CA1193295A - Apparatus and system for preparing data cards and mailer forms and for attaching data cards to respectively associated mailer forms - Google Patents

Abstract

ABSTRACT OF THE DISCLOSURE

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.

Description

1193~95 ( ~ITL~ OF THE INVENTION
l!APPARATUS ~D SYSTEM FOR PRE~ARING
~ATA CARDS AND M~LER FORMS AND FOR
LATTACHING DATA CARD; TO RESPECTIV~LY
~SSOCIATED ~$P.IIER ~ORMS.

Field of the_Invention This invention relates to a system for automatically attachlng¦
data cards to respectively associated mailer forms and especially to a system which receives information ~rom a common data source for embossing and/or encoding a mag~etic stripe on the data cards and for printing the mailer forms with corresponding information.
The system controls the subsec~ent processing and handling of cards and forms to assure ~hat the cards are attached to their properly corresponding, respectively associated for~s.

Descr~ption of the Prior Art . .. ..
There exist, 1~ the prior art, system-~ for automati~:ally matching embossed data cards with pre-printed mailer forms and for attaching the da~a cards to their matching, respectively associatec pre-printed mailer forms. One such prior art system is manu-factured and sold under the trademark "DATA-MATC~" by Data Card Corporation, assignee of the present application, and affords highly reliable, high speed operation. The system includes an optical character reader for rezding the pre-printed forms and an ¦
embossed character reader (ECR) or a mzynetic stripe reader or reading data correspondingly embossed or encoded on the data cardO
The ~wo sets of data thus read are then compared to verify that a match exists. When the re~uisite nu~ber of corre~tly matched cards for a given form is available, they are simultaneously attached to that formO

" ll C ~ ~932~ ( ~ ~ , Prior axt systems of the type of the ~DATA- ~TCH~ inserter are desisned to function as in~ependent systems, implying that separate apparatus is employed .o emboss/encoae the credi~ cards and to print the mailers, prior ~o the supply of the mailer forms and data cards to the DATA-MATC~ inserter. These independen~
opera,ions introduce the potential of errors particulaxly as to j mis-matching of cards and forms~ For example, if a card is lost or if cards are out of sequence in the supply thereof relative to ¦
¦the corresponding ~equence of the pre-prin~ed mailer forms, a mis-¦
match error will be detected by the sys~em; moreover, if any mailer form is printed imperfectly such that it is not readable by . the DATA-MA~C~ inserter or is incorrectly xead, or should other defects exist whether in reading or transporting the form, an . error condition will occur. ~he DATA-MATC~ inserter pexmits operator intervention ~o correct for the circumstance of an erroneous machine detec~ion of a mis-match condition (e.gO, ~ form is correct but has been misxead by the system resulting in an erroneous mismatch error condition). ~owever, where either the foxm or a required card therefor is in fact defectiYe, or a card i~ ;
missing, there is no recovery capability in the sense that the imperfect form and any associated cards must be rejected, sinc~
replacements are not readily a~ailable~
There is therefore a need in the industry for a system which automates the totality of involved runctions, n~mely the embossing and/or encoding of the data cards as well as the printing of the foxms and the attachment of the appropriate nu~ber of co~rectly matching cards to the respectively associated forms. Moreover, I
i there is a need in the industxy for a sys~em which permits ~¦ recovery of operations when an error condition occurs. By ~ay of example, in a system whlch combines and automztes all OL the --2~

requisite functions as above described, reprinting of defective forms or re-embossing of defective cards can be achieved such -that, means normal automated processing results in rejects of either forms or cards, the system can print substitute or replacement forms or produce substitute or replacement cardst as required, such tha~
at the end of a run, all cards and forms have been successfully gen~rated and assembled. There is also a need for a low-cost such system, suitable for use by low-volume issuers of credit cards and thus one which, while not having the speed of operation of the DATA-MATCH
inserter, nevertheless is available in a less complex 3 mechanism and at lower cost for such lower-volume card issuers.
SUMM~RY OF THE INVENTION
An object of an aspect of the present inven-tion is to provide a system for the attachment of data cards to mailer forms which overcomes the deficiencies of prior art systems.
In particular, it is an object of an aspec-t of the present invention to provide a system for the attachment of the correct number of data cards to properly matching mailer forms, but which does not require reading of data from either ~he cards or forms, or comparison of the data ~or verification that there is a match hetween the data of a particular data card and its corresponding mailer form.
An object of an aspect of this invention is to provide a system wherein up to two data cards are ~a3~

held in position while a mailer form, haviny predetermined slots of slanted divergent configuration, passes thereby and is flexed to pick up, within the slots, the respectiYe ends of the data cards and thereby retain them with the mailer form.
An object of an aspect of this invention is to provide electronic circuitry for controlling the placement of identifying information on respective data cards and for employing corresponding identifying information, provided by a common data source, to print or otherwise provide desired information on a mailer form which will be associated with the corresponding data cards. The apparatus is always subject to operator intervention, wherein an operator responds to an error signal and takes steps to correct the cause of the error.
Various aspects of the invention are as follows:
A system for attaching data cards authorized to be issued for predetermined accounts and coded with predetermined card account information, ~o respectively associated carrier forms having corresponding predetermined form account information printed thereon, said system including means for operative connection to a co~non data ba~e 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 ~ ~33~

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 relation-ship 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 a-ttachment 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 ~or receiving and releasabl~ holding the irst and second coded data cards in a desired pickup positiont and means for attaching the first and second coded data cards for the given account to the corresponding printed one of the carrier forms.
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 havi.ng predetermined form account information printed thereon, comprising:
means for supplying identifying information -4a-~93~5 i.n synchronized timed relationship for each of a plurality of accounts, said identifying information including predet-ermined card account informakion 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 gi~en account;
coding means for receiving the predetermined card account information from said means for supplying identifying informat:ion and for coding the predetermined card account information on the data cards;
a card attachment station;
means for transporting in succession, the coded 5 data cards to said card attachment station;
electronic control means, operatively connected to said means for supplying identifying informa-tion, for receiving the print signal, for providing, as an output, the predetermined form account information, and ~0 for sending a second card request signal ~o 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 a.t said transporting means;
means for supplying blan~ carrier forms in 5 individual succession;
means, operatively connected to said electronic con~rol 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 ~orm account information corresponding to the predetermined card account information coded on the da~a cards for ~he given account, said printlng -~h~

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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 gi~en 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 req~lest signal is received by said coding means.
The system and apparatus of the present invention have a number of novel features, as set forth below. A data card is embossed, encoded, prin-ted, or otherwise formed and is then fedt ~or example, by a con-veyor belt transport mechanism, to a card transfer and pickup station. If more than one data card is to be attached to a particular mailer form then the second data card is embossed, encoded, printed, or other~ise formed and is then fed to the card transfer and pickup stationO
When the required number of data cards reaches the trans-fer and pickup station, the card(s) are moved transversely so as to be placed in a position for insertion on a mailer form.
In timed relationship to the card processing and transporting functions, serially connected~ blank -4c-~32~i mailer forms are fed from a form supply by a paper drive system, past a printer station and -to the pickup or insertion station Print data from the data card indicia or code forming apparatus is fed to the printer station for printing information on the mailer form correspond- -ing to the information which is used to form the partic-ular data card or cards. For example, a particular data card may be embossed with the name and account number of an individual li.e., the account holder); in timed rela-tionship, corresponding infoxmation, which may include the account holder's name and address, is printed -4d-~ ~ ~ 3 ~

on a mailer form currently positioned at a print station.
The mailer form is then fed to the data card pickup station to pick up the card(s).
For this purpose~ each individual mailer is provided with two se-ts of dive~gent slots spaced to receive the ends of two corresponding data cards held at the pickup station.
As the mailer form approaches the pickup station, spring fingers deflect portions of the mailer form adjacent the divergent slots, thereby opening the slots. As the printed mailer form moves past the held data cards, the respective ends of each data card are received within the opened, divergent slots, and when the remote ends of the divergent slots engage the lower edge of each card, the form picks up the cards and remo~es them from the card pickup station.
As the printed mailer form is picking up the cards, the succeeding mailer form is being transported toward the form printing station. Transport of the forms continues until the succeeding form is at the print station. At that time, the hurst line (i.e., a pre-perforated line) delinea-~ 20 ting the trailing edge of the printed form containing .~
caxds and the succeeding, blank form currently at the print station, is positioned at a burster station. During this time, the card~carrying mailer form is checked by a detection device positioned a predetermined distance past the card pickup station to determine if the proper number of cards are attached to the mailer form. At the burs-~er station, the mailer forms are te~sioned and gripped and a bursting bar is moved trans~ersely of the plane o~ the forms to burst~ or se~er, the mailer forms alon~ the burs-t line. ~e burst~ card~carrying mailer form then is advan ced in~o a folder mechanism.

In the folder mechanism~ the form is folded. If-the ~ 3~
etection device determined that a particular mailer form does ;not have the correct number of data cards associated there-~ith, the defective1y ~illed mailer form will be automatically rejected ¦from the folder in~o a 'orm reject area. ~.ssuming the required ~umber of cards has been picked up by the form, the card-filled and folded mailer form is then fed to an output stacker. An operator can then remove the folded mailer LOr~.S ror stuffing into mailing envelopes; optionally, an envelope stuffing machine may ~e attached to receive the folded mailer forms and automatic~lly stuf, the folded mailer forms into mailing envelopes.
In an optimum embodiment of the present invention, semi-automa~ic error recovery is performed. I an error signal is generated (or example,-because O~r a card jam, a form jam or a missing second card), the operator may clear the system of all cards and forms and rewind the data ~ape to the position where the error has occurred. The operator may then restart the auto-matic processing of the systemO In this manner, once a particul~r tape run is finished, all of the data cards are attached to their corresponding mailer forms and no ~urther processing (Lor example, manually generating cards or forms in which the errors have been ound) is necessary.
The system and apparatus of the present invention have signiicant advantages over the prior art in that no sep~rate equipment is required for form printing, no readers for either lorms or cards are required, and the complexity or the system is substantially reduced, making machine operation and error recovery simple.
These together with other objects ~nd adv2nt2ges, which will become subsequently apparent, reside in the details of constru~.io~
and operation as more fully herelnafter described and claimed, 1.

1193ZO'-~eference being had to the accompanying drzwings forming z pzrt hereof, wherein like numerals refer to like parts throushouk.

~RIEF DESCRIPTION OF THE DRA~INGS
Figure 1 is a perspective view or the overall system of the ~resent invention;
Figure 2 is a left side eleva~ional view depicting, in block format, the bzsic components comprising the printer, burster, older and card pickup stations;
Figure 3 is a top plan view of ~he data card transpor~
~echanism, card diver~er structure, and card pickup station; .
~ igure 4 is a rear elevational view of the structure of Figuxe 3;
Figure 5 is a side elevational view, partly in cross-section, taken generally along lines 5-5 o ~igure 3 showing the card pickup station;
Figure 6 is a view similar to Figure 5, showing the relati~e positioning of the mailing form and data card just prior to attachment of the data card on the form;
Figure 7 is a fra~mentary portion of a cross-sec~ional view taken generally along lines 7-7 of Figure 5i ~ igure 8 is a perspective ~iew of the data card retention structure of the card pickup station;
Figure 9 is a perspective view of the divergent slot configu- ¦
ration of an individual mailer rorm, the slot opening spring-biased finger structure, and two data cards,in position re.ady for ,pickup thereby;
l Figure 10 is a perspective view of a fragmentary portion of a mailer form containing two data cards;
Il .

'I .
,; .

l l ( 3Z95ii Fisure 11 is a perspective view of ~he clu~cn drive mechanis~.
for driving ~he form output feed rcllers znd .he folder inpu~
rollers ~ igure 12 is a top plan view of the _o-m burster s~ructure in a normal, rest position;
Figure 13 is a top plan ~iew of the form burster structure in an advanced, activated position;
Figure 14 is a left side elevational view of the form burster ¦
struc~ure, partly in cross-section, take~ generally along lines 14-14 of Figure 12;
Fig~ire 15 is a left side elevational view OL the fonm burster structure, partly in cross-section, taken generally along lines 15-15 of Figure 13;
Figure.16 is a block diagram illustrating the electro~ic control circuitry 30 of Figure 2 and other related circuitry;
Figures 17A-17D comprise a flow chart illustrating the oper-ation of the system of the present inventioni and Figure 18 illustrates the Lormat of the data on the magnetic tape which may be employed as the common data source in the present invention.

D SCRIPTION OF T~E PREFERRED E.~BODIMENT
Figure 1 illustrates the o~7erall system of the present inven-tionv The form printing and card a,tachment apparatus (or inserter;
of the present invention is identiried by n~meral 20. Apparatus for encoding and embossing, printing, molding or otherwise forming thc data cards is indicated, in general, by re'erence numeral 22 (hereinafter, referred to as the embosser/er.coder 22). In the preferred embodiment, an embossing/encoding machine substan~izlly corresponding to the Data Card Series 400~ embossing machine is l!

3~3~ ~

I used, that machine being described in U. S. Pa~ent 4,088,216 the I disclosure of which is hereby incorporz~ed `~y re~erence. A co.~mon supply of card account and identifica~ion aata, such as from magnetic tape, is employed for bo~h the embosser/encoder 22 and the form printing and card attachment z~paratus 20, as later described in detail. In the preferred emboaiment, an embosser/
encoder employing a magnetic tape aata input as illustrated in Figure 10 of the '216 p2tent is employed; however, the tape format and internal data handling o the embosser/encoder disclosed in ~he 216 patent are modified in accordance with the present invention.
Referring to Figur~! 2, the iorm printing and card attachment apparatus 20 receives a supply 26 of serially connected, blank mailer forms 25 and includes printer and paper drive apparatus 28, and electronic control circuitry 30. A photocell Z7 detects whether there are any mailer forms present, and a photoceli 29 detects when a given, Ol current,- mailer form 25 is in a "top of form" position, ready for printins thereon. ~he electronic ccntrol circuitry 30 receives a~:count identiiication iniormation corres ponding to that inormat:ion cuxrently employed by the embosser/
encoder 22 for forming 1:he data card for that account, to control the printer and paper dxive apparatus 28 for printing the corres-ponding mailer form for those cards. That is, after the first of a required number of data cards (1 or 2) is formed in embosser/
encoder 22, correspo~ding accoun~ identi,ication information is transmitted to the electronic control circuitry 30 for use by ~he i form printing and card attachment apparztus 20.
Figure 18 illustrates the data format on the magnetic ta~e for a given account. Rlthough many other ~ormats are ?ossible an~
come within the scope of this invention, the form2t of Fig.

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18 is especially well adapted to the processing functions to be performed by the present system. Particularly, the requisite data and inEormation for successive forms N-l, N, N+17...is formatted in serial succession. For a given Form N, the embosser/encoder 22 receives the EMBOSSIENCODE
DATA as read from the tape and forms a data card with cor-responding~ embossed and~or encoded identification informa-tion. This data typically includes at least an account number or other unique identifying number, and may include the name and other identification information ~e.g., expi-ration date) of the card or account holder and the account itself. The magnetic tape also carries PRINT DATA
which is sent by embosserlencoder 22 to the electronic control circuitry 30 where it is processed and sent to the printer and paper drive apparatus 28. The PRINT DATA
includes PRINT CODE data le.g.~ the same account number as for the EMBOSS~ENCODE DATA and~ typically, not only the name but also the mailing address for the card or account holder)~ NU~BER OF CARDsJFoRM data lindicating the number

2~ o~ cards for the particular form)~ and ~INE LOCATION AND
PRINT ~NFORMATION data ~indicating the printing format).
If a second card is to be placed in a particular mailer form, "CAP~ 2 EMBOSS~ENCODE DATA" will be present on the tape~ The embosser/encoder 2~ will read the CARD 2 EMBOSS~
ENCODE D~TA and will emboss and~or encode a second card.
If a second card is not needed for a particular form, "CARD 2 EMBOSS~ENCODE DATA" i5 omitted.

1~L93Z9~

The zpparatus of this inven,ion prints ,he identification information on a mailer 'orm after the first o' a required nu~er of d~ta cards has been emDossed, bu. prior to ,he attacnment of ~any data cards to the associa'ed form. As later described, the sequence and timing of the transfer o print data to the appzratus 28, ir. relation to embossing/encoding 'unctions, guarantees ,hat the intended correspondence of the printe~ form and embossed/
encoded cards is achieved. After ~he identification information has been printed on the mailer ~orm 25 and the desired number o, cards have been received at the card pickup station 32, the printed mailer form 25 is transpor~ed past the pickup station, to pick up the associated cards as previously described. In this manner, the form printing and card attachment apparatus of the s~~s';em of the present invention effectively eli.mi~ates the source of errors encountered in reading and matching operations which are required in prior axt systems which assemble pre-prin~ed forms and pre emb~ssed/encoded cards, yet still assures that only the ~roperly corresponding mail~er forms and da~a cards are assembled.
In the form printing and card attachment apparatus 20, a card input and pickup station 32 receives the embossed/encoded cards from the topper ~echa~ism (see Fig. 10 of U. S. Paten, No.
4,088,216) or the embosser/encoder 22 by way of a card transport mechanism (Fig. 3) and mo~es the cards into position Lor card pickup ~y ~he associated, printed mailer form 25. The serially connected mailer forms 25 are fed upwardly 50 that the corres-ponding printed form 25 proceeds u?wardly past the card input and pickup station 32 where it engages and picks up the associated l,ldata cards, removing same from the card pickup station 32~
il The movement of the serially connected form5 25 con~ir,ues until the burst line delineating between the card-carrying printed . :

~33~
li .
¦Irom 25 and the succeeding blank form 25 is ?osi~ioned a. burster ¦Istation 34. The succeeding lorm 25 is then a~ the "~op of form"
position, as detected by a signzl from ?hotocell 29. 3urster Ist2tion 34 separates the card-carrying printed mailer -orm 25 from the following, serially-connected blank mailer forms 2~ and the ~czrd-c~rryins printed mailer form ~5 is then sent to a folder station 36.
A pair of photocells 37 detects whether or not the required number of cards are properly inserted in maller form 25 before the form 25 is folded. After the card-carrying printed mailer form 25 is folded by the folder station 36, it is fed to an output stac~er 38. A "folder-out" photocell 39 is used to generate a detection signal indicating that the card-carrying mailer form 25 has exited folder station 36; so the detection signal is supplied to the electronic control circuity 30 which thereby monitors tne elapsed time of travel of the form through the rolder, for jam detection.
An operator then removes the successfully assembled and properly folded card-carrying mailer forms in a stacked group from stacker 38 for fux~her processing, e.g., stufflng into mailing envelopes for mailing~to the designated recipients of the cards. In an alternative embodiment, an automatic envelope stuffer may be attached to the output OL the form printi~g and card attachment l apparatus 20 so that the card-carrying printed forms 25 may be I automatically StUfLed into envelopes. I the photocells 37 detect ¦la defectively filled foxm (e.g., a form containing less than the ~required number of cards or in which the cards are askew) the latter is rejected, after leaving .he rolder 36, into a form reject area 40 rather than to stac~er 38.

Referring ~o Figures 3 and 4 of the dr~wings, the card input and pickup station 3~ will now be described. A pair of data card ~12--liL93;Z9~;

transport belts 42 are supported by pulleys 44 and dr,iven by 2 lldrive pulley 46 mounted on the ~rive shaft 48 of a track motor 50.
¦~ card (e.g., as shown at 72) is pushed onto ~he transport belts 142 by solenoid driven arm 33 posltioned a, ~he output of the topper~
~echanism of the embosser/encoder 22 znd is transferred by belts ., 42 in the direction indicated by arrow A in Fiyure 3, in~o the form printing and card attachment apparatus 20. A photocell 43 de~ects the pxesence of the card on the transport belts 42 and generates a de~ection signal. The card is transported on the transport belts 42 until it reaches either a first bin (pocket) 45 or a second bin (pocket) 47. A rotary solenoid 49 and its attached bracket arm 51 and pinch roller 53 axe actuated in dependence upon whether one or two data cards are required for a given account, and thus for attachment to a corresponding mailer form 25. When the bracket arm 51 is in the position illustrated in solid lines in Figure 3, the data card will be caught between belts 42 and pinch roller 53 a~d will not drop into bin 45 but will be transported to bin 47.
When the bracket arm 51 is moved to the position indicated b~ the dotted lines in Figure 3, the data card will drop into bin 45. If only one card is required the bracket arm 51 is maintained in the dotted line position, as seen in Fig. 3, so that the single card will drop into bin 45. Thus, the rotary solenoid 49 is selectively actuated in dependence upon the nu~ber OL cards required to be inserted (NUMBER OF CARDS/FORM, ~ig. 18). Photocells 55 and 57 detect the presence of cards in bins ~5 and 47, respectively, j,and generate detection si~nals. ', ,I Figures 5 and 6 are side elevational views of the apparatus Il .
for attaching a data card(s) on mailer form 25, in relat~on .o 'Icard bin 45 of the card input and pickup station 32, illustrating ,two different states of operation. As notea above, if only one -~.3-1193Z9s card is recuired this card will drop in the bin 45 znd i~ o aata cards 72 are requlred, the second data c2rd 72 is dropped into bin 147 ~not shown in Figs. 5 and 6). A slideable ~ransverse plate 52 has fixedly attached thereto a T~sha?ed guice block 54 received and supported in sliding engagement by a support mount ~6 (~ig.
7). A thrusting apparatus 57, including a rctary solenoid ;8, an eccentric linkage 60, an extension 64 and a sprins 66, reciprocates the transverse pla~e 52. Transverse plate 52 includes an upright . plate portion 68 which cooperates with a corresponding pivotable cl&mp member 70 (one for each of bins 45 and 47) to releasably engage data card 72 therebetween. Thus, one or a pair of da~a cards 72 may be simultaneously held in position at the card pickup station 32 in the bins 45 and 47. .
¦ As best seen in Figure 8, the pivotable clamp membex 70, ¦having a contact member 78 and a lever 76 with an abutment 76a, is pivotally mounted by shaft 7Oa to pla~e 52 and biased against the associated upright plate 68 by ~ coil spring 74 to clamp the card 72 in po~ition (~ig. 6). Pivotable member 70 is~pivoted away from upright plate 68 to an open positicn, by abutment 76 engaging a stationary stop 77 (Fig. ~), to receive a data card 72 there-between. After data card 72 is positioned between upright plate 68 and contact member 78 (Fig. 6), the transverse plate 52 i5 moved toward the left, i.e., in the direction indicated by zrrow B
in Pigure 5, to the position shown in ~igure 6, releasing, or freeing, lever 76 from stztionary block 77; the coil spring 74 thereupon rotates the pivotal clzmp member 70 and causes the contact member 78 to grip the data card 72 against the inner . surface of upright plate 68. When the trznsverse plate 54 com-pletes its movement to the far left (Fig. 6), the data card 72 (or~
pair of cards) is then ln proper position or pickup by its

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associzted printed mziler form 25. ', Figure S shows the printed mailer form 25 znd the s2ring biased fingers 80 which contact and de.lect the form portion adjacent to the slots to open the slots to a card receiving posi-tion. An upright guide 82 is provided wi~h slots 84 through which the spring biased fingers 80 protrude. The spring biased fingers 80, as best seen in Pigure 9, are mounted on a pivot rod 86, which i is biased by a coil spring 88 so that the fingers 80 are spring biased to a righ~~most position (clockwise direction), as shown in Figures 5 and 6.
Relerring to ~igure ~, as each printed mailer form 25 moves upwardly, the individual spring biased fingers 80 extend through slots 8-4 in the upright guide 82 to contact and deflect the form portions 90 adjacent the slots 92 to open the slots 92. The opened slots 92 receive the lower end corners of the cards 72, and, as the ~orm 25 continues its'upward travel, the bottoms 95 of the divergent slots 92 engage the lower, or trailing, edges of the cards 72, as shown.in Figure 10, removing the data card(s) 72 from ensagement by the upright plate 68 and contact member 78 (Fig~ 6).
The printed mailer for,m 25, with the data card(s) 72 held thereby, is theA burst and fed upwardly by rollers 94 and 96 (Fig. 11) until it is in a position to be gripped by dxiven rollers (driven through a belt 126 in Fig. 11) in the folder s'ation 36.
Reerring to Figure 11, upper feed rollers 94 and 96 are mounted upon an idler shaft 98 and a driven shaft 100, respective-ly. The idler shaft 98 is supported for free rotation in bearings mounted on support frame members (not shown) while the driven shalt 100 is sLmilarly suyported in bearings and has a drive pulley 102 fixed at one end ~hereof. The drive pulley 102 ls i,n .urn driven by belt 104 and drive pulley 106. Lower feed rollers ~L~93~

108 and 110 are mounted on idler shaft 112 and driven shaft 114, res,ectively~ A gear 116 is driven by pinion 118 affixed to the output shaft 120 of motor 122. Motor 122 is selectively energized under control of the elec-tronic control circuit:ry 3U. The driven shaft 10~carries at its opposit:e end from the drive pulley 102, a drive pulley 124 for clriving a belt 126 which-powers the folder mechanism of the folding station 36. The folding station 36 may be of the type disclosed in co-pending Canadian Patent No. '1"102,605, Donald W. Hewitt et al and assigned to the assignee of the present application.
~see Figs. 32-36 of Patent No. 1,102,605~.
Figures 12-15 show features of the burster mechanism of the burster station 34 for separating the printed mailer form 25 from the serially connected supply of forms 25. A U-shaped channel member 128 IFig~ 14~
has mounted therein an elongated spring 130 which ~iases a:..resilient pad 132 to ~he open edge of U-shaped channel member 128. A complementary member 134 is mounted for transverse movement on a support plate 136 and is restrain-ed against such transverse movement by retainer springs 138. When a rotary-electro-solenoid 140 is actuated~ it moves an arm 142 with a roller 144 thereon to force the complementary member 134 towards and against the mailer forms 25 (see Figs. 12 and '15) to engage same against the U-shaped channe~ member 128 ~Fig. 15).

Once the burst (perforation) line between the mailer forms 25 is taut,, burster knife 146 is advanced by linkages 148 actuated by movable plate 150 mounted on and driven by electro-solenoid 152, to burst an individual mailer from 25 from the successi~2 serially-connected form.

lP932~5 The tangential relationship of the unequal length linkages 148 causes burster knife 146 to move in a totally parallel manner. After the bursting action takes place, both electro--].6a-~L93~95 solenoids 140 and 152 are de-energized to permit sprinys 138 to retract all the elements to their inactive or rest positions ~Fiy. 12), Figure 16 is a block diagram illustratiny the inter-connection between embosser~encoder 22, the motors, printerand electronic control circuitry 30 of the present inven-tion.
A console 154 includes a display 156 and a control switch panel 158. The display 156 will indicate various conditions in the system.~ for example, no paper, jam, error, no card, etc. The panel 158 includes a CLEAR
) switch, ADVANCE switch, REVERSE~REPRINT switch and ON~OFF
LINE switch.
The CLEAR switch is employed to initialize the microcomputer network of the ~orm printing and card attachment apparatus 20. The card transport lor track) motor 50 is turned on to clear any cards from the transport belts 42 and a mailer form 25 is then advanced, burst, folded and discharged into the form reject area ~0.
) 20 The ADVANCE switch is func-tional only when the inserter is of~ line.. When this switch is actuated to a first position, a form 25 i.s ad~anced, burst f~lded and rejected.
The REPRINT switch is functional only when the inserter is off line. If the switch is in the ~EPRINT
position the inserter wi.ll reprint the previous form 25 and discharge the reprin~ed form 25 in the form rejec1-area 40~

~193Z95 The ON/OFF LINE switch is used to selec, the ON LII~E or OF~
IIILINE status of the inserter. Af~er the system has genera.ed zn error message, actuation of this switc~ clears the error.
In zn optimum e~bodiment, an additional RER~ switch 16; is connected to CPU circuitry 162 and the embosser/encoder 22. Ac~,u-ation of the RERUN switch provides for semiautomatic error ecovery as described in the operation section below.
The electronic control circuitry 30 lncludes the central processing unit circuitry 162, input/output (I/O) interface circuitry 164, sensor interface circuitry 166, stepper motor driver circuitry 168 and solenoid driver circuitry 170.
The rPU circuitry 162 includes a central processing unit (CPU), programmable peripheral in~erfaces, an erasable programmable read-only memory (E~ROM) and a random access memory (RP*l). The EPROM contains the instructions o the system program which the CPU follows to initiate and control all operations. The R~M
provides the CPU with the capacity to store and retrieve data and instructions. In à preferred embodiment, the CPU i5 an 8-bit ¦microprocessor and the EPROM comprises our 2~ x 8 EPROM chips.
The input/output interîace circuitry 164 functions as an interrace between the CPU and the embosser/encoder 22 and solenoid driver ci.rcuitry 170. It should be noted that embosser/encoder 22 has its own CPU for controlling the embossing operation. The input/output (I/O) interface circuitry 164 also contains a program-ma~le timer/counter used to generate car~ check and stepper motor interrupts.
The sensor interface circuitry 166 inter aces the CPU with various photocells and switches in the system. The "Paper" input to sensor interface circuitry 166 is connected ~o photocell 27 (Fig. 2). The "~opper Full" input to interLace circuilry 166 may-"
.

~.19329~

be connected to a microswitch (not shown) for detectins when the output stacker 38 is full. ~he ~TOF" input to ser.sor in~erface circuitry 166 is connected to the top-of-fo~m pnotocell 29 (Pis.
2). The "Card In" input to sensor inter~ace circuitry 166 is connected .o track photocell 43 (Fig. 3). The "Card In ~in 1"
input to sensor interface circuitry 166 is connected to the bin 1 photocell 55 (Fig. ~). The "Card In Bin 2" input to sensor inter-face circuitry 166 is connected to the ~in 2 photocell 57 (~ig.

4). The "Right Card In Form" input to sensor interface 166 is connected to one of the pair of photocells 37 (Fi~. 5). The "Left Card In Form" input to sensor interface 166 is connected to the other of the pair of photocells 37 (not shown in the drawings).
The "Folder Out" lnput to sensor interface circuitry 166 is con-nected to photocell 39 (Fig. 2). The remaining two inputs to sensor interface circuitry 166 ("Envelope Switch" and 'IStuffer Out") are activated in an optional embodiment of the inserter of the present inventlon i~ which an envelope stuffer 173 is connected to the output o the inserter. The "Envelope Switch" input is a signal indicating whetner or not the envelope stuffer 173 is attached to the system and the "Stuffer Out" input is a signal indicating the output of an envelope from the Stuffer 173.
The stepper motor drive circuitry 168 is connected to the CPU ¦
and the stepper motor 172 for energizing the windings of the stepper motor 172 either indi-~idually or in pairs ~o advance .:ne rotor o~ the stepper motor 172 through its 8-step cycle.
The solenoid driver circuitry 170 includes transistor drivers 174 and 176 for drivins the solenoids and the print wires of printer 178, respectively. The transistar arivers 174 are used to drive the various solenoids in the inserter system and have the Collowing outputs: Card Transfer, Insert, Clam?, Kni~e, Rejec, and Forms Counter.

~32~

The "Card Transfer" ou~put is connected ~o rotary solenoid 49 (Fig. 3). The "Insert~ output is connected to rotary solenoid 58 (Fig. 5). The ~Clamp~ output is connected to rot~ry solenoid 1~0 (Fig. 12~. The ~'Knife~ output is connected to rotary solenold 152 (Fig. 12). The ~Reject~' ou~put is connected to a rot~xy solenoid (not shown) for controlling the actuation of ~he form reject mechanism. The "Forms Counter" output is an o~tional output which may be connected to a solenoid (not shown~ used in co~nting the number of forms.
The printer 178, which is a part or printer and paper drive apparatus 28, is a standard matrix wirehead printer. The prin~-head is driven by an AC synchronous motor which also drives ratchet mechanisms for advancins the print ribbon. The CPU
controls the print motor and provides wire control words to Lhe printhead through transistor drivers 176 in order to actuate the desired cumbination o wires. A printer control signal from the CPU includes a ribbon advance signal, printhead forward ~ignal and printhead reverse signal, provided through switches 180, 182 and lB4, respecti~ely, for driving th~ printhead to print several lines of indicia~
Figures 17A-17D comprise a rlow chart illustrating ~he sort-ware for the system of the present invention.
Referring to Figure 17A, after the system is turned on and initialized, the CPU determines whether or not a run request exists (RUN REQUEST). If no run request is present then the transport motor 50 is turned off (TURN XPORT MOTCR O~F) and the CPU determines whether a console request is present (CO~SOL~
REQUEST). If a run request is present then ~he run moGe is begun (RUN).

, 1, , .

-20~

I ~i932~
I
In the run mode, the CPU first detenmines ~he~her .he emboscer'~
encoder 22 is set up for embossing operations (EM~ PP~ESENT~. If ~the embosser/encoder 22 is not -o be used 'or e~.~ossing, ~hen the stand alone mode is entered (SET U~ PRINT ~D LIN~ LOC DAT~ POR
STAND ALONE MODE). If, as is the usuzl case, the embosser/e~coder 22 is to be usPd for embossing, then the CPU determines whether the e~bosser/encoder 22 is ready (E.MB REP~Y). I' the embosser/
encoder 22 is ready then 2 d~ta request is sent to the embosser/
encoder 22 (SEND DATA ~EQU~ST TO E~ ext, the CPU again deter-mines whether the embosser/encoder 22 is ready (EMB R~ADY) and, if it is, then a data type byte is fetched ~rom the embosser~encoder 22 (FETCH DATA TYPE BYTE FROM EMB~. After the data type byte has been ~etched, the CPU determines whether the data is print type data (PRINT DATA). If it is print type data, then the system goes into a read mode of operation (READ). If it is not print type data, then the CP~ de~ermines whether it is line location data (LL ! DATA) or a malxltenance request (MAINT REQ) and processes the data accordingly.
Referring to ~igure 17B, in the read mode of operation, the CPU determines whether the data is ready to be read (CHAR READY) and, if i~ is, then data is fetched from ~he embosser/encoder 22 for reading (FETC~ CHAR ~ROM EMB). If the characters are ~roperly ¦
read they are stored in memory (CHPR OK and STO~E C~AR). I' thexe ¦
is an error (E~ROR),.the data is reread. At the end o~ a block of data, an end code is received ~.N~ CODE) and the CPU then.deter-ines whether the embosser/ encoder 22 is re2dy to proceed (EM~
READY). Arter the data has been chec~ed (FETCH CHECX SUM C~AR
FROM EMB and CHECK SUM OK), the CPU determines whether it is print data or line location data (DATA TYPE), a~d the data ls processed accordingly (PROCESS LINE ~OC DATA AND SET PLP ACTIVE 2nd PRO OE SS
PRINT DATA AND SET PRT ACT).
., -21~

1 ~93~

A- er the print data and line loca~ion Ga,a have been pro-cessed, the transport motor 50 is turnea on (~PORT ~lOTOR GN) and the system is pl2ced in the transDort and print cycle mode o~
operation (XPC).
Referring to Figure 17C, in the transport and print mode, the CPU first determines i it hzs sent a czrd received s~atus signal to the embosser/encoder 22 (SEND C~D ~CVD STATUS TO E2~).
If the signal has been sent, ~hen the CPU sends 2 send card request status signal to the embosser/encoder 22 (SE~D CARD REQUEST STATUS
TO EMB) and a card is transported down the track (C~L XPORT
TRA~SPORT CAR3DOWN TRACK & P~ACE). If no card 72 is received, the CPU then determines whether there are any cards 72 left in the e~bosser/encoder 22 ~CARDS LEFT = 0). If no cards 72 are left in the embosser/encsder 22, then the system ceases to inquire as to card status. If there are cards 72 left in the embosser/encoder 22, the CPU determines wnether a card request has been sent to the embosser/encoder 2~. (SEND CP~D REQUEST TO E~). If a card request has been sent, the CPU de~ermines whether the embosser/encoder 22 has an available card 72 tEMB HAS CARD AV~IL). If a card 72 is available, then the card request status signal is sent to the embo~ser/encoder 22 (SEND CARD REQUEST STA~ TO EMB). If no czrd 72 is available, then a request to transfer cards down ~he track is made (CALL XPORT TRANSPORT CARD DO~ TR~CK & PLACE). If no c~rd request has been sent to the embosser/encoder 22, then the CPU determines whether there is a card 72 at the track entry photocell 43 (CARD AT TRACK ENTRY PHOTOCELD). If there is no card¦
72 at the ~rack, then the .ransport mechanism is called. I there is a card 72 at the track entry photocell 43, then a requested card received status signal is sent to the embosser/encoder 22 (ACTIVATE REQ CARD RCVD STAT TO BE SENT TO E.~) and the trans~or.

mechGrlism is again called.

--:~2 -~1~33Z9~i Once the transport has been called, or ir the trznsport has not been called (for example, i~ there are no cards leC,)~ .he CPu then determ~nes whether the print buffe~ is active [PRT ~U~FER
jlACTI~). If the print bufrer is acti~, then printing is begun (CALL PRINT MAINTAIN PRINTING). If the print bufer is not active,l then the CPU determines whether there are any cards 72 leCt (CARDS I
L FT = 0). If there are no cards 72 left, then the CPU determines ¦
whether the last card received status signal has ~een sent to the embosser/encoder 22 (LAST CARD RCVD ST~T SENT TO ~M3). If this signal has been sent, then the transport and print cycle is completed (SET XPC DONE). If there are cards left or if the last card received status signal has not been sent to the embosser/
encoder 22, then the CPU determines whether the transport and ¦print cycle has been completed (XPC DON~). If the printing cycle ¦has not been completed, then the system is recycled back to the ¦beginnlng o the transpor~ and print cycle mode.
¦ Referring ~o Figure 17D, if the printing cycle hzs been ¦completed, then th`e insert cycle mode of operation is begun (CYC~E
I~. A delay operation totalling a delay of 500 milliseconds is conducted to steady the form (DELAY 500 ms). Next, the insert control operation is called (C~IL IC INSERT CONTROL) and the mailer form 25 is transported to pick up the cards 72. Transport of the forms 25 is halted when the succeeding form 25 is at the top o' form position (CAL~ STOF MOVE FORM TO NEXT FOR~), and the bursting operation is called (C~LL BC 3URST FO~) to burst the completec mailer form 25. Next the folder operation is called (CALL FOLDER
FOI,D FORM A~D STACK OR STUFF) and the completed form is Colded and stacked or optionally stuffed into an envelope. The system is then checked for errors. If there are no errors, then the CPU
determines whether the stacker hopper 38 is lull ~STAC~ER ~OPPER

, ,, ~23-i FU~L) and, if the stac~er hopper 38 is no. full, tne sys_em goes ~into the run mode of operaticn again (R~). If the s~ac.~er ho2per 38 is .full, then a full message is di.splayed on display ~anel 156 (DISPI.AY FU~L MSG).
The operation of the system is as follows. Once the form printing and card attachment apparatus 20 and the ernbosser/encoder 22 have been turned on, the CPU circuitry 162 activa~es the AC
transport drive motor (track motor 50) when it has active print data and print line position codes from the embosser/encoder 22.
Alster a card is topped (the raised characters are coatedl the solenoid driven arm 33 pushes the data card 72 onto the transport belts 42. Three photocells (photocells ~3, 55 and 57) monitor the successive positions o~ the card 72 while it is transported. When the card 72 passes photocell 43 (Fig. 3) the CPU activates a software t~mer and sends an acknowledgment signal to the embosser/
encoder 22 to indicate that the card 72 has been received. It should be recalled xecalled that embosser/encoder 22 has its own CPU (and associated memory, etc.) for cornmunicating with the CPU
circuitry 162 of the inserter system 20. If the embosser/encoder CPU does not receive this acknowledgment signal within a preset time interval, it halts system operatipn and displays an error messzge on the em~ossex console (not shown). The software timer activate~ by the CPU ~ircuitry 162 is used to insure that the card travels the distance between pho.ocell 43 and the photocell 55 (mounted over the first bin 45) in a predete.rmined length oS
time. When the card 72 reaches photocell 55, the timer is dis-cbled (Fig. 4).
A setting desisnat.ing the ra.io of cards per mailer fo~n (NU~'~ER O~ CARDS/~O~M data, Fig. 18) determines whe.her .he iirst ¦Icaxd 72 drops in bin 45 or continues on to hin 47. Ir the ratio .

-2~-~ 3~

ecuals 1, the card 72 Ialls into bin 45 anG trzr.s?ort is comDlele.
If ,he r2tio equals 2, rotary solenoid ~9 is energized znd Dinch roller 53 srips the card asainst the trans?ort belts 42, thereby ~reventing it from falling into bin 4~. The card 72 acco.Glngly is transported to bin 47. A so,tware timex is asain em~loyed .o insure that the card 72 travels the distance from phot~cell 55 to photocell 57 within a predetermined time interval. ~hen the second card reaches bin 45, the rotary solenoid 49 is not energized so that the second card 72 drops into bin 45 (~ig. 4~.
When the lorm printing znd card attachment apparatus 20 is ready to process a form and cards, it sends a request for a czrd and PRINT DATA to the embosser/encoder 22. If a particular mailer form 25 requires two cards 72, the CPU circuitry 162, upon receipt of the ~irst card 72, sends a request for a second card to the embosser/encoder 22. I~ the second card 72 is available, the embosser/encoder 22 sends the second card 72 twhich has already been embossed by this time) to the form printing and card attach- ¦
ment apparatus 20. ~owever, if the embosser/encoder 22 is holding a card 72 and PRINT DATA (i.e./ it is data for the succeeding mailer form 25), the CPU for the embosser/encoder 22 detects an error (i.e., the proper second card 72 for the present form is missing); the system thereupon is shu, ao~m ~nd an error mess2ge is displayed on the embosser console (not shcwn). It is then ~ecessary ror the operator to clear the inserter by actu2ting ,he ,CLEAR switch. This causes the prln,ed form 25 to pick up the ',!Lirst card 72, and the form 25 (carryiny only the first of two ,required cards) is folded and rejected into the form reject area 40. Prior to the generation of the error message, the card for ~t:~e next form has already been embossed and rema~ns in e~bosser/
encoder 22. The operator may actuate the ON LINE swl,ch to restart the system.

( ~ ~Lg~

¦I Tn an optimum e~odiment, upon noting an error ressage, tbe o?er2tor may ac-ua.e the RERUN switch 165 .o re,ect all for~s remaining in the Lorm printing znd card attachment appara~us 20 I,and zll cards remaining in the em~osser/encoder 220 The zctuation 1I~ OL the RERUN switch 165 also sends a signal LO the em~osser/encode~
22 .o cause the e~bosser/encoder 22 to reverse the magnetic tape (~is. 18) to the data portion where the error sisn21 was yeneratec znd restart the system. In this manner, once an entire magnetic tzpe has been processed by ~he system of the present inven ion, there are no indi~idually defective forms or cards which need to be corrected.
The LOrm printing and card attachment CPU also monitors the photocells 5~ and 57 to insure that the cards 72 drop into the bins properly. If a card jams or hanss up at any point during transport or in dropping into one of bins 45 and 47, the entire system is halted and a card error message appears on the display 156. Similarly, if a form 25 jams, an error signal is generated.
The operator will then manually clear the jammed form and may reprint the jammed form by actuating the REPRINT switch which causes a reprinted form to be burst and fed to the form reject area 40. The operator then takes the cards out of the jammed form z~d places them in the xeprinted form. The system is then re-star.ed by actuating the ON LINE switch~
Il The printer 178 receives identiication inLormation from the ¦¦storage device (e.g., magnetic tape) in the embosser/encoder 22 by way of CPU circuitry 162 and prints indicia on the mailer form 25 zs the card 72 (the first card, if two cards zre required) is bein~
.ransported to the czrd attachment mechanism. As mentioned above, ,he prinLer 178 comprises a stzndard matrix printer, .or exzmple, a 5 x 7 dot mztrix pri~ter. The paper photocell 27 detects whether Il ~.193;Z95 or no~ .here is another mailer fxom 25 in the form prin~ing ana card att2chment apparatus 20. ~he "to? Oc for~" photocell 29 checks for a "top of form~ hole in the mailer form 25 because ~he mailer form 25 must be a~ the "top of form" position when ?rintins begins.
ACter printing is completed and the card(s) is loaded in~o ,he bin(s) 45 (and 47), the CPU causes .he stepper mo_or 172 to advance ~he mailer from to a pre-inser. position. In Lhis position~
.he lower edge of the mailer form 25 is approximately l/2 inch ¦below the printhead, and the divergent slots 92 in the mailer form ¦
125 axe just below the level of the card(s) 72. q'he CPU 162 then ¦energizes rotary solenoid 58, thereby czusing upright plate 68 to ¦be moved ayainst mailer form 25 so that the spring biase~ fingers ¦80 open the s1ots 92 in the mailer form 25. After a 200 milli-¦second delay the CPU activates the stepper motor 172 to advance ,he succeeding (blank) mailer form to the top of form position, 25 monitore~ by photocell 29. As the printed mailer form 25 advances, ¦the card(s) 72 is (are) received in the opposite ends thereof in ¦the corresponding slots 92 of the mailer form 25.
¦ When the succeeding mailer form 25 reaches the ~top of form~
¦position, following the pickup of the card(s) 72, the card-carrying printed mailer form is ready to be separated from the remaining serially connected mailer forms 25. First, the C~U sets a 50 ~millisecond delay to allow the mailer forms 25 to stabilize.
IIINext, rotary solenoid 140 (Fig. 12) is energized to secure the - burst line between the card carrying, printed mailer form and the !' succeecing blank mailer form 25 against U-shaped channel member 128. After a lO0 millisecond delay, the CPU energizes rotary solenoid 152, thereby driving burster knife 146 Cor~ard to sepa-rate the mailer forms 25 along the burst line. Then the CPU

-27~

1 -~.193Z~ii , li de-energizes rotary solenoids 190 and 1~2 a~d sets a 50 millisecond delay to allow burster knife 146 and roller 144 Il to re~ract.
¦l Af ,er the card-carrying ~rinted maller f~r~ 25 has bGen burs~, lt is then trans~orted through folaer station 36 where it is folded along pre-formed old lines.
From folder station 36, the card-carrying printed mailer form 25 is fed to output'stacker 38. Alternatively, the mailer form 25 may be fed to an envelope stuf~er 173.
Ater turning on folder motor 122, the CPU checks to see if the cards 7~ are properly inserted in the mailer form 25. A card 72 is properly inserted if the hole 93 at the bottom of the card receiving area of the mailer form 25 is approximately 2/3 covered. Using timers, the CPU checks to see if the photocells 37 sense light for the proper lencth of time as the mailer form 25 travels past them. If a card 72 is not inserted far enough, or if it totally covers hole 93, the CPU circuitry.162 detects the error and energizes a reject solenoid (not shown) so that the mailer form 25 is outputted in the form reject area 40. An error messaqe then appears on inserter display 156 and system o~eration is .
halted. The CPU circuitry 162 also checks to see if mailer rorm 25 remains in the folder station 36 less than two seconds by monitoring photocells 37 and 39. ~hen an acceptable mailer form 25 clears photocell 39, a forms counter (not shown) is incremented. The stacker station 38 has an AC
drive motor 186 which is activated simultaneously with the activation of folder motor 122. If the CPU circuit~y 162 detects any errors in the mailer form at any ,ime in the ~ insertion cycle, then the reject solenoid is activated and i the form is rejected into the form reject area 40.

~ ~ 93295 The system of the present in~ention may be implemented in numerous ways. The data cards may be coded in any suitable manner7 for example~ by emboss-ing, printing or encoding a magnetic stripe carried by the data cards. Similarly, the carrier forms may be marked in any suitable manner, for examplet by printing or coding the carrier forms. In addition, although for convenience the system has been shown to accommodate eithex 1 or 2 cards, it readily can accom-modate 3 or 4 cards per form. In the latter instance~the CPU circuitry 162~ upon receipt of the second card, sends a request for the card to the embosser/encoder 22.
Thusy the 3rd and 4t~ cards are processed in the same manner as the irst and second cards~
The many features and advantages of the inven-tion are apparent from the detailed sepecification and thus it is intended by the appended claims to cover all such features and advantages of the system which fall within the true spirit and scope of the invention.
Further, since numerous modifications and changes will readily occur to those s~illed in the art7 it is not desired to limit the in~ention to the e~act construc-tion and operation shown and described, and accordingly all suitable modifications and equivalents may be resorted to, falling within the scope of the invention,

Claims (16)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. 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 relation-ship 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.

2. The system as set forth in claim 1, 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.

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

4. The system as set forth in claim 1 or 2, 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.

5. The system as set forth in claim 2, 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.

6. The system as set forth in claim 5, wherein said first and second sensor means comprise photocells.

7. The system as set forth in claim 1, 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 transport-ing 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.

8. The system as set forth in claim 1, 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.

9. The system as set forth in claim 8, 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.

10. The system as set forth in claim 9, 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 con-nected 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.

11. The system as set forth in claim 8, further comprising means for folding the separated carrier forms.

12. The system as set forth in claim 11, further comprising means for stacking the folded carrier forms.

13. The system as set forth in claim 12, further comprising means for stuffing the folded carrier forms in envelopes.

14. 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 predet-ermined 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 relation-ship 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.

15. The system as set forth in claim 14, 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.

16. The system as set forth in claim 14, 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 predeter-mined period of time.