Card printing mechanism with card return path

Abstract

Card personalization system (10), comprising: a card feeding mechanism (12) having at least one card magazine containing a plurality of cards to be fed individually onto a card processing path (22), each card having a first surface, a second surface and an integrated circuit chip; a smart card programming mechanism (14) configured to program personal information onto the integrated circuit chips on the plurality of cards, the smart card programming mechanism (14) being disposed on the card processing path (22) downstream of the card feed mechanism (12); a card printing mechanism (16) disposed on the card processing path (22) downstream of the smart card programming mechanism (14), the card printing mechanism (16) comprising: a drop-on-demand printing station (26) having at least one printhead configured to print the personal information onto the plurality of cards using drop-on-demand printing with a UV-curable ink; a card return movement path (28) configured to return a card to a location on the card processing path (22) upstream of the drop-on-demand printing station (26) and downstream of the smart card programming mechanism (14) after the card has been printed by the drop-on-demand printing station (26), wherein the card is to be passed through the drop-on-demand printing station (26) again; and a UV curing station (34) arranged downstream of the drop-on-demand printing station (26), wherein the card printing mechanism (16) is configured to contain a first card and a second card simultaneously in sequence with each other, and is configured to arrange the first card and the second card such that the first card is oriented with its first surface facing upward and its second surface facing downward, and the second card is oriented with its second surface facing upward and its first surface facing downward; and a card dispenser (20) configured to collect processed cards, the card dispenser (20) being located on the card processing path (22) downstream of the card printing mechanism (16).

Description

Field of InterestThe disclosure relates to card processing systems that personalize or otherwise process plastic cards, such as financial cards, including credit and bank cards, identification cards, driver's licenses, gift cards, and other plastic cards.Prior ArtPlastic cards, such as financial cards, including credit and bank cards, identification cards, driver's licenses, gift cards and other plastic cards, can be personalized with personal information of the intended card holder. Examples of personalization include, but are not limited to, names, addresses, photographs, account numbers, personal numbers, or the like. The personal information can be applied to the card in a number of different ways including, but not limited to, printing on a surface of the document, storing the information on a magnetic stripe disposed on the card, and storing the information on an integrated circuit chip or smart chip embedded in the card.Card processing systems that personalize plastic cards are used by institutions that issue such personalized plastic cards. In some cases, map processing systems may be designed for relatively small individual map personalization in relatively small amounts, for example, as measured in ten or a few hundred per hour. In these mechanisms, a single document to be personalized is input into a card processing system, which typically has one or two processing capabilities, such as printing and laminating. These processing machines are often referred to as desk-top processing machines because they have a relatively small space requirement that is intended to allow the machine to stand on a desk. Many examples of desk top processing engines are known, such as the SD or CD family of desk card printers available from Entrust Datacard Corporation of Shakopee, Minnesota. Other examples of desktop processing machines are disclosed in U.S. Patents 7,434,728 and 7,398,972 each of which is incorporated herein by reference in its entirety.For large-scale production of personalized cards (e.g., on the order of many hundred or thousand per hour), institutions often use card processing systems that employ multiple processing stations or modules to process multiple cards simultaneously to reduce the overall processing time per card. Examples of such machines include the MX and MPR family of central output processing machines available from Entrust Datacard Corporation of Shakopee, Minnesota. Other examples of central output processing machines are disclosed in U.S. Patents 4,825,054, 5,266,781, 6,783,067, and 6,902,107, all of which are incorporated herein by reference in their entirety.SummaryCard processing mechanisms, systems and methods are described by which, after a card has been processed on a surface thereof in a card processing station, such as, but not limited to, a card printing mechanism, the card can be recirculated upstream of the card processing station along a card return travel path that is separate from the primary card travel path through the card processing station, which card can then be reinserted into the primary card travel path and transported a second time through the card processing station. As the card is fed back along the card return travel path, the card can be turned over so that as the card is fed back through the card processing station, the opposing surface of the card can be processed.Processing as used herein is intended to include any processing operation on a card surface, including, but not limited to, printing, laminating, imprinting, embossing, and other processing operations. In one embodiment, the card processing station is configured to perform a printing operation. Printing may include drop-on-demand (drop-on-demand) printing with an ultraviolet (UV) curable ink, printing using a thermal ink transfer ribbon, laser marking using a laser, retransfer printing, and other card printing techniques.In some embodiments, improved card processing systems include a card printing mechanism having a primary card path and a separate card return path. The card return path allows a card that has been passed through a printing station to be returned to the primary card path at a portion upstream of the printing station so that the card can be passed through the printing station again. One or more card realignment mechanisms (e.g., reversing means) may be disposed on the card return path to orient the card in a desired position for the second pass through the printing station. In some embodiments, the card realignment mechanism positions the card such that the same surface of the card that was processed during the first pass through the printing station can be processed during the second pass through the printing station. In other embodiments, the card realignment mechanism may position the card such that the opposite side of the card may be processed during the second pass through the printing station. The card return path may be of any general shape so long as it serves to return cards efficiently to the printing station for a second pass through the printing station. In some embodiments, the card return path may be substantially in the same plane as the primary card path. Alternatively, the card return path may be located in a plane that is above or below the plane of the primary path. In systems that use a module or component upstream and / or downstream of the card printing mechanism that has a lower maximum card processing rate, the use of a card return path allows the card printing mechanism to process cards at a higher rate and eliminate the need for a second card printing mechanism, reducing the cost and space requirements of the system.In one embodiment, a method for processing cards in a card processing system having a card printing mechanism with a printing station includes: printing on a first side of a first card in the card processing system using the printing station of the card printing mechanism. After printing on the first page of the first card, printing is performed on a second page of a second card in the card processing system using the printing station, the second card including printing on a first page thereof previously applied to the first page thereof using the printing station. In addition, after printing on the second page of the second card, printing on a second page of the first card is performed using the printing station. In another embodiment, after printing on the first page of the first card and before printing on the second page of the first card, printing on a first page or a second page of multiple cards may be performed in addition to the second card using the printing station.In one embodiment, the card processing station having the card return travel path may process cards at a card rate that is higher than, for example, up to twice as high as, a card processing rate of card processing stations immediately upstream and / or downstream of the card processing station.In another embodiment, the card processing system may be configured such that a card may move through the card processing system in a first orientation, for example vertically relative to the ground. However, upon reaching a card processing station, such as the card processing station having the card return travel path, the card may be rotated 90 degrees to a second orientation, such as horizontally relative to the ground, for processing within the card processing station. After processing is complete at the card processing station, the card may be rotated back to the first orientation, if necessary, for further processing downstream of the card processing station.The card processing mechanisms and methods described herein can be used in large volume production or central issue card processing systems with large quantities, as well as desk top card processing systems with smaller quantities.DRAWINGSFIG. 1 schematically illustrates an embodiment of a card processing system that may employ the card printing mechanism described herein. FIG. 2 illustrates an example of a sequence of cards advancing through the card printing mechanism described herein. Figure 3 illustrates a sequence similar to Figure 2, but with the cards advanced by one position. Figure 4 illustrates a sequence similar to Figure 3, but with the cards advanced by another position. FIG. 5 is a perspective view of a portion of an example of a card printing mechanism showing mechanisms for rotating the cards from one orientation to the other.Detailed DescriptionFIG. 1 illustrates an embodiment of a card processing system 10 configured to personalize or otherwise process plastic cards, such as financial cards including credit and bank cards, identification cards, driver's licenses, gift cards, and other plastic cards. The personal information may also be referred to as variable data, as the data varies from card to card. Examples of personalized information include, but are not limited to, names, addresses, photographs, account numbers, personal numbers, or the like. Non-personal or non-variable data, such as corporate logos, printed backgrounds, and the like, may also be applied to the cards. The personal and non-personal information may be applied to a card in system 10 in a number of different ways including, but not limited to, printing on a surface of the card, storing the information on a magnetic stripe disposed on the card, and storing the information on an integrated circuit chip or a smart chip embedded in the card.In the example illustrated in FIG. 1, the system 10 may include a card feed mechanism 12, a card processing mechanism 14, a card printing mechanism 16, which may also be referred to as a card processing mechanism, another card processing mechanism 18, and a card output 20 into which processed cards are output. The card processing system 10 illustrated in FIG. 1 is a large volume, batch, or central issue card processing system. However, the card printing mechanism 16 described herein can be used in other card processing systems, including small series, desk top card processing systems.The mechanisms 14, 16, 18 may be arranged in any order in the system 10. In addition, not all of the mechanisms 14, 16, 18 need be used. For example, in one embodiment, the mechanism 16 may be used alone without the other mechanisms 14, 18. In addition, an additional card processing mechanism may be used with mechanisms 14, 16, 18.The card feed mechanism 12 feeds cards to be processed by the system 10 onto a card processing path 22 at up to a first card rate. The card rate of the feed mechanism 12 refers to how fast the mechanism 12 can feed cards into the processing path 22 one after the other. In one embodiment, the first card rate may be up to about 3000 cards per hour. The card feed mechanism 12 may include one or more card magazines containing cards waiting to be fed sequentially onto the card processing path 22.The card processing mechanism 16 is disposed on and along the card processing path 22 for receiving cards. The card processing mechanism 16 is configured to perform a processing operation on each card. In one embodiment, the map processing mechanism 16 is configured to perform printing. Examples of printing include drop-on-demand printing with a UV curable ink, printing using a thermal ink transfer ribbon, retransfer printing, laser marking using a laser, and other card printing techniques.As discussed in more detail below with respect to FIGS. 2-4, when the card printing mechanism 16 is configured to print, the processing mechanism 16 may be referred to as a card printing mechanism that includes: a primary card travel path 24 that is collinear with the card processing path 22, at least one printing station 26 on the primary card travel path 24 that performs a printing operation on a surface of a card on the primary card travel path 24, and a card return travel path 28 that returns a card to a location on the primary card travel path 24 that is upstream of the at least one printing station 26 after the card is printed by the at least one printing station 26. When configured as a card printing mechanism, the card processing mechanism 16 may process cards at up to a card rate greater than the first card rate. For example, mechanism 16 may have a second card rate of up to about 6000 cards per hour or more. The card rate of the card processing mechanism 16 refers to how fast (i.e., the rate) the card processing mechanism 16 can perform its intended processing operation(s) on the cards.Referring again to FIG. 1, in the example illustrated, the card processing mechanism 14 is disposed on and along the card processing path 22 downstream of the card feed mechanism 12. The card processing mechanism 14 is configured to perform one or more processing operations on each card at up to the first card rate, for example, up to about 3000 cards per hour. The card rate of the card processing mechanism 14 refers to how fast (i.e., the rate) the card processing mechanism 14 can perform its intended processing operation(s) on the cards. The card processing mechanism 14 may be a smart card programming mechanism configured to program a chip embedded in each card, for example. The smart card programming mechanism may be configured to individually program a card. Alternatively, the smart card programming mechanism may be configured to program multiple cards simultaneously. Examples of smart card programming mechanisms that simultaneously program multiple cards and that could be used are described in U.S. Patent 6,695,205 (which discloses an elevator type smart card programming mechanism) and U.S. Patent 5,943,238 (which discloses a drum type smart card programming mechanism), the entire contents of each patent being incorporated herein by reference. The card processing mechanism 14 may alternatively be configured to program a magnetic stripe on each card, or the card processing mechanism 14 may perform both smart card programming and magnetic stripe programming. In another embodiment, a separate magnetic stripe programming mechanism (not shown) may be disposed between the card processing mechanism 14 and the card feed mechanism 12 or between the card processing mechanism 14 and the card processing mechanism 16. Additionally, the card processing mechanism 14 may or may not be located at other positions in the system 10, in which case the card processing mechanism 14 is not located between the card processing mechanism 16 and the card feed mechanism 12. For example, if the card processing mechanism 14 is configured as a smart card programming mechanism, it may also be disposed downstream of the card processing mechanism 16.In the embodiment illustrated in FIG. 1, the card processing mechanism 16 is shown downstream of the card processing mechanism 14. In another embodiment, the card processing mechanism 16 may be the first processing mechanism downstream of the card feed mechanism 12, in which case the card processing mechanism 16 is not downstream of the card processing mechanism 14. The map processing mechanism 16 is configured to perform a processing operation on each map different from the map processing operation performed by the map processing mechanism 14.The embodiment illustrated in FIG. 1 also shows the card processing mechanism 18 disposed along the card processing path 22 downstream of the card processing mechanism 16. However, other locations of the map processing mechanism 18 are possible in the system 10. The card processing mechanism 18 is configured to perform a processing operation on each card different from the card processing operations performed by the card processing mechanism 14 and the card processing mechanism 16. For example, the card processing mechanism 18 may be configured to make a laser mark on each card using a laser and / or apply a hologram overlay on each card and / or perform other card processing operations. In one embodiment, the card processing mechanism 18 may have a card processing rate that is approximately equal to the first card rate. The card rate of the card processing mechanism 18 refers to how fast (i.e., the rate) the card processing mechanism 18 can perform its intended processing operation(s) on the cards.Cards that have been processed are collected in the card issue 20 that is located along the card processing path 22 downstream of the card processing mechanism 16. The processed cards can then be distributed to their intended recipients, for example, by placing the cards in envelopes and shipping them to the intended recipients.Many other card processing mechanisms may be used in addition to or in place of the processing mechanisms illustrated in FIG. 1. For example, a push-in mechanism that performs a push-in on each card may be provided upstream or downstream of the card processing mechanism 16. A quality assurance mechanism that checks the quality of the processed cards may be interposed between the card issue 20 and the card processing mechanism 18. Many other processing mechanisms and combinations of processing mechanisms may be used.Referring now to Figures 2 through 4, for convenience, the card processing mechanism 16 will be described as a card printing mechanism configured to print, particularly drop-on-demand printing, with a UV curable ink. Suitable drop-on-demand printing mechanisms that could be used are sold under the trade name PERSOMASTER by Atlantic Zeiser GmbH of Emmingen, Germany. Figures 2 through 4 illustrate a number of different cards 30 at various locations upstream, downstream, and within mechanism 16. In addition, the letter "A" on a card 30 denotes one side of the card 30, while the letter "B" denotes the opposite side of the card 30.The mechanism 16 includes the at least one printing station 26 on the primary card travel path 24 that performs a printing operation on the surface A or B of each card 30 on the primary card travel path 24. Printing station 26 may include a plurality of printheads 27 (shown in Figure 5), some of which print a different color. Optionally, at least one of the printheads 27 may apply a spray coating to the card surface A or B. In the case of drop-on-demand printing with a UV curable ink, an optional surface treatment station 32 may be located on the primary card travel path 24 upstream of the printing station 26. Optional surface treatment station 32, if used, is configured to treat surface A or B of each card 30 to reduce the surface tension of the card surface so that the UV ink will better retain when applied to the card surface. Additionally, a UV curing station 34 may be located on the primary card travel path 24 downstream of the printing station 26. The UV curing station 34 is configured to apply a UV light to the card surface to cure the applied UV ink.The card return travel path 28 intersects the primary card travel path 24 both downstream and upstream of the printing station 26. The card return travel path 28 is configured to deflect or recirculate a card that has been fed by the printing station 26 from the primary card travel path 24, and return the card to the primary card travel path 24 at a location upstream of the printing station 26, such that the card can be fed through the printing station 26 again. Additionally, in some embodiments, as the card is recirculated along the card return travel path 28, the card may be turned 180 degrees so that the surface A or B previously printed now faces downward and the non-printed surface A or B faces upward ready to be printed.The card return travel path 28 may be of any configuration and location suitable for recirculating the cards upstream of the printing station 26 so that they may be passed through the printing station 26 a second time or even more than twice. The card return travel path 28 may be of any general shape so long as it is effective to return cards to the primary card travel path 24 upstream of the printing station for a second pass through the printing station 26. In some embodiments, the card return travel path 28 may be substantially in the same plane as the primary card travel path 24. In addition, the card return travel path 28 may be substantially linear or may be curved. In addition, any mechanism(s) may be used for selectively recirculating the cards along the card return path 28 and optionally turning the cards 180 degrees.For example, in the embodiment illustrated in FIGS. 2-4, the card travel path 28 may include a first portion 28a that is substantially perpendicular to the primary card travel path 24, a horizontal portion 28b that is substantially parallel to the primary card travel path 24, and a second portion 28c that is substantially perpendicular to the primary card travel path 24. Mechanism 16 may include a first mechanism 36 that may transport a card along first portion 28a between primary card travel path 24 and horizontal portion 28b so as to transfer a card from travel path 24 to horizontal portion 28b of travel path 28. A card turning device 38 may be provided along the horizontal portion 28 bof the travel path 28 turning a card 180 degrees. This is evident from Figures 2 to 3 where the card (6) will just enter the card turning device 38 with the side A facing up in Figure 2, and in Figure 3 the card (6) will enter the card turning device 38 which turns the card (6) so that only its side B faces up. A second mechanism 40 is also provided which is capable of transporting a card along the second portion 28c between the primary card travel path 24 and the horizontal portion 28b of the card return travel path 28 so as to bring a card from the horizontal portion 28b to the travel path 24.The mechanisms 36, 40 may be of any configuration that can properly transport the cards between the primary card travel path 24 and the portion 28a of the card return travel path 28. For example, as discussed further below in FIG. 5, mechanisms 36, 40 may be rotating mechanisms that rotate each card from primary card travel path 24 to portion 28 aof card return travel path 28 (in the case of mechanism 36) and from portion 28 aof card return travel path 28 back to primary card travel path 24 (in the case of mechanism 40).In other embodiments, the mechanisms 36, 40 may be elevator mechanisms that transport the cards between the card travel paths. An example of a card elevator mechanism is disclosed in U.S. Patent 6,105,493, the entire contents of which are incorporated herein by reference. In other embodiments, a sequence of card reversal devices may be used to transport cards between card travel paths. Examples of card turning devices are disclosed in U.S. Published Application No. 2013 / 0220984 and U.S. Patent 7,398,972, the entire contents of which are incorporated herein by reference.Referring to FIG. 2, a sequence of cards 30 is illustrated as they pass through mechanism 16 at any time. This example is described using optional surface treatment station 32. If the surface treatment station 32 is not used, similar card sequencing may occur, but with a card less inside the mechanism 16. the card (1) is shown being dispensed from the mechanism 16 with the side B facing up. The card (7) is shown in a position on the mechanism 36 with side A facing up ready to be transported to the portion 28b of the card travel path 28. The card (6) is shown after being transported to the section 28b of the travel path 28, with side A facing up, ready to enter the turning device 38. The card (5) is shown in the turning device 38 and by turning it from the side A to the side B, so that now the side B faces upwards. The card (4) is shown with side B facing up and ready to be returned by mechanism 40 to the primary card travel path 24. The card (9) is shown with the card side A facing up and just entering the mechanism 16. The card (3) is shown in the surface treatment station 32 with the card page B facing up after being recirculated back to the travel path 24 so that the page B can be treated prior to printing. The card (8) is shown in the printing station 26 with page A facing up for printing by the printing station 26 on page A. The card (2) is shown facing side B up in the UV curing station 34 after it has been printed, the UV curable ink being UV cured in the station 34. The card (10) is shown with side A facing up and ready to enter the mechanism 16. The card (11) is shown with side A facing up and ready to take the position of the card (10) after the card (10) enters the mechanism 16.Figure 3 shows the cards of Figure 2 advanced by one step in an example of possible sequencing of the cards in Figure 2. The card (1) has not been moved forward and is shown in the same position that is being dispensed from the mechanism 16 with the side B facing upwards. The card (7) with the side A facing upward was transported by the mechanism 36 to the portion 28b of the card travel path 28. The card (6) has been advanced along the card moving path portion 28b into the reversing device 38 and turned from the side A to the side B so that the side B now faces upwards. The card (5) with side B facing up was advanced by the inverter 38 into the mechanism 40 ready to be fed back to the primary card travel path 24. The card (4) with side B facing up was fed back by mechanism 40 to the primary card travel path 24. The card (9) has been advanced with page A facing up into the surface treatment station 32 so that page A can be treated prior to printing. The card (3) with the page B facing up was moved forward into the printing station 26 for printing the page B. The card (8) having the side A turned up was advanced into the UV curing station 34 after being printed, whereby the UV curable ink is UV cured in the station 34. The card (2) has been moved with the side B facing upwards into the elevator mechanism 36 and the position previously occupied by the card (7).Figure 4 shows the cards of Figure 3 advanced a further step in an example of possible sequencing of the cards of Figure 3. In this example, the card (1) is moved forward and the card (2) is moved forward by the mechanism 16 to the position previously occupied by the card (1). The cards (7), (6) and (5) remain in position. The card (8) is advanced by the UV curing station 34 to the position previously occupied by the card (2). The card (3) is advanced into the UV curing station 34. The card (9) is advanced into the printing station 26 for printing on page A. The card (4) is advanced into the surface treatment station 32 so that the page B can be treated before printing. The card (10) is moved forwards into the mechanism 16 to the position previously occupied by the card (4) with the side A facing upwards. In addition, the card (11) is moved forward to the position previously occupied by the card (10), and the card (12) is moved forward to the position previously occupied by the card (11).Once a card reaches mechanism 36, if no further printing on the card is required, the card can be advanced by mechanism 36 and out of mechanism 16. As the card is advanced from mechanism 16, a new card may be simultaneously transported into mechanism 16 via mechanism 40 to begin the process of printing on a surface of the new card. After a surface of the new card is printed, it may be recirculated and turned upstream of the printing station 26 along the card return travel path 28 so that the other side of the new card faces upwardly so that printing may be done on the other side of the new card.If printing is not required on both sides A and B of the card, the card can be passed through the printing station 26 a single time and then discharged from the mechanism 16 without recirculation of the card through the card return travel path 28.One method of processing cards in the card processing system 10 that results from the example of the system 10 and the example of sequencing illustrated in Figures 2 through 4 involves printing on a first page (such as page A) of a first card, such as card 8, using the printing station 26. see Figure 2. Referring to Figure 3, the second card, for example card 3, includes printing on a first page (such as page A) thereof that was previously applied to the first page thereof using printing station 26. In other words, the second card, such as card 3, has been previously transported through printing station 26 which has printed page A, the second card, such as card 3, being ultimately recirculated upstream of the printing station and ultimately recirculated through printing station 26 to print page B, as illustrated in Figure 3. Additionally, after printing on the second page of the second card, such as card 3, the second page (such as page B) of the first card, such as card 8, is printed at printing station 26 by the first card, such as card 8, being ultimately recirculated upstream of the printing station and ultimately recirculated through printing station 26 to print page B using any implemented card sequencing.As can be seen from Figures 2 to 4, after printing on the first page of the first card, for example card 8, page A or page B of at least one additional card is printed before printing on the second page of the first card, for example card 8. Printing on (one) additional card(s) is performed while the first card, for example card 8, is recirculated for printing on the second side thereof in printing station 26. An additional card, two additional cards, three additional cards, four additional cards, five additional cards, or more than five additional cards may be printed while the first card, for example card 8, is recirculated for printing on the second side thereof.In drop-on-demand printing, it is preferred that the card printed at the printing station 26 be oriented such that the card is oriented substantially flat or horizontal relative to the ground. However, in some card processing systems, cards may be transported along the card processing path 22 in a second orientation where the cards are oriented substantially vertically relative to the ground. Thus, in such an embodiment, upon reaching mechanism 16, the cards must be re-aligned by rotating the cards 90 degrees, e.g., from a vertical orientation to a horizontal orientation, and upon exiting mechanism 16, the cards may have to be re-aligned by rotating the cards 90 degrees, e.g., from the horizontal orientation back to the vertical orientation.Figure 5 shows a portion of an embodiment of mechanism 16 that is configured to re-align the cards by 90 degrees at both the input and output of mechanism 16. In this example, the cards enter the mechanism 16 in a vertical orientation. The mechanism 16 in Figure 5 also has the primary card travel path 24, and the portion 28b of the card return travel path 28 is located adjacent to and in the same plane as the primary card travel path 24.The cards may initially enter mechanism 16 into an optional roller mechanism 50. The mechanism 50 may rotate about a vertical axis A-A. Mechanism 50 is useful for turning the cards about axis A-A when necessary so that when side A of a card faces forward upon entering mechanism 16, mechanism 50 can rotate the card so side B faces forward. If a card does not need to be turned, the card can easily pass through mechanism 50 without being turned about axis A-A.Each vertically oriented card is then fed into a first rotating mechanism 52. The rotating mechanism 52 is configured to receive each card and then rotate in any direction about an axis substantially parallel to the primary card travel path 24 to rotate the card from its vertical orientation to a horizontal orientation aligned with the primary card travel path 24. The new horizontal card can then be transported by mechanism 52 and onto primary card travel path 24. Mechanism 52 can rotate 90 degrees in either direction to bring the now horizontal card into alignment with primary card travel path 24. Mechanism 52 is also configured to receive a card from portion 28b of card return travel path 28 and rotate 180 degrees together with the card about the axis substantially parallel to primary card travel path 24 to return the card to primary card travel path 24.The now horizontal card is then moved past the print head or heads 27 of the printing station 26 for printing the surface, which also always faces upwards towards the print head or heads 27. Once printing is complete, the card is fed into the UV curing station 34. After curing, the card is fed into a second rotating mechanism 54 close to the exit of mechanism 16. The rotating mechanism 54 is adapted to receive each card and then rotate in any direction about an axis substantially parallel to the primary card travel path 24 to transport the horizontally oriented card from the primary card travel path 24 to the portion 28b of the card return travel path 28. In one embodiment, the rotating mechanism 54 rotates 180 degrees to transport the card from the primary card travel path 24 to the portion 28b of the card return travel path 28 while the card is still in its horizontal orientation. The card can then be transported along the portion 28b of the card travel path 28 to the turning device 38 which can turn the card (if necessary) so that the appropriate side faces upwards. The card is then transported into the first rotating mechanism 52, which rotates to transport the card back to the primary card travel path 24.An optional roller mechanism 56 may be provided adjacent the exit of the mechanism 16. Mechanism 56 is similar in construction and operation to mechanism 50 in that mechanism 56 is capable of rotating about a vertical axis A-A. Mechanism 56 is useful for turning the cards about axis A-A, if necessary, so that when side A of a card faces upwardly while it just exits mechanism 16, mechanism 56 can rotate the card so side B faces forwardly. If no turning of a card is required, the card can easily pass through mechanism 56 without turning about axis A-A.The techniques described herein may be used in printing other than drop-on-demand printing. For example, in the case of thermal color diffusion printing, if printing is required on both sides A and B of the card, the card may be recirculated back to the thermal color diffusion print head. In the case of thermal color diffusion printing, the stations 32, 34 in Figures 2-4 would not be required and realignment of the cards from vertical to horizontal and from horizontal back to vertical would not be required, thereby eliminating the need for the rotating mechanisms 52, 54.The cards may be transported along the primary card travel path 24 and the portion 28b of the card return travel path 28, as well as along the card processing path 22 by the mechanisms 14, 18 using any card transport mechanisms well known to those of ordinary skill in the art. For example, the cards may be transported using rollers, (transport) belts, and combinations thereof.Mechanisms 12, 14, and 18 have been described as having approximately equal card rates (e.g., up to about 300 cards per hour, respectively) and mechanism 16 has been described as having a card rate (e.g., up to about 6000 cards per hour, or even more) that is greater than the card rates of mechanisms 12, 14, 18.The examples disclosed in this application are to be considered in all respects as illustrative and not restrictive. The scope of the invention is indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.Aspects of the present disclosure include:Aspect 1. A card processing system comprising:a card processing path;a card printing mechanism disposed along the card processing path, the card printing mechanism comprising:a primary card path along which cards can travel in a downstream direction;at least one printing station on the primary card travel path that performs a printing operation on a surface of a card on the primary card travel path;a card return travel path intersecting the primary card travel path downstream and upstream of the at least one printing station, and along which a card that has been guided by the at least one printing station may be deflected from the primary card travel path and returned to the primary card travel path at a location upstream of the at least one printing station for re-guiding by the at least one printing station.Aspect 2. the card processing system according to Aspect 1, further comprising a card supply mechanism that supplies cards to be processed on the card processing path, wherein the card supply mechanism is disposed upstream of the card printing mechanism.Aspect 3. The card processing system of any of the foregoing aspects, particularly of Aspect 1, further comprising a card processing mechanism disposed downstream of and receiving cards from the card printing mechanism, and a card issue disposed downstream of the card processing mechanism into which processed cards are issued.Aspect 4. The card processing system of any of the preceding aspects, particularly of Aspect 3, further comprising a card processing mechanism disposed upstream of the card printing mechanism and outputting cards to the card printing mechanism.Aspect 5. The card processing system of any of the preceding aspects, particularly of aspect 4, wherein the card processing mechanism disposed upstream of the card printing mechanism has a first card processing rate, the card printing mechanism has a second card processing rate that is greater than the first card processing rate, and the card processing mechanism disposed downstream of the card printing mechanism has the first card processing rate.Aspect 6. The card processing system of any of the preceding aspects, particularly of aspect 3, wherein the card processing mechanism disposed downstream of the card printing mechanism is configured to process a card while the card is in a first orientation, the card printing mechanism is configured to process a card while the card is in a second orientation, and the first card orientation is 90 degrees relative to the second card orientation.Aspect 7. A method of processing cards in a card processing system having a card printing mechanism with a printing station, the method comprising:printing on a first page of a first card in the card processing system using the printing station of the card printing mechanism;after printing on the first side of the first card, printing on a second side of a second card in the card processing system using the printing station, the second card comprising printing on a first side thereof previously applied to the first side thereof using the printing station;after printing on the second side of the second card, printing on a second side of the first card using the printing station.Aspect 8: The method of any of the preceding aspects, in particular of aspect 7, wherein, after printing on the first page of the first card and before printing on the second page of the first card, printing on one of a first page or a second page of a plurality of cards in addition to the second card using the printing station.Aspect 9: The method of any of the preceding aspects, in particular of aspect 7, wherein, after printing on the first side of the first card, unloading the first card from the printing station to a location downstream of the printing station and thereafter transporting the first card to a location upstream of the printing station without passing through the printing station.Aspect 10. The method of any of the preceding aspects, particularly of aspect 9, wherein, after printing on the first side of the first card and before printing on the second side of the first card, inverting the first card 180 degrees while the first card is being transported to the location upstream of the printing station.Aspect 11 A card processing system comprising:a card feeding mechanism that feeds cards to be processed onto a card processing path at up to a first card rate;a first card processing mechanism disposed along the card processing path, the first card processing mechanism processing cards at up to the first card rate; anda second card processing mechanism disposed along the card processing path, the second card processing mechanism processing cards at up to a second card rate greater than the first card rate.Aspect 12 The card processing system of any of the preceding aspects, particularly of Aspect 11, further comprising a third card processing mechanism disposed along the card processing path, wherein the third card processing mechanism processes cards at up to the first card rate.Aspect 13 The card processing system according to any of the preceding aspects, in particular according to aspect 12, wherein the first card processing mechanism is arranged upstream of the second card processing mechanism, the third card processing mechanism is arranged downstream of the second card processing mechanism, and the second card processing mechanism is between the first card processing mechanism and the third card processing mechanism.Aspect 14. Card Processing System Comprising:a card feeding mechanism that feeds cards to be processed onto a card processing path;a first card processing mechanism disposed along the card processing path downstream of the card feed mechanism, the first card processing mechanism processing each card while the card is disposed in a first card orientation relative to the ground and while within the first card processing mechanism;a second card processing mechanism disposed along the card processing path downstream of the card feed mechanism, the second card processing mechanism processing each card while the card is disposed in a second card orientation relative to the ground and while within the second card processing mechanism; andwherein the first card orientation is 90 degrees relative to the second card orientation.Aspect 15. The card processing system of any of the preceding aspects, in particular of aspect 14, wherein the first card orientation is vertical relative to the ground and the second card orientation is horizontal relative to the ground.References included in the specificationThis list of documents cited by the applicant has been produced in an automated manner and is only included for the better information of the reader. The list is not part of the German patent application or utility model application. The DPMA does not take any adhesion for any faults or omissions.Patent Literature citedU.S. Pat. No. 7,434,728

[0003] U.S. Pat. No. 4,825,054

[0004] U.S. Pat. No. 6,695,205

[0018] U.S. Pat. No. 5,943,238

[0018] U.S. Pat. No. 6,105,493

[0029] US 2013 / 0220984

[0029] U.S. Pat. No. 7,398,972

[0029]

Claims

A card personalization system (10) comprising: a card feed mechanism (12) having at least one card magazine containing a plurality of cards to be individually fed onto a card processing path (22), each card having a first surface, a second surface, and an integrated circuit chip; a smart card programming mechanism (14) configured to program personal information onto the integrated circuit chips on the plurality of cards, the smart card programming mechanism (14) being disposed on the card processing path (22) downstream of the card feed mechanism (12); a card printing mechanism (16) disposed on the card processing path (22) downstream of the smart card programming mechanism (14), the card printing mechanism (16) comprising: a drop-on-demand printing station (26) comprising at least one printhead configured to print the personal information on the plurality of cards using drop-on-demand printing with a UV curable ink; a card return travel path (28) configured to return a card to a location on the card processing path (22) upstream of the drop-on-demand printing station (26) and downstream of the smart card programming mechanism (14) after the card has been printed by the drop-on-demand printing station (26), the card to be passed through the drop-on-demand printing station (26) again; A UV curing station (34) located downstream of the drop-on-demand printing station (26), wherein the card printing mechanism (16) is configured to contain a first card and a second card simultaneously in sequence with each other and is configured to locate the first card and the second card such that the first card is oriented with its first surface facing up and its second surface facing down and the second card is oriented with its second surface facing up and its first surface facing down; and a card issue (20) configured to collect processed cards, wherein the card issue (20) is located on the card processing path (22) downstream of the card printing mechanism (16).The card personalization system (10) of claim 1, wherein the card printing mechanism (16) further comprises a surface treatment station (32) upstream of the drop-on-demand printing station (26), the surface treatment station (32) configured to treat the first surface or the second surface of each card.The card personalization system (10) according to any one of the preceding claims, wherein the card printing mechanism (16) has exactly one drop-on-demand printing station (26).The card personalization system (10) of any preceding claim, wherein the card printing mechanism (16) includes a turning device (38) for turning a card, the turning device (38) being disposed on the card return travel path (28) within the card printing mechanism (16).The card personalization system (10) of any preceding claim, further comprising an additional card processing mechanism (18) configured to perform a processing operation on the cards that is different from the programming of the integrated circuit chips by the smart card programming mechanism (14).The card personalization system (10) of claim 5, wherein the additional card processing mechanism (18) is disposed between the card feed mechanism (12) and the card print mechanism (16).The card personalization system (10) of claim 5, wherein the additional card processing mechanism (18) is disposed between the card printing mechanism (16) and the card dispenser (20).The card personalization system (10) of any of claims 5 to 7, wherein each card further comprises a magnetic stripe and the additional card processing mechanism (18) comprises a magnetic stripe programming mechanism.The card personalization system (10) of any preceding claim, wherein the card printing mechanism (16) is further configured to include a third card in sequence with the first card and the second card in the card printing mechanism (16), the second card being disposed between the first card and the third card, and the card printing mechanism (16) is configured to arrange the third card such that the third card is oriented with its first surface facing upward and its second surface facing downward.A card personalization system (10) comprising: a card feed mechanism (12) having at least one card magazine containing a plurality of cards to be individually fed onto a card processing path (22), each card having a first surface, a second surface, and an integrated circuit chip; a smart card programming mechanism (14) disposed on the card processing path (22) downstream of the card feed mechanism (12) and configured to program personal information onto the integrated circuit chips on the plurality of cards; a drop-on-demand printing station (26) disposed on the card processing path (22) downstream of the smart card programming mechanism (14), the drop-on-demand printing station (26) including a printhead configured to print the personal information on the plurality of cards using drop-on-demand printing with a UV curable ink; a card return travel path (28) configured to return a card to a location on the card processing path (22) upstream of the drop-on-demand printing station (26) after the card has been printed by the drop-on-demand printing station (26), the card to be passed through the drop-on-demand printing station (26) again; a UV curing station (34) located downstream of the drop-on-demand printing station (26); and a card dispenser (20) disposed on the card processing path (22) downstream of the UV curing station (34) and configured to collect processed cards, wherein the drop-on-demand printing station (26) is configured such that the drop-on-demand printing station (26) includes a first card and a second card simultaneously in sequence with each other, wherein the first card is oriented such that its first surface faces upward and its second surface faces downward, and the second card is oriented such that its second surface faces upward and its first surface faces downward.The card personalization system (10) of claim 10, further comprising a surface treatment station (32) disposed upstream of the drop-on-demand printing station (28), the surface treatment station (32) configured to treat the first surface or the second surface of each card.The card personalization system (10) of claim 10 or 11, further comprising an additional card processing mechanism (18) configured to perform a processing operation on the cards different from the programming of the integrated circuit chips performed by the smart card programming mechanism (14).The card personalization system (10) of claim 12, wherein each card further comprises a magnetic stripe, and the additional card processing mechanism (18) comprises a magnetic stripe programming mechanism.A card personalization system (10) that personalizes cards having a first surface, a second surface, and an integrated circuit chip, the card personalization system (10) comprising: a smart card programming mechanism (14) configured to program personal information onto the integrated circuit chips of the cards; and a card printing mechanism (16) comprising: a drop-on-demand printing station (26) comprising a plurality of printheads configured to print personal information onto the cards using drop-on-demand printing with a UV curable ink, wherein a first printhead prints a different color than a second printhead; a card return travel path (28) configured to return a card to a location upstream of the drop-on-demand printing station (26) after the card is printed by the drop-on-demand printing station (26), the card to be passed through the drop-on-demand printing station (26) again; A UV curing station (34) located downstream of the drop-on-demand printing station (26), the drop-on-demand printing station (26) configured such that the drop-on-demand printing station (26) includes a first card and a second card in sequence with one another, the first card being oriented such that its first surface faces upward and its second surface faces downward, and the second card being oriented such that its second surface faces upward and its first surface faces downward.The card personalization system (10) of claim 14, wherein the card printing mechanism (16) further comprises a surface treatment station (32) disposed upstream of the drop-on-demand printing station (26), the surface treatment station (32) configured to treat the first surface or the second surface of each card.The card personalization system of claim 14 or 15, wherein each card further comprises a magnetic stripe and the card personalization system (10) further comprises a magnetic stripe programming mechanism.The card personalization system of any of claims 14 to 16, wherein the drop-on-demand printing station (26) is further configured such that the drop-on-demand printing station (26) includes a third card and a fourth card in sequence with the first card and the second card, wherein the second card is disposed between the first card and the third card and the third card is disposed between the second card and the fourth card, and wherein the third card is oriented such that its first surface faces upward and its second surface faces downward, and the fourth card is oriented such that its second surface faces upward and its first surface faces downward.

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