WO2002035911A2

WO2002035911A2 - Ink jet identification card printer system

Info

Publication number: WO2002035911A2
Application number: PCT/US2001/051342
Authority: WO
Inventors: Gary M. Klinefelter; Erick Hagstrom; Robert P. Cummins; Jeffrey D. Upin
Original assignee: Fargo Electronics, Inc.
Priority date: 2000-10-30
Filing date: 2001-10-29
Publication date: 2002-05-10
Also published as: WO2002035911A3

Abstract

The present invention is directed to an ink jet printer (2) that includes an ink jet print head (14) and a drying device (24). The ink jet print head is positioned in a printing path (15) of a identification card (10) and configured to move in a direction transverse to the printing path and print ink on a surface of the identification card to thereby form a printed identification card. The drying device, positioned in a drying/holding area, includes a heater (30, 38) that accelerates the drying of ink on the surface of the identification card to prevent smearing and undesired dispersion of the ink, improve water resistance, and set the ink.

Description

INK JET IDENTIFICATION CARD PRINTER SYSTEM

FIELD OF THE INVENTION

The present invention relates to ink jet printers. More specifically, the invention relates to an ink jet printer which includes a drying device for accelerating the drying of ink printed on an identification card.

BACKGROUND OF THE INVENTION Identification cards are widely used to carry information relating to the card holder, for example. The use of such identification cards is becoming more and more widespread and they are used for many purposes, such as driver licenses, identification badges, etc._^ In the past, identification cards -have been manufactured using a labor intensive process in which an individual's data was manually stamped or imprinted onto a card. Additionally, in some cases an instant photograph was taken of the subject and adhered or laminated to a card. However, with the advent of computers, manufacturing of identification cards has become increasingly automated. An individual's data may be obtained from a computer database and formatted by the computer. The formatted information is then provided to a special identification card printer for printing onto the identification card.

Typical identification card printers use dye sublimation ribbon based printers. These printers use a ribbon that carries primary color panels to print an image. Typically, a thermal print head is used to heat the ribbon and cause ink on the color panels to be released and to adhere to the medium. The print head carries a series of resistive thermal elements which are controlled by a circuit in a microcontroller using an algorithm to provide the correct level of heat for optimally printing each color panel. Examples of a dye sublimation based identification card printers include the^' PRO, PRO-L, and the 4250 printers available from Fargo Electronics, Inc. of Eden Prairie, Minnesota.

In addition to being expensive, the image quality of dye sublimation ribbon based identification card printers can be difficult to control. Their image quality is affected by a number of factors including the quality of the dye and the accuracy of the head control. For example, the failure to achieve proper alignment of the head can result in image smearing or the introduction of a shadow into the. printed image. '

Although these prior art identification card printers have worked well for large scale operations, smaller operations having more limited budgets often find it difficult to justify their expense. One option for the small operation is to use a simple, rudimentary prior art identification card impression device. Such a device is, however, very limited in its versatility. Alternatively, identification cards can be written out by hand on cardboard and placed into a plastic sleeve. Unfortunately, none of these solutions are particularly attractive and have left the small user with only limited identification card printing options .

There exists a need for an identification card printer that is more affordable and easier to use than current identification card printers.

SUMMARY OF THE INVENTION

The present invention is directed to an ink jet printer that includes an ink jet print head and a drying device. The ink jet print head is positioned in a printing path of a identification card and configured to move in a direction transverse to the printing path and print ink on a surface of the identification card to thereby form a printed identification card. The drying device, positioned in a drying/holding area, accelerates the drying of ink on the surface of the identification card to prevent smearing and undesired dispersion of the ink, improve water resistance, and set the ink.

One aspect of the invention includes a card flipper adapted to flip the identification card and return the identification card to the printing path.

Another aspect of the invention includes a lamination station where a protective layer can be applied to the surface to protect the ink from the environment

(i.e., light, water, chemicals, and abrasion). Yet another aspect of the invention includes a data encoder used to record data onto the identification card.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a simplified cross-sectional view of an identification card printer in accordance with various embodiment of the present invention.

FIG. 2 is a simplified cross-sectional view of an identification card printer in accordance with various embodiment of the present invention.

FIG. 3 is a simplified perspective view of a heated roller in accordance with one embodiment of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention provides a low cost, high quality printer for printing identification cards. In the present invention, an ink jet printer is used to perform the printing function. Ink jet printers are relatively fast, reliable and relatively inexpensive to produce. The present invention is well suited for low volume identification card production. However, additional cost savings can be obtained in high volume installations as well. The printer may be coupled to a computer whereby identification cards are inexpensively produced. Furthermore, the production of such cards can be on an as needed basis in which cards are printed on demand and can be immediately put into use. For example, the printer of the present invention could be used to produce identification badges at a guard desk at the entrance to an industrial facility. FIGS. 1 and 2 are simplified side cross- sectional views of an ink jet identification card printer in accordance with various embodiments of the present invention. Printer 2 may be divided into three general areas, printing station 4, intermediary station 6 and laminating station 8. Printer 2 is shown -coupled to a controller, such as a personal computer 6 which is used to provide information for printing onto an identification card 10 and controlling the operation of printer 2. Additionally, an internal circuit board (not shown) provides internal control of operation of printer 2.

Printer 2 includes an input hopper 12 which is adapted for- receiving an identification card 10. One such suitable card is the UltraCard™, which is coated with Tuff-Coat™, an ink jet printable surface, and is produced by Fargo Electronics, Inc. of Eden Prairie, Minnesota. Identification card 10 can include an ink jet printable surface such as that described in U.S. Patent No. 6,051,306, which is assigned to Fargo Electronics, Inc. of Eden Prairie,. Minnesota. ^" Identification card 10 can also be formed of Teslin®, thick paper stock, or other suitable materials . A transport mechanism is used to transport identification card 10 through printer 2. In one embodiment, the transport mechanism is generally formed of various rollers including, for example, input roller 13, which moves the identification card 10 from input hopper 12 along an identification card printing path 15 toward ink jet print head 14. Other rollers are also used to move card 10 between the various components of printer 2, as will be discussed below. Many alternative devices exist for forming the transport mechanism that can be used alone or in combination with rollers.

Ink jet print head 14 may comprise any type of ink jet print head and may optionally include an ink jet ink cartridge for supplying ink jet ink. Print head 14 moves along a rod 16 in a direction generally transverse or perpendicular to the direction of the path 15 followed by identification card 10 to accomplish the desired printing on card 10. Identification card 10 is held in place and moved past print head 14 using pinch or drive rollers 18 and star roller 20, which are components of the transport mechanism. Star roller 20 has a plurality of ridges adapted to secure card 10 and maintain registration of card 10 relative to print head 14. However, in another embodiment, a circular roller is used which has a substantially circular outer circumference. A position sensor (not shown) may also be provided such that the location of card 10 can be monitored as card 10 moves along the card path 15 through printer 2. ^•

After printing on card 10 is completed, the printed card 10 moves out of printing station 4 and into intermediary station 6. Intermediary station 6 includes a drying/holding area 22 where the ink printed on card 10 by ink jet print head 14 can dry. In one embodiment, drying/holding area 22 includes drying device 24, shown generally by a dashed line in FIG. 1, which is adapted to accelerate the drying of the ink on card 10. Although depicted as being positioned above card 10, drying device 24 could also be positioned, for example, beneath or to the side of card 10. Additionally, multiple drying devices 24 could be used if necessary to decrease the drying time of the ink printed on card 10. Drying device 24 is preferably stationary allowing card 10 to be moved across, or held within drying range 26, where the drying of the ink on card 10 is accelerated, until the freshly printed ink on card 10 has dried sufficiently. Alternatively, drying device 24 could include moving or oscillating components to increase drying range 26 of drying device 24. A drying device controller 28 can couple to drying device 24 through connection 29 and control the operation of drying device 24.

In one embodiment of the invention, drying device 24 includes heated -roller 30, shown in FIG. 1. Heated roller 30 is positioned in the printing path 15 to receive card 10 and conductively heat card 10 to accelerate the drying of the ink. Additionally, heated roller 30 can apply pressure to card 10 as desired. As card 10 moves along the printing path 15, card 10 can be pulled under heated roller 30 as heated roller 30 rotates. Heated roller 30 can be formed of metal, rubber, ^'or other suitable materials. In one embodiment, heated roller 30 includes a channel or groove 32 formed on cylinder 34, as shown in FIG. 3. Groove 32 has a depth that is approximately the thickness of card 10 and a width that is approximately the width of card 10. Groove 32 is generally adapted to allow heat to conductively pass to the sides or edges of card 10 and to reduce warping of card 10.

In another embodiment of the invention, drying device 24 can be a fan 36 that is configured to produce an airflow directed toward the surface of card 10 which has been printed on, as shown in FIG. 2. The airflow produced by fan 36 must have a velocity and direction that is not likely to cause card 10 to .be displaced from the desired identification card path. However^', additional rollers 18 and 20 could be used to secure card 10 where necessary. In this embodiment, the airflow defines drying range 26. and drying device controller 28 can control the force of the airflow by adjusting the power to fan 36. In yet another embodiment, drying device 24 can be a heater 38 that is configured to direct heat toward card 10. Heater 38 could be positioned, for example, below card 10 to primarily heat card 10, ^• or to a side of card 10 or above card 10 to directly heat both card 10 and the freshly printed ink. Heater 38 generally includes heating elements (not shown) such as resistive heating elements, infrared heating elements, quartz tubes, or other heating elements known by those skilled in the art to be applicable to the function of drying device 24. Heater 38 can be, ^• for example, a heat lamp that is capable of radiantly heating card 10. Additionally, drying device 24 can be a combination of fan 36 and heater 38 such that drying device 24 can produce an airflow of heated air to heat card 10 convectively.

Drying device controller 28 can be adapted to control the heat produced by heater 38, the temperature of the heat produced, and even the airflow of the fan used to blow heated air on card 10, if applicable. Thus,- drying device controller 28 can cause the temperature of the heat produced by drying device 24 to remain constant, ramp up, ramp down, ramp up then down, or ramp down then up, as desired. In yet another embodiment, drying device 24 can include temperature sensor 40 that is adapted to produce a temperature signal which is indicative of the temperature of the heat produced by the heater, card 10, or the ink on card 10. Drying device controller 28 can receive the temperature signal through connection 41 and control drying device 24 in response to the temperature signal.

Once the desired drying of card 10 is complete, another pinch roller 18 and star roller 20 can continue to move card 10 along the printing path ^' 15 through intermediary station 6 and into a card flipping device 42. Flipping device 42 rotates about its axis such that card 10 may be selectively moved down into a magnetic card encoder 44 and/or up ^' into a smart card encoder 46. Encoders 44 and 46 draw card 10 inward and include data encoder such' that additional data may be encoded onto card 10. Stations other than smart card and magnetic card encoders may be provided. Further, flipper 42 may move card 10 between additional stations as desired. Following the encoding process, flipper 42 can move card 10 out of intermediary station 6 and into laminating station 8. Laminating station 8 includes transport rollers 48 (components of the card transport mechanism) which are used to move card 10 therethrough. Lamination station 8 is generally configured to apply a protective layer to card 10 to protect the printing on card 10 from water, light, chemicals, abrasion, and/or other elements or actions which may damage the printing on card 10.- In one embodiment, the protective layer is in the form of a spray-on sealant. In another embodiment, the protective layer is in the form of a laminate aterial 50, which is moved between a supply roll 52 and a take up roll 54 past rollers 56 and heater 58. Laminate material 50 preferably comprises a thermal transfer over-laminate film that is available from Fargo Electronics, Inc. Here, platen 60 is provided to press card 10 against heater 58, which includes an actuator (not shown) to press^' laminate material 50 against card 10. Pinch rollers 62 are provided opposite transport rollers 48 to secure card 10 and maintain registration of card 10 during the lamination process. In another- embodiment, laminate material 50 comprises a plurality of individual laminates carried on a web. A sensor 64 can be provided to sense the position of the individual laminates carried on web 50. Operation of laminating station 8 may be in accordance with that described in U.S. Patent No. 5,807,461, entitled LAMINATION TECHNIQUE which issued September 15, 1998 and is incorporated herein by reference. Lamination station 8 can also be operated in accordance with U.S. Patent No. 6,022,429, entitled LAMINATION STATION which issued February 8, 2000 and is incorporated herein by reference.

In one aspect of the present invention, card 10 may be moved back into flipper 42 and the card rotated 180°. This allows both sides of card 10 to be laminated with laminate material 50. Double sided lamination is particularly advantageous with the identification card is made of thin flexible material such as paper, because the extra lamination adds strength to the card. Further, those skilled in the art will recognize that through the use of flipper 42, information may .be printed onto both sides of the card 10 using print head 14, or data may be recorded on both sides of card 10 using encoders 44 and ^ 6.

After the printing and lamination processes are complete, card 10 is moved to output hopper 66. In some embodiments, multiple cards may be processed simultaneously with the various cards positioned at various locations within printer 2. Typically, printer 2 is controlled by circuitry on a circuit board^' (not shown) contained within printer 2 in accordance with instructions from PC 68. However, such control can be exclusively within printer 2, exclusively within PC 68, or shared therebetween.

In one embodiment, flipping mechanism 42 operates in a manner similar to that disclosed in U.S. patent application Serial No. 08/854,969, entitled PRINTER WITH AUXILIARY OPERATION which was filed May 44, 1997 which is incorporated herein by reference .

Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.

Claims

WHAT IS CLAIMED IS:

1. An identification card printer and laminator system, comprising: an ink jet print head configured to move in a direction that is transverse to a printing path, the ink jet print head further configured to print ink on a surface of an identification card traveling along the printing path to thereby form a printed identification card; a drying device, in a drying/holding area, configured to accelerate the drying of the ■ink on the printed identification card, wherein the drying device includes a heater configured to direct heat toward' the printed identification card; and a lamination station configured to laminate a cover on the printed identification card, wherein the ink jet print head, the drying device, and the lamination station- are contained within a single housing.

2. The identification card printer system and laminator of claim 1, wherein the drying device includes a fan configured to produce an airflow- directed toward the printed identification card.

3. The identification card ^' printer and laminator system of claim 1, wherein the heat is directed toward ^' the surface of the printed identification card from substantially above, below, and/or a side of the printed identification card.

4. The identification card printer and laminator system of claim 1, wherein the heater is configured to heat at least one of the printed identification card and the ink on the printed identification card.

5. The identification card printer and laminator system of claim 1, wherein the heat is radiant heat .

6. The identification card printer and laminator system of claim 1, wherein the heater includes heating elements selected from the group consisting of resistive heating elements, quartz tubes, and infrared^' heating elements.

7. The identification card printer and laminator system of claim 1, further comprising a fan configured to blow air heated by the heater toward the printed identification card.

8. The identification ^• card printer and laminator system of claim 1, wherein the printed identification card is moved across the heat and/or held within the heat for a predetermined period of time.

9. The identification card printer and laminator system of claim 1, wherein the heat is ramped from a low temperature to a high temperature, a high temperature to a low temperature, a low temperature to a high temperature to a low temperature, and/or a high temperature to a low temperature to a high temperature.

10. The identification card printer and laminator system of claim 1, further comprising a drying device controller for controlling the heater.

11. The identification card printer and laminator system of claim 1, including: a temperature sensor adapted to produce a temperature signal related to a temperature of one of the heat generated by the heater and the printed identification card; and a controller adapted to control the heater in response to the temperature signal.

12. The. identification card printer and laminator system of claim 1, wherein the heater includes a heated roller adapted to conductively heat at least one of the identification card and the ink printed on the identification card.

13. The identification card printer and laminator system of claim 12, wherein the heated roller is further adapted to apply pressure to the surface of the identification card.

14. The identification card printer and laminator system of claim 12, wherein the heated roller includes a groove shaped to receive the identification card.

15. The identification card printer and laminator system of claim 1, including an identification card supply configured to provide identification cards to a card transport mechanism that is adapted to move the identification cards along the printing path.

16. The identification card printer and laminator system of claim 1, including at least one of: a card flipper adapted to flip the identification card and return the identification card to the printing path; and a data encoder adapted to record data onto the identification card.

17. An identification card printer system, comprismg: an ink jet print head positioned in a printing .path of a identification card and configured to move in a direction perpendicular to the printing path, the ink jet print head further configured to print ink on a surface of the identification card to thereby form a printed identification card; a drying device, in a drying/holding area, including a heater configured to accelerate the drying of the ink on the printed identification card; and a card flipper adapted to flip the identification card and return the identification card to the printing path.

18. The identification card printer system of claim 17, wherein a single housing encloses the ink jet print head, the drying device, and the card flipper.

19. The identification card printer system of claim 17, wherein the drying device further includes a fan.

20. The identification card printer system of claim 17, including a lamination station adapted to receive the printed identification card and apply a protective layer to the surface of the printed identification card.

21. An identification card printer system, comprising: an ink jet print head positioned in a printing path of a identification card and configured to move in a direction perpendicular to the printing path, the ink jet print head further configured to print ink on a surface of the identification card to thereby form a printed identification card; a drying device, in a drying/holding area, including a heater configured to accelerate the drying of the ink on the printed identification card; a card flipper adapted to flip the identification card and return the identification card to the printing path; and a lamination station adapted to receive the printed identification card and apply a protective layer to the surface of the printed identification card.

22. The identification card printer system of claim 21, wherein the lamination station laminates the surface of the printed identification card with a la inate material or a sealant.

23. The identification card printer system of claim 21, wherein a single housing encloses the ink jet print head, the drying device, and the lamination station.

24. The identification card printer system of claim 21, wherein the drying device includes a fan.