Lamination of patch films on personalized cards through heat transfer

1. An apparatus for laminating a personalized document, the apparatus comprising:

a supply component containing a web material that is configured to deliver the patch film to the personalized document;

a platen structure comprising a head portion having an end surface, configured to affix a portion of the patch film that is less than the entire patch film delivered by the supply component to a portion of one side of the personalized document that is less than the entire side of the personalized document;

a take-up component configured to receive the web material after the patch film is delivered to the personalized document; and

a lamination assembly configured to laminate a remaining unlaminated portion of the patch film to the personalized document after having the patch film partially affixed thereto by the platen structure.

2. The apparatus of claim 1 , wherein the platen structure comprises a heating element for heating the end surface of the head portion to affix the portion of the patch film to the portion of one side of the personalized document.

3. The apparatus of claim 2 , wherein the apparatus further comprises a thermocouple in the platen structure or an IR thermal detector for monitoring the temperature within the lamination assembly.

4. The apparatus of claim 1 , wherein the end surface comprises a substantially planar end surface having a leading end and a trailing end and the planar end surface slightly radiuses towards the trailing end.

5. The apparatus of claim 1 , wherein the head portion further comprises a plurality of side surfaces that taper toward the end surface.

6. The apparatus of claim 1 , wherein the apparatus comprises a strip pin configured to facilitate removal of the patch film from the web material, the strip pin being disposed downstream of and adjacent to the platen structure proximate the end surface.

7. The apparatus of claim 1 , the platen structure is configured to tack a portion of the patch film delivered by the supply component to a portion of one side of the personalized document.

8. The apparatus of claim 1 , wherein the lamination assembly comprises:

a heated lamination shoe;

a backing roller that presses against the lamination shoe and is configured to laminate the remaining unlaminated portion of the patch film to the personalized document when a personalized document is delivered between the lamination shoe and the backing roller.

9. The apparatus of claim 8 , wherein the lamination shoe is biased towards a lamination ready position.

10. The apparatus of claim 8 , wherein the lamination shoe comprises an arcuate surface with a chord length longer than a length of the personalized document.

11. The apparatus of claim 8 , wherein the lamination shoe comprises an arcuate surface with a chord length shorter than a length of the personalized document and configured to laminate only a portion of the personalized document.

12. The apparatus of claim 8 , wherein the lamination shoe comprises a cutout portion corresponding to a laminate sensitive surface of the personalized document, whereby the cutout portion does not allow that portion of the lamination shoe to press against the personalized document.

13. The apparatus of claim 1 , wherein the supply component comprises:

the web material; and

a plurality of patch films disposed thereon,

the patch films are arranged and configured on the web material so as to be substantially close together.

14. The apparatus of claim 13 , wherein the web material is arranged as a roll of web material.

15. The apparatus of claim 13 , wherein a length of one patch film is about 3.31 inches and a leading edge of one patch film is about 4.0 inches away from a leading edge of the next patch film.

16. The apparatus of claim 13 , wherein a length between a trailing edge of one patch film and the leading edge of the next patch film is less than or equal to 0.69 inches.

17. A method laminating personalized documents, the method comprising:

delivering a patch film disposed on a web material from a supply component to a personalized document;

contacting a platen structure to a portion of one side of the patch film that is less than the entire patch film;

affixing the portion of the patch film that is less than the entire patch film to a portion of one side of the personalized document that is less than the entire side of the personalized document using the platen structure;

laminating a remaining unlaminated portion of the patch film to the personalized document by a lamination assembly.

18. The method of claim 17 , further comprising heating an end surface of the platen structure such that when the platen structure presses the portion of the patch film against the personalized document, the patch film is affixed to the portion of one side of the personalized document.

19. The method of claim 17 , further comprising removing the patch film from the web material by a stripping pin.

20. The method of claim 17 , further comprising biasing a lamination shoe towards a lamination ready position for laminating a subsequent patch film after laminating one patch film to the personalized document.

21. The method of claim 17 , further comprising laminating the entire patch film to an entire side of the personalized document.