trailing edge 130 of the card 132. As the groove 144 of the feeding finger engages the trailing edge 130, the card is propelled forwardly (122). The vacuum cup 126 may continue to hold the card 132 and may follow the card as it is fed into the assembly machine 101 as shown by the arrow 145 in FIG. 5. Note that the stack feeder 100 may be constructed as a discrete unit that may be attached to and removed from an assembly machine 101 interchangably.

As the card 132 is fed to the assembly machine 101, its leading edge 141 encounters a pair of pinch rollers 146 that firmly grip and take over the task of propelling the card forwardly into the machine 101. The pinch roller 146 may be independently driven to control the feeding position.

An anti-static device 148 may be positioned downstream of the pinch rollers 146 to remove any residual static that the card may have gathered in the stack prior to processing.

The feeder finger 142 in this example does not operate to propel the card 132 further in the feeding direction (122) than a position at which its leading edge 141 contacts the pinch rollers 146. At such time, the pinch rollers 146 take over the process of feeding the card 132. At the moment the pinch rollers 146 obtain a firm grip on the card 132, the feeding finger 142 and rollers 136 withdraw on the chains 138 down the side of the stack along the chain line (position 140) as shown i FIG. 1.

The particular actuation of the roller 136 and feeding finger 142 arrangement into and out of engagement with a card stock sheet may be accomplished by means of a transfer bar 150 also connected between the chains 138 and itself interconnected with a reciprocating air cylinder 152 as shown in FIG. 1. Upon an extending stroke, the roller 136 and feeding finger 142 arrangement may be made to retract out of interfering engaging position the top of the stack, while upon a return stroke, inwardly toward the air cylinder 152, the arrangement 136, 142 may be made to drive forwardly into engagement with a lifted card stock sheet on the stack top. Each cycle of the feeding mechanism involves the lifting of a top card by the vacuum cup, then the driving forward of the rollers to fully lift the card and force it forwardly until it is gripped by the pinch rollers which feed it into the assembly machine. The cup then withdraws from the card and the rollers return to a point

behind the stack. Once the pinch rollers have fully fed the card, the process is repeated. If the stack is empty, the reserve stack moves into position before repeating the process.

Since the card stack becomes increasingly smaller as cards are taken therefrom, in order to elevate each fed card to the appropriate feeding level, the stack must either be brought closer to the feeding height (so the top sheet in the stack remains at a constant level) or, alternatively, the vacuum cup 126 must travel further downwardly to the progressively lower stack top and then travel further upwardly with a raised card stock piece in order to attain the prescribed feeding height. FIG. 5 depicts a system in which the support base 116, 118 continuously rides upwardly upon feed screws 154 to maintain the stack top at an appropriate height. As noted, the vacuum cup 126 may alternatively travel further downwardly as the stack top height decreases with each new card.

It should be noted that while only two stacks are utilized in this example, a multiplicity of track-mounted reserve stacks may be utilized according to this invention as long as their repositioning is properly coordinated by the applicable control system.

Having described one embodiment of the present invention, it should now be apparent to those skilled in the art that numerous other embodiments are contemplated as falling within the scope of this invention. What is claimed is:

Claims

1. Card assembly apparatus for producing a laminated card, comprising; a stock of printed card sheets, means for feeding the sheets one at a time to a laminating station, means for storing a plurality of adjacent stacks of sheets including means for selectively presenting each of said stacks of sheets to said means for feeding, a source of an overlay web having arranged thereon a series of parallel-disposed magnetic stripes, means for feeding the overlay web to the laminating station, means for controlling both said aforementioned means for feeding to concurrently feed both the card sheet and overlay web so as to form a lamination, and means for controlling the inter-positional relationship between the card sheet and overlay web to maintain a predetermined positional arrangement between the magnetic stripe and a predetermined position on the card sheet.

2. Card assembly apparatus as set forth in claim 1 wherein said card sheets are flat and are adapted to be printed in separate individual card format.

3. Card assembly apparatus as set forth in claim 1 wherei said card sheet has multiple lengthwise card segments, the number of which correspond to the number of magnetic stripes.

4. Card assembly apparatus as set forth in claim 3 wherein each card segment is separated into a plurality of individual cards .

5. Card assembly apparatus as set forth in claim 1 wherein said overlay web is provided in a continuous roll.

6. Card assembly apparatus as set forth in claim 5 wherein the stock of card sheets includes a stack of individual sheets having a length substantially less than the length of the continuous roll web.

7. Card assembly apparatus as set forth in claim 6 including means for cutting the web to a length comparable to each sheet length.

8. Card assembly apparatus as set forth in claim 1 wherein said means for controlling feed includes selectively operated feed rollers.

9. Card assembly apparatus as set forth in claim 1 including^""means* -for cutting the web to a length comparable to card sheet length.

10. --ard assembly apparatus as set forth in claim 1 wherein -said means for controlling position includes means for detecting web position and means for adjusting card sheet position in the event of misalignment between the magnetic stripe arid card^"sheet.

11. Card assembly apparatus as set forth in claim 10 wherein s-ai^'d⁵ means for detecting web position includes a magnetic stripe detector.

12. Card assembly apparatus as set forth in claim 1 including means for at least temporarily affixing the web and card sheet.

13. Card assembly apparatus as set forth in claim 1 including a source of a second overlay web and means for feeding the second- web also to the laminating station.

14. Card assembly apparatus as set forth in claim 13 wherein one overlay web is for covering one side of the card sheet and the second overlay web is for covering the opposite side of the card sheet.

15. Card assembly apparatus as set forth in claim 14 wherein the second overlay web is a plain transparent web.

16. A card assembly apparatus as set forth in Claim 1 wherein said means for storing includes means for supporting at least two adjacent stacks, slidably mounted to be disposed alternatively to said means for feeding.

17. A card assembly apparatus as set forth in Claim 16 wherein said means for supporting includes track means disposed transverse to a feeding direction for enabling displacement of said means for supporting for inter-positional change of each of said stacks.

18. A card assembly apparatus as set forth in Claim 17 wherein said means for selectively presenting includes detector means for determining the occurrence of an empty stack of said adjacent stacks at said means for feeding to change the position of said stacks so that a loaded stack of said adjacent stacks is presented to said means for feeding and the empty stack is removed therefrom.

19. A card assembly apparatus as set forth in Claim 1 wherein said means for feeding includes means for lifting a trailing edge of a top sheet of one of said stacks to enable feeding thereof.

20. A card assembly apparatus as set forth in Claim 19 further comprising means for selectively controlling said means for lifting .to move said means for lifting between interfering and non-interfering contact with said stack in response to a movement of stacks by said means for selectively presenting.

21. A card assembly apparatus as set forth in Claim 20 wherein said means for lifting includes vacuum cup means positioned to contact said top sheet.

22. A card assembly apparatus as set forth in Claim 21 further comprising feed roller means, responsive to said means for lifting, for supporting at a feeding height and driving a lifted sheet into said means for feeding.

23. A card assembly apparatus as set forth in Claim 22 further comprising means for selectively engaging and disengaging said feed rollers to remove them from interfering contact with said stack during the operation of each of said means for selectively presenting and said means for lifting.

24. A card assembly apparatus as set forth in Claim 23 wherein said means for selectively engaging and disengaging includes a pair of roller chains disposed upon opposite sides of said feed rollers that displace to translate said feed rollers into and out of interfering contact with said stack.

25. A card assembly apparatus as set forth in Claim 24 further comprising a feeding finger disposed upon said roller chains for engaging a trailing edge of said sheet to move it in a feeding direction.

26. A card assembly apparatus as set forth in Claim 25 wherein said means for storing includes means for raising the level of each stack so that a top sheet thereof is maintained at a constant elevation.

27. A card assembly apparatus as set forth in Claim 26 wherein said means for feeding includes pinch roller means disposed downstream in a feeding direction from said feed roller, for receiving a sheet from said feed rollers.

28. A card assembly apparatus as set forth in Claim 27 further comprising anti-static means disposed downstream in a feeding direction from said pinch roller means.

29. In a card assembly apparatus for producing a laminated card, a means for storing a plurality of stacks for continuous loading and feeding of sheets comprising: a plurality of adjacently disposed support means for each carrying a plurality of stacks of sheets thereon; guide means for allowing displacement of each of said support means in a direction transverse to an apparatus sheet feeding direction; means for selectively positioning each of said means for supporting in a feeding position relative to said apparatus; and means for removing and elevating each top sheet in a stack in the feeding position into alignment with an apparatus feed input.

30. A means for storing as set forth in Claim 29 wherein said guide means includes track means disposed transverse to a feeding direction for enabling displacement of said means for supporting for interpositional change of each of said stacks.

31. A means for storing as set forth in Claim 30 wherein said means for selectively positioning includes detector means for determining the occurrence of an empty stack of said adjacent stacks at said means for feeding to change the position of said stacks so that a loaded stack of said adjacent stacks is presented to said means for feeding and the empty stack is removed therefrom.

32. A means for storing as set forth in Claim 31 wherein said means for removing and elevating includes means for lifting a trailing edge of a top sheet of one of said stacks into said alignment with an apparatus feed input.

33. A means for storing as set forth in Claim 32 further comprising means for selectively controlling said means for lifting to move said means for lifting between interfering and non-interfering contact with said stack in response to a movement of stacks by said means for selectively positioning.

34. A means for storing as set forth in Claim 33 wherein said means for lifting includes vacuum cup means positioned to contact said top sheet.

35. A means for storing as set forth in Claim 34 further comprising feed roller means, responsive to said means for lifting, for supporting at a feeding height and driving a lifted sheet into said means for feeding.

36. A means for storing as set forth in Claim 35 further comprising means for selectively engaging and disengaging said feed rollers to remove them from interfering contact with said stack during the operation of each of said means for selectively positioning and said means for lifting.

37. A means for storing as set forth in Claim 36 wherein said means for selectively engaging and disengaging includes a pair of roller chains disposed upon opposite sides of said feed rollers that displace to translate said feed rollers into and out of interfering contact with said stack.

38. A means for storing as set forth in Claim 37 further comprising a feeding finger disposed upon said roller chains for engaging a trailing edge of said sheet to move it in a feeding direction.

39. A means for storing as set forth in Claim 38 wherein said support means includes means for raising the level of each stack so that a top sheet thereof is maintained at a constant elevation.

40. A means for storing as set forth in Claim 39 further comprising pinch roller means, disposed downstream in a feeding direction from said feed rollers, for receiving a sheet from said feed rollers.

41. A means for storing as set forth in Claim 40 further comprising anti-static means disposed downstream in a feeding direction from said pinch roller means.

42. A means for storing as set forth in Claim 41 wherein each of said feed rollers, vacuum cup means and means for selectively positioning includes a pneumatic cylinder for actuation thereof . ""~ J.

43. A method of assembling a laminated card, comprising the steps of; providing a source of printed core material including selectively drawing core material from each of a plurality of stacks of core material while others of the stacks are in a reserve position for reloading, feeding the core material from a selected stack to a laminating station, providing a source of an overlay web having arranged thereon a series of parallel-disposed magnetic stripes, feeding the overlay web to said laminating station, controlling both said aforementioned core material and web so as to feed them concurrently to form a lamination, and controlling the inter-positional relationship between the core material and overlay web to maintain a predetermined positional arrangement between the magnetic stripe and a predetermined position on the core material.

44. A method as set forth in claim 43 including providing a source of a second overlay web and feeding the second web also to the laminating station.

45. A method as set forth in Claim 44 wherein said step of selectively drawing includes moving an empty stack out of a feeding position and moving a full stack into a feeding position upon detection of the empty stack in the feeding position.

46. A method as set forth in Claim 45 further comprising the step of lifting a trailing edge of a core material in a top position of a stack in the feeding position to a feeding height

47. A method as set forth in Claim 46 further comprising the step of engaging a lifted trailing edge of the core material with a set of rollers to raise a leading edge of the core material and support the core material at the feeding height.

48. A method as set forth in Claim 47 wherein said step of engaging includes the step of driving the core material forwardly for input to the feeding step.

49. A method as set forth in Claim 48 wherein said step of moving includes discontinuing the steps of lifting and engaging while an empty stack is moved from the feeding position and a reserve stack is moved thereinto.