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 sequentially onto a card processing path (22); a card printing mechanism (16) disposed on the card processing path (22) downstream of the card feeding mechanism (12) and configured to contain two or more cards, the card printing mechanism (16) comprising: a drop-on-demand printing station (26) including at least one printhead configured to print personal information on the plurality of cards using drop-on-demand printing with a UV-curable ink; a UV curing station (34) located downstream of the drop-on-demand printing station (26); a card return movement path (28) having a transport mechanism 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), wherein the card is to be passed through the drop-on-demand printing station (26) again; and a mechanism (36) configured to transport the card from the card processing path (22) to the card return movement path (28), wherein a card requiring no further printing is transported through the mechanism (36) and out of the card printing mechanism (16); 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.

Description

Area

[0001] The disclosure relates to card processing systems that personalize or otherwise process plastic cards, such as financial cards, including credit and debit cards, identification cards, driver's licenses, gift cards, and other plastic cards. State of the art

[0002] Plastic cards, such as financial cards, including credit and debit cards, identification cards, driver's licenses, gift cards, and other plastic cards, can be personalized with personal information of the intended cardholder. Examples of personalization include, but are not limited to, names, addresses, photographs, account numbers, employee 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.

[0003] Card processing systems that personalize plastic cards are used by institutions that issue such personalized plastic cards. In some cases, card processing systems may be designed for relatively small, individual card personalization in relatively small quantities, such as tens or a few hundred per hour. In these mechanisms, a single document to be personalized is fed into a card processing system, which typically has one or two processing capabilities, such as printing and lamination. These processing machines are often referred to as desktop processing machines because of their relatively small footprint, designed to allow the machine to be placed on a desk.Many examples of desktop processing machines are known, such as the SD or CD family of desktop card printers available from Entrust Datacard Corporation, 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.

[0004] For high-volume production of personalized cards (e.g., on the order of many hundreds or thousands 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 issue processing machines available from Entrust Datacard Corporation, Shakopee, Minnesota. Other examples of central issue 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. Summary

[0005] Card processing mechanisms, systems, and methods are described by which, after a card has been processed on one surface thereof in a card processing station, such as, but not limited to, a card printing mechanism, the card can be recirculated upstream from the card processing station along a card return travel path separate from the primary card travel path through the card processing station, wherein the card can then be reinserted into the primary card travel path and transported through the card processing station a second time. While the card is being returned along the card return travel path, the card can be turned over so that when the card is transported back through the card processing station, the opposite surface of the card can be processed.

[0006] Processing, as used herein, is intended to encompass any processing operation on a card surface, including, but not limited to, printing, laminating, indenting, 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 printing with an ultraviolet (UV) curable ink, printing using a thermal dye transfer ribbon, laser marking using a laser, retransfer printing, and other card printing techniques.

[0007] 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., flippers) may be disposed on the card return path to realign the card into 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 so that the opposite side of the card can be processed during the second pass through the print station. The card return path may have any general shape as long as it serves to efficiently return cards to the print station for a second pass through the print 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 above or below the plane of the primary path.In systems that utilize 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 can eliminate the need for a second card printing mechanism, reducing system cost and footprint.

[0008] In one embodiment, a method for processing cards in a card processing system having a card printing mechanism with a printing station comprises: 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 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 including printing on a first side thereof that was previously applied to the first side thereof using the printing station. Additionally, after printing on the second side of the second card, printing on a second side of the first card is performed using the printing station.In a further embodiment, after printing on the first side of the first card and before printing on the second side of the first card, printing may be performed on a first side or a second side of a plurality of cards in addition to the second card using the printing station.

[0009] In one embodiment, the card processing station having the card return travel path is capable of processing 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.

[0010] In a further embodiment, the card processing system may be configured such that a card can move through the card processing system in a first orientation, for example, vertical relative to the floor. However, upon reaching a card processing station, for example, the card processing station with the card return travel path, the card can be rotated 90 degrees to a second orientation, for example, horizontal relative to the floor, for processing within the card processing station. After processing at the card processing station is complete, the card can be rotated back to the first orientation, if necessary, for further processing downstream of the card processing station.

[0011] The card processing mechanisms and methods described herein can be used in high-volume, high-volume, centrally-issued card processing systems, as well as in smaller-volume, desktop card processing systems. Drawings Fig. 1 schematically illustrates one embodiment of a card processing system that may employ the card printing mechanism described herein. Fig. Figure 2 illustrates an example of a sequence of cards advancing through the card printing mechanism described herein. Fig. 3 illustrates a sequence similar Fig. 2, but the cards were moved forward one position. Fig. 4 illustrates a sequence similar Fig. 3, but the cards were moved forward one position. Fig. Figure 5 is a perspective view of a portion of an example card printing mechanism showing mechanisms for rotating the cards from one orientation to the other. Detailed description

[0012] Fig. 1 illustrates one embodiment of a card processing system 10 configured to personalize or otherwise process plastic cards, such as financial cards, including credit and debit cards, identification cards, driver's licenses, gift cards, and other plastic cards. The personal information may also be referred to as variable data because the data varies from card to card. Examples of personalized information include, but are not limited to, names, addresses, photographs, account numbers, employee numbers, or the like. Non-personal or non-variable data, such as company 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 smart chip embedded in the card.

[0013] In the Fig. 1, the system 10 may include a card feeding 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. Fig. The card processing system 10 illustrated in Figure 1 is a high-volume, batch-production, or central-issue card processing system. However, the card printing mechanism 16 described herein may be used in other card processing systems, including low-volume, desktop card processing systems.

[0014] The mechanisms 14, 16, 18 may be arranged in any order in the system 10. Additionally, 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. Additionally, an additional card processing mechanism may be used with the mechanisms 14, 16, 18.

[0015] 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 quickly the mechanism 12 can feed cards sequentially into the processing path 22. In one embodiment, the first card rate may be up to approximately 3,000 cards per hour. The card feed mechanism 12 may include one or more card hoppers containing cards waiting to be fed sequentially onto the card processing path 22.

[0016] The card processing mechanism 16 is disposed on and along the card processing path 22 to receive cards. The card processing mechanism 16 is configured to perform a processing operation on each card. In one embodiment, the card 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 dye transfer ribbon, retransfer printing, laser marking using a laser, and other card printing techniques.

[0017] If, as described below in relation to Fig. 2 through 4, the card printing mechanism 16 is configured to perform printing, the processing mechanism 16 may be referred to as a card printing mechanism, comprising: a primary card travel path 24 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 upstream of the at least one printing station 26 after the card has been 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, the mechanism 16 may have a second card rate of up to approximately 6,000 cards per hour or more. The card rate of the card processing mechanism 16 refers to how quickly (i.e., the rate) the card processing mechanism 16 can perform its intended processing operation(s) on the cards.

[0018] With further reference to Fig. 1, in the illustrated example, 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 approximately 3,000 cards per hour. The card rate of the card processing mechanism 14 refers to how quickly (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, for example, to program a chip embedded in each card. The smart card programming mechanism may be configured to program one card at a time. 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 (disclosing an elevator-type smart card programming mechanism) and U.S. Patent 5,943,238 (disclosing a barrel-type smart card programming mechanism), the entire contents of each patent being incorporated herein by reference. Alternatively, the card processing mechanism 14 may 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 illustrated) 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 be located at other locations in the system 10 or may not be used, 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 located downstream of the card processing mechanism 16.

[0019] In the Fig. In the embodiment illustrated in Figure 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 located downstream of the card processing mechanism 14. The card processing mechanism 16 is configured to perform a processing operation on each card that is different from the card processing operation performed by the card processing mechanism 14.

[0020] The Fig. The embodiment illustrated in Figure 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 card processing mechanism 18 in the system 10 are possible. The card processing mechanism 18 is configured to perform a processing operation on each card that is 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 perform a laser marking on each card using a laser and / or apply a hologram overlay to each card, and / or perform other card processing operations. In one embodiment, the card processing mechanism 18 may have a card processing rate approximately equal to the first card rate.The card rate of the card processing mechanism 18 refers to how quickly (i.e., the rate) the card processing mechanism 18 can perform its intended processing operation(s) on the cards.

[0021] Cards that have been processed are collected in the card dispenser 20, which 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 mailing them to the intended recipients.

[0022] Many other card processing mechanisms can be used in addition to or instead of the Fig. 1 may be used. For example, an indentation mechanism that performs an indentation 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 disposed between the card dispenser 20 and the card processing mechanism 18. Many other processing mechanisms and combinations of processing mechanisms may be used.

[0023] With reference to Fig. 2 to 4, for convenience, the card processing mechanism 16 will now be described as a card printing mechanism configured to perform printing, particularly drop-on-demand printing with a UV-curable ink. Suitable drop-on-demand printing mechanisms that could be used are marketed under the trade name PERSOMASTER by Atlantic Zeiser GmbH, of Emmingen, Germany. Fig. Figures 2 through 4 illustrate a series of different cards 30 at various locations upstream of, downstream of, and within the mechanism 16. Each card 30 is numbered to aid in describing the sequencing of cards. Additionally, the letter "A" on a card 30 indicates one side of the card 30, while the letter "B" indicates the opposite side of the card 30.

[0024] The mechanism 16 includes at least one printing station 26 on the primary card movement path 24 that performs a printing operation on surface A or B of each card 30 on the primary card movement path 24. The printing station 26 may include a plurality of print heads 27 (in Fig. 5), some of which print a different color. Optionally, at least one of the printheads 27 may apply a spray coating to 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 print station 26. The 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 adheres better 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 print station 26. The UV curing station 34 is configured to apply a UV light to the card surface to cure the applied UV ink.

[0025] The card return path 28 intersects the primary card path 24 both downstream and upstream of the printing station 26. The card return path 28 is configured to divert or recirculate a card that has been fed through the printing station 26 from the primary card path 24 and return the card to the primary card path 24 at a location upstream of the printing station 26 so that the card can be fed through the printing station 26 again. Additionally, in some embodiments, while the card is being recirculated along the card return path 28, the card may be flipped 180 degrees so that the previously printed surface A or B is now facing down, and the non-printed surface A or B is facing up, ready to be printed.

[0026] The card return movement path 28 may have any configuration and location suitable for recirculating cards upstream of the print station 26 so that they can be passed through the print station 26 a second time, or even more than twice. The card return movement path 28 may have any general shape as long as it effectively serves to return cards to the primary card movement path 24 upstream of the print station for a second pass through the print station 26. In some embodiments, the card return movement path 28 may be substantially in the same plane as the primary card path 24. Alternatively, the card return movement path 28 may be disposed in a plane that is above or below the plane of the primary card movement path 24. Additionally, the card return movement path 28 may be substantially linear, or it may be curved.In addition, any mechanism(s) may be used for selectively recirculating the cards along the card return movement path 28 and, if necessary, for turning the cards 180 degrees.

[0027] For example, in the Fig. 2 to 4, the card movement path 28 includes a first portion 28a substantially perpendicular to the primary card movement path 24, a horizontal portion 28b substantially parallel to the primary card movement path 24, and a second portion 28c substantially perpendicular to the primary card movement path 24. The mechanism 16 may include a first mechanism 36 capable of transporting a card along the first portion 28a between the primary card movement path 24 and the horizontal portion 28b, thereby transferring a card from the movement path 24 to the horizontal portion 28b of the movement path 28. A card flipping device 38 may be provided along the horizontal portion 28b of the movement path 28, which flips a card 180 degrees. This is apparent from Fig. 2 to 3, where the card (6) is just inserted into the card turning device 38 with the side A facing upwards in Fig. 2 will occur, and in Fig. 3, the card (6) enters the card turning device 38, which turns the card (6) so that only its side B faces upward. A second mechanism 40 is also provided that can transport a card along the second section 28c between the primary card movement path 24 and the horizontal section 28b of the card return movement path 28, so as to bring a card from the horizontal section 28b to the movement path 24.

[0028] The mechanisms 36, 40 may have any design that can suitably transport the cards between the primary card movement path 24 and the portion 28a of the card return movement path 28. For example, as described below in Fig. 5, the mechanisms 36, 40 may be rotating mechanisms that rotate each card from the primary card movement path 24 to the portion 28a of the card return movement path 28 (in the case of mechanism 36) and from the portion 28a of the card return movement path 28 back to the primary card movement path 24 (in the case of mechanism 40).

[0029] In other embodiments, mechanisms 36, 40 may be elevator mechanisms that transport the cards between the card movement 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 flipping devices may be used to transport cards between the card movement paths. Examples of card flipping 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.

[0030] With reference to Fig. 2 illustrates a sequence of cards 30 as they pass through the mechanism 16 at any one time. This example is described using the optional surface treatment station 32. When the surface treatment station 32 is not used, a similar card sequencing can occur, but with one less card within the mechanism 16. Card (1) is shown ejected from the mechanism 16 with side B facing up. Card (7) is shown in position on the mechanism 36 with side A facing up, ready to be transported to section 28b of the card travel path 28. Card (6) is shown after being transported to section 28b of the travel path 28, with side A facing up, and ready to enter the turning device 38.Card (5) is shown in the turning device 38 and being turned from side A to side B so that side B is now facing up. Card (4) is shown with side B facing up and ready to be returned by mechanism 40 to the primary card travel path 24. Card (9) is shown with card side A facing up and having just entered mechanism 16. Card (3) is shown in surface treatment station 32 with card side B facing up after being recirculated back to travel path 24 so that side B can be treated before printing. Card (8) is shown in print station 26 with side A facing up for printing by print station 26 onto side A. The card (2) is shown in the UV curing station 34 with side B facing up after being printed, with the UV curable ink being UV cured in the station 34.The card (10) is shown with side A facing upwards, ready to enter the mechanism 16. The card (11) is shown with side A facing upwards, ready to assume the position of the card (10) after the card (10) enters the mechanism 16.

[0031] Fig. 3 shows the maps of Fig. 2, which is one step in an example of a possible sequencing of the cards in Fig. 2 have been moved forward. Card (1) has not been moved forward and is shown in the same position being dispensed from mechanism 16 with side B facing up. Card (7) with side A facing up has been transported by mechanism 36 to section 28b of card movement path 28. Card (6) has been advanced along card movement path section 28b into flipper 38 and flipped from side A to side B so that side B is now facing up. Card (5) with side B facing up has been advanced by flipper 38 into mechanism 40 ready to be transported back to primary card movement path 24. Card (4) with side B facing up has been transported back to primary card movement path 24 by mechanism 40.The card (9) with side A facing up was advanced into the surface treatment station 32 so that side A could be treated before printing. The card (3) with side B facing up was advanced into the printing station 26 for printing on side B. The card (8) with side A facing up was advanced into the UV curing station 34 after being printed, where the UV curable ink was UV cured in station 34. The card (2) with side B facing up was advanced into the elevator mechanism 36 and the position previously occupied by the card (7).

[0032] Fig. 4 shows the maps of Fig. 3, which shows a further step in an example of a possible sequencing of the cards of Fig. 3 were moved forward. In this example, card (1) is moved forward and card (2) is moved forward by mechanism 16 into the position previously occupied by card (1). Cards (7), (6) and (5) remain in their position. Card (8) is moved forward by UV curing station 34 into the position previously occupied by card (2). Card (3) is moved forward into UV curing station 34. Card (9) is moved forward into printing station 26 for printing on side A. Card (4) is moved forward into surface treatment station 32 so that side B can be treated before printing. Card (10) is moved forward into mechanism 16 into the position previously occupied by card (4), with side A facing up.In addition, card (11) is moved forward to the position previously occupied by card (10), and card (12) is moved forward to the position previously occupied by card (11).

[0033] Once a card reaches mechanism 36, if no further printing is required on the card, the card can be advanced through mechanism 36 and out of mechanism 16. As the card is advanced out of mechanism 16, a new card can be simultaneously transported into mechanism 16 via mechanism 40 to begin the process of printing on one surface of the new card. After one surface of the new card is printed, it can be recirculated upstream of print station 26 along card return travel path 28 and turned over so that the other side of the new card is facing up, allowing printing to occur on the other side of the new card.

[0034] If printing on both sides A and B of the card is not required, the card may be fed through the printing station 26 once and then ejected from the mechanism 16 without recirculating the card through the card return movement path 28.

[0035] A method for processing cards in the card processing system 10, which results from the example of the system 10 and the example of sequencing, which in Fig. 2 to 4, comprises printing on a first side (such as side A) of a first card, for example card 8, using the printing station 26. See Fig. 2. Next, a second side (such as side B) of a second card, for example card 3, is printed using the printing station 26. See Fig. 3. The second card, for example card 3, comprises printing on a first side (such as side A) thereof, which was previously applied to the first side thereof using the printing station 26. In other words, the second card, for example card 3, has previously been transported through the printing station 26, which has printed on side A, with the second card, for example card 3, ultimately being recirculated upstream of the printing station and ultimately being fed back through the printing station 26 to print on side B, as in Fig. 3. After printing on the second side of the second card, for example, card 3, the second side (such as side B) of the first card, for example, card 8, is additionally printed in the printing station 26 by ultimately recirculating the first card, such as card 8, upstream of the printing station and ultimately returning through the printing station 26 to print side B, using any implemented card sequencing.

[0036] As from Fig. 2 to 4, after printing on the first side of the first card, for example card 8, side A or side B of at least one additional card is printed before printing takes place on the second side of the first card, for example card 8. Printing on (an) additional card(s) takes place while the first card, for example card 8, is recirculated for printing on the second side thereof in the printing station 26. One additional card, two additional cards, three additional cards, four additional cards, five additional cards, or more than five additional cards can be printed while the first card, for example card 8, is recirculated for printing on the second side thereof.

[0037] In drop-on-demand printing, it is preferred that the card being printed in the print station 26 be oriented such that the card is substantially flat or horizontally oriented 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 substantially vertically oriented relative to the ground. Therefore, in such an embodiment, upon reaching the mechanism 16, the cards may need to be reoriented by rotating the cards 90 degrees, for example, from a vertical orientation to a horizontal orientation, and upon exiting the mechanism 16, the cards may need to be reoriented by rotating the cards 90 degrees, for example, from the horizontal orientation back to the vertical orientation.

[0038] Fig. Figure 5 shows a portion of an embodiment of the mechanism 16 configured to realign the cards by 90 degrees at both the entrance and exit of the mechanism 16. In this example, the cards enter the mechanism 16 in a vertical orientation. The mechanism 16 in Fig. 5 also has the primary card movement path 24, and the portion 28b of the card return movement path 28 is arranged adjacent to and in the same plane as the primary card movement path 24.

[0039] The cards may initially enter mechanism 16 into an optional roller mechanism 50. Mechanism 50 may rotate about a vertical axis AA. Mechanism 50 is useful for flipping cards about axis AA, if necessary, so that if side A of a card is facing forward upon entry into mechanism 16, mechanism 50 may flip the card so that side B is facing forward. If flipping a card is not required, the card may simply pass through mechanism 50 without being flipped about axis AA.

[0040] Each vertically aligned card is then fed into a first rotating mechanism 52. The rotating mechanism 52 is configured to receive each card and then rotate it in either direction about an axis substantially parallel to the primary card movement path 24 to rotate the card from its vertical orientation to a horizontal orientation aligned with the primary card movement path 24. The newly horizontal card can then be transported from the mechanism 52 and onto the primary card movement path 24. The mechanism 52 can rotate 90 degrees in either direction to bring the now horizontal card into alignment with the primary card movement path 24.The mechanism 52 is also configured to receive a card from the portion 28b of the card return movement path 28 and rotate 180 degrees along with the card about the axis substantially parallel to the primary card movement path 24 to return the card to the primary card movement path 24.

[0041] The now horizontal card is then moved past the print head(s) 27 of the print station 26 for printing on whatever surface faces upward toward the print head(s) 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 near the exit of the mechanism 16. The rotating mechanism 54 is configured to receive each card and then rotate in either 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 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 movement path 24 to the portion 28b of the card return movement path 28 while the card remains in its horizontal orientation. The card can then be transported along the portion 28b of the card movement path 28 to the flipper 38, which can flip the card (if necessary) so that the appropriate side is facing up. The card is then transported into the first rotating mechanism 52, which rotates to transport the card back to the primary card movement path 24.

[0042] An optional roller mechanism 56 may be provided adjacent the exit of mechanism 16. Mechanism 56 is similar in construction and operation to mechanism 50 in that mechanism 56 can rotate about a vertical axis AA. Mechanism 56 is useful for flipping cards about axis AA when necessary, so that if side A of a card is facing up as it is just exiting mechanism 16, mechanism 56 can flip the card so that side B is facing forward. If flipping a card is not required, the card can simply pass through mechanism 56 without being flipped about axis AA.

[0043] The techniques described here can be used for printing other than drop-on-demand printing. For example, in the case of thermal dye diffusion printing, if printing on both sides A and B of the card is required, the card can be recirculated back to the thermal dye diffusion printhead. In the case of thermal dye diffusion printing, stations 32, 34 would be Fig. 2 to 4 would not be required, and reorientation of the cards from vertical to horizontal and from horizontal back to vertical would not be necessary, thus eliminating the need for the rotating mechanisms 52, 54.

[0044] The cards can be transported along the primary card movement path 24 and the portion 28b of the card return movement 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 can be transported using rollers, belts, and combinations thereof.

[0045] Mechanisms 12, 14 and 18 have been described as having approximately equal card rates (e.g., up to approximately 300 cards per hour each), and mechanism 16 has been described as having a card rate (e.g., up to approximately 6000 cards per hour or even more) that is greater than the card rates of mechanisms 12, 14, 18. However, mechanisms 12, 14, 16 and 18 may have card rates that are approximately equal.

[0046] 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.

[0047] Aspects of the present disclosure include: Aspect 1. Card processing system, comprising: a card processing path; a card printing mechanism arranged along the card processing path, the card printing mechanism comprising: a primary card path along which cards can move in a downstream direction; at least one printing station on the primary card movement path that performs a printing operation on a surface of a card on the primary card movement 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 passed through the at least one printing station can be diverted 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 to be passed through the at least one printing station again. Aspect 2. The card processing system according to aspect 1, further comprising a card feeding mechanism that feeds cards to be processed onto the card processing path, the card feeding mechanism being arranged upstream of the card printing mechanism. Aspect 3. A card processing system according to any one of the preceding aspects, in particular according to aspect 1, further comprising a card processing mechanism arranged downstream of the card printing mechanism and receiving cards therefrom, and a card output arranged downstream of the card processing mechanism, into which processed cards are output. Aspect 4. A card processing system according to any one of the preceding aspects, in particular according to aspect 3, further comprising a card processing mechanism which is arranged upstream of the card printing mechanism and which outputs cards to the card printing mechanism. Aspect 5. The card processing system according to any one of the preceding aspects, in particular according to aspect 4, wherein the card processing mechanism arranged 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 arranged downstream of the card printing mechanism has the first card processing rate. Aspect 6. The card processing system according to any one of the preceding aspects, in particular according to aspect 3, wherein the card processing mechanism arranged 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 side of a first card in the card processing system using the print 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 print station. Aspect 8. A method according to any one of the preceding aspects, in particular according to aspect 7, wherein, after printing on the first side of the first card and before printing on the second side of the first card, printing on one of a first side or a second side of a plurality of cards in addition to the second card using the printing station. Aspect 9. A method according to any one of the preceding aspects, in particular according to 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. A method according to any one of the preceding aspects, in particular according to aspect 9, wherein, after printing on the first side of the first card and before printing on the second side of the first card, turning the first card 180 degrees while transporting the first card to the location upstream of the printing station. Aspect 11. 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; and a second card processing mechanism disposed along the card processing path, the second card processing mechanism processing cards at up to a second card rate that is greater than the first card rate. Aspect 12. A card processing system according to any one of the preceding aspects, in particular according to aspect 11, further comprising a third card processing mechanism arranged along the card processing path, the third card processing mechanism processing cards at up to the first card rate. Aspect 13. The card processing system according to any one 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 floor 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 floor and while within the second card processing mechanism; and where the first map orientation is 90 degrees relative to the second map orientation. Aspect 15. A map processing system according to any one of the preceding aspects, in particular according to aspect 14, wherein the first map orientation is vertical relative to the ground, and the second map orientation is horizontal relative to the ground. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] US 7,434,728

[0003] US 7,398,972 [0003, 0029] US 4,825,054

[0004] US 6,695,205

[0018] US 5,943,238

[0018] US 6,105,493

[0029] US 2013 / 0220984

[0029]

Claims

[1] Card personalization system (10), comprising: a card feeding mechanism (12) having at least one card magazine containing a plurality of cards to be fed sequentially onto a card processing path (22); a card printing mechanism (16) disposed on the card processing path (22) downstream of the card feeding mechanism (12) and configured to contain two or more cards, the card printing mechanism (16) comprising: a drop-on-demand printing station (26) including at least one printhead configured to print personal information on the plurality of cards using drop-on-demand printing with a UV-curable ink; a UV curing station (34) located downstream of the drop-on-demand printing station (26); a card return movement path (28) having a transport mechanism 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), wherein the card is to be passed through the drop-on-demand printing station (26) again; and a mechanism (36) configured to transport the card from the card processing path (22) to the card return movement path (28), wherein a card requiring no further printing is transported through the mechanism (36) and out of the card printing mechanism (16); 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. [2] The card personalization system (10) of claim 1, wherein the card return movement path (28) includes a turning device (38) for turning a card. [3] The card personalization system (10) of claim 1 or claim 2, wherein each card includes an integrated circuit chip, and wherein the card personalization system (10) further includes a smart card programming mechanism (14) configured to program the 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) upstream of the card printing mechanism (16). [4] 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 and a second surface; a card printing mechanism (16) disposed on the card processing path (22) downstream of the card feeding mechanism (12), the card printing mechanism (16) comprising: a drop-on-demand printing station (26) having at least one printhead configured to print personal information on the plurality of cards using drop-on-demand printing with a UV-curable ink; a UV curing station (34) located downstream of the drop-on-demand printing station (26); a card return movement path (28) having a transport mechanism configured to return a first card to a location on the card processing path (22) upstream of the drop-on-demand printing station (26) after the first card has been printed by the drop-on-demand printing station (26), wherein the first card is to be passed through the drop-on-demand printing station (26) again; a first mechanism (36) configured to transport the first card from the card processing path (22) to the card return movement path (28), wherein a card requiring no further printing is transported through the first mechanism (36) and out of the card printing mechanism (16); and a second mechanism (40) configured to transport the first card from the card return movement path (28) to the card processing path (22), wherein the first card is transported onto the card processing path (22) between a second card and a third card, wherein both the second card and the third card are oriented with their first surfaces facing upward and their second surfaces facing downward, and the first 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). [5] A card personalization system according to claim 4, wherein the card return movement path (28) comprises a turning device (38) for turning a card. [6] The card personalization system (10) of claim 4 or 5, wherein each card further comprises an integrated circuit chip, and wherein the card personalization system (10) further comprises a smart card programming mechanism (14) configured to program the 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 upstream of the card printing mechanism (16). [7] 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 and a second surface; a card printing mechanism (16) disposed on the card processing path (22) downstream of the card feeding mechanism (12), the card printing mechanism (16) comprising: a drop-on-demand printing station (26) having at least one printhead configured to print personal information on the plurality of cards using drop-on-demand printing with a UV-curable ink; a UV curing station (34) located downstream of the drop-on-demand printing station; a card return movement path (28) having a transport mechanism configured to return a first card to a location on the card processing path (22) upstream of the drop-on-demand printing station (26) after the first surface of the first card has been printed by the drop-on-demand printing station (26), wherein the first card is to be passed through the drop-on-demand printing station (26) again for printing the second surface, wherein the first surface of a second card is printed by the drop-on-demand printing station (26) before the second surface of the first card is printed by the drop-on-demand printing station (26), and wherein the card printing mechanism (16) is configured to contain the first card and the second card simultaneously in sequence with each other; 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). [8] The card personalization system (10) of claim 7, wherein the first card is returned to the card processing path (22) between the second card and a third card, the first card being oriented with its second surface facing up and its first surface facing down, the second card being oriented with its first surface facing up and its second surface facing down, and the third card being oriented with its first surface facing up and its second surface facing down. [9] Card personalization system (10) according to claim 7 or 8, further comprising: a first mechanism (36) configured to transport the first card from the card processing path (22) to the card return movement path (28), wherein a card requiring no further printing is transported through the first mechanism and out of the card printing mechanism; and a second mechanism (40) configured to transport the first card from the card return movement path (28) to the card processing path (22). [10] The card personalization system (10) of any one of claims 7 to 9, wherein each card further comprises an integrated circuit chip, and wherein the card personalization system (10) further comprises a smart card programming mechanism (14) configured to program the 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).

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