U.S. patent application number 11/431170 was filed with the patent office on 2006-09-14 for identification card printer ribbon cartridge.
This patent application is currently assigned to Fargo Electronics, Inc.. Invention is credited to Gary P. JR. Countryman, Matthew K. Dunham, Leon Gershenovich, Chadwick M. Johnson, Gary M. Klinefelter, Gary A. Lenz, Stacy W. Lukaskawcez, James R. Meier, Ryan G. Park, Thomas C. Platner, Jeffrey D. Upin.
Application Number | 20060204308 11/431170 |
Document ID | / |
Family ID | 33162213 |
Filed Date | 2006-09-14 |
United States Patent
Application |
20060204308 |
Kind Code |
A1 |
Meier; James R. ; et
al. |
September 14, 2006 |
Identification card printer ribbon cartridge
Abstract
A ribbon cartridge includes a cartridge housing, a supply spool,
a take-up spool, a supply of ribbon, and a supply circuit. The
cartridge housing includes a supply spool enclosure and a take-up
spool enclosure. The supply spool is contained in the supply spool
enclosure and the take-up spool is contained in the take-up spool
enclosure. The supply of ribbon extends from the supply spool to
the take-up spool. The supply circuit includes a memory containing
supply information relating to the ribbon cartridge.
Inventors: |
Meier; James R.; (St. Paul,
MN) ; Johnson; Chadwick M.; (Savage, MN) ;
Countryman; Gary P. JR.; (Columbia Heights, MN) ;
Lukaskawcez; Stacy W.; (Shakopee, MN) ; Klinefelter;
Gary M.; (Eden Prairie, MN) ; Park; Ryan G.;
(Farmington, MN) ; Dunham; Matthew K.; (Eagan,
MN) ; Upin; Jeffrey D.; (Edina, MN) ; Lenz;
Gary A.; (Eden Prairie, MN) ; Gershenovich; Leon;
(Eden Prairie, MN) ; Platner; Thomas C.; (Eden
Prairie, MN) |
Correspondence
Address: |
WESTMAN CHAMPLIN & KELLY, P.A.
SUITE 1400
900 SECOND AVENUE SOUTH
MINNEAPOLIS
MN
55402-3319
US
|
Assignee: |
Fargo Electronics, Inc.
Eden Prairie
MN
|
Family ID: |
33162213 |
Appl. No.: |
11/431170 |
Filed: |
May 10, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10647666 |
Aug 25, 2003 |
|
|
|
11431170 |
May 10, 2006 |
|
|
|
60459712 |
Apr 2, 2003 |
|
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|
60497009 |
Aug 19, 2003 |
|
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|
Current U.S.
Class: |
400/208 |
Current CPC
Class: |
B41J 17/12 20130101;
B65H 1/04 20130101; B41J 35/36 20130101; B41J 2/355 20130101; B41J
11/009 20130101; B41J 2/17546 20130101; B65H 2405/31 20130101; G06Q
20/203 20130101; B41J 13/12 20130101; B41J 17/36 20130101; B65H
2701/1914 20130101; B41J 13/103 20130101; B41J 11/0015
20130101 |
Class at
Publication: |
400/208 |
International
Class: |
B41J 35/28 20060101
B41J035/28 |
Claims
1. A ribbon cartridge for use in a card printer comprising: a
cartridge housing including a supply spool enclosure and a take-up
spool enclosure; a supply spool contained in the supply spool
enclosure; a take-up spool contained in the take-up spool
enclosure; a supply of ribbon that extends from the supply spool to
the take-up spool; and a supply circuit having a memory containing
supply information relating to the ribbon cartridge.
2. The ribbon cartridge of claim 1 further comprising a pair of
ribbon guides and a gap between the ribbon guides, wherein the
supply of ribbon extends across the ribbon guides.
3. The ribbon cartridge of claim 2, wherein the gap is defined by
interior side walls of the spool and take-up enclosures, wherein
the ribbon guides are formed by exposed top surfaces of the
interior side walls.
4. The ribbon cartridge of claim 1, wherein the supply information
includes a security code.
5. The ribbon cartridge of claim 1, further comprising a card
cleaner roller having a debris-collecting surface received by the
housing.
6. The ribbon cartridge of claim 1, including a rotation inhibitor
having a tab member extending from the housing and configured to
engage one of the supply spool and the take-up spool and provide
frictional resistance to rotation thereof.
7. The ribbon cartridge of claim 1, wherein the supply circuit is
mounted to the cartridge housing.
8. The ribbon cartridge of claim 1, wherein the supply circuit is
mounted to the supply spool or the take-up spool.
9. The ribbon cartridge of claim 1, wherein the supply information
includes a number of prints remaining.
10. The ribbon cartridge of claim 1, wherein the memory of the
supply circuit includes a memory bank, the memory bank having a
limit as to a number of times data can be written thereto.
11. The ribbon cartridge of claim 1, wherein: one of the supply and
take-up spools includes a core and a ribbon guide that extends
substantially perpendicularly from the core; and the supply circuit
is mounted to the ribbon guide and includes an opening through
which the core extends.
12. A ribbon cartridge for use in a card printer comprising: a
cartridge housing including a supply spool enclosure and a take-up
spool enclosure; a supply spool contained in the supply spool
enclosure; a take-up spool contained in the take-up spool
enclosure; and a card cleaner roller rotatably supported by the
housing and having a debris-collecting surface.
13. The ribbon cartridge of claim 12, wherein: the housing further
comprises front and rear walls; and the card cleaner roller
includes front and rear ends that are each respectively received in
an aperture of the front and rear walls of the housing.
14. The ribbon cartridge of claim 13, wherein the apertures are
shaped to allow the cleaner roller to move between a receiving
position and a cleaning position.
15. The ribbon cartridge of claim 12, wherein: the supply and
take-up spool enclosures each have an interior side wall separated
from each other by a gap, and a plate connecting the interior side
walls; and the cartridge further comprises print ribbon having a
first end wound on supply spool, a second end wound on the take-up
spool, and a middle portion extending between the supply and
take-up spools and across the interior side walls.
16. The ribbon cartridge of claim 12, further comprising a supply
circuit mounted to one of the supply spool, the take-up spool and
the housing, the supply circuit including a memory containing
supply information relating to the supply.
17. The ribbon cartridge of claim 16, wherein the supply
information includes a security code.
18. The ribbon cartridge of claim 16, wherein the supply
information includes a number of prints remaining.
19. A ribbon cartridge for use in a card printer comprising: a
cartridge housing including a supply spool enclosure, a take-up
spool enclosure, a pair of ribbon guides, and a gap between the
ribbon guides and between the supply and take-up spool enclosures;
a supply spool contained in the supply spool enclosure; a take-up
spool contained in the take-up spool enclosure; a supply of ribbon
that extends from the supply spool, across the ribbon guides and
the gap, and to the take-up spool; a card cleaner roller rotatably
supported by the housing and having a debris-collecting surface;
and a supply circuit having a memory containing supply information
relating to the ribbon cartridge.
20. The ribbon cartridge of claim 19, wherein the supply
information includes a number of prints remaining for the
cartridge.
Description
[0001] The present application is a Continuation of U.S. patent
application Ser. No. 10/647,666, filed Aug. 25, 2003, entitled
"IDENTIFICATION CARD PRINTER AND RIBBON CARTRIDGE, which claims the
benefit of Provisional Patent Application Ser. No. 60/459,712,
filed Apr. 2, 2003 and claims the benefit of U.S. Provisional
Patent Application Ser. No. 60/497,009, filed Aug. 19, 2003.
FIELD OF THE INVENTION
[0002] The present invention generally relates to identification
card printers, and more particularly, to a ribbon cartridge for use
in identification card printers.
BACKGROUND OF THE INVENTION
[0003] Identification cards are widely used to carry information
typically relating to the card holder. Identification card printing
systems are used to form identification cards by printing an image,
which can contain textual and graphical information, on a card
substrate, such as a plastic card.
[0004] Many identification card printing systems, such as those
produced by Fargo Electronics, Inc. of Eden Prairie, Minn., are
thermal based printing systems. Such systems print images on card
substrates using a thermal printhead and a thermal print ribbon
that is held taut between the printhead and the card substrate. The
thermal print ribbon or dye sublimation ribbon is typically divided
up into different color frames or panels along its length. The
frames or panels repeat in a sequence or group consisting of a
yellow panel, followed by a magenta panel, which is followed by a
cyan panel. In addition, a black resin frame or panel can be
provided in the sequence of the color panels, if desired. The
thermal printhead includes a plurality of resistive heating
elements that are selectively energized to individually heat the
panels of the thermal print ribbon and cause print material from
the selected panels to transfer to the card substrate and form the
desired image.
[0005] The thermal print ribbon can be supported in a ribbon
cartridge to simplify the loading of the ribbon in the printer. The
ribbon cartridge generally incudes a supply spool on which a first
end of the ribbon is wound and a take-up spool on which a second
end of the ribbon is wound. A middle portion of the ribbon extends
between the supply and take-up spools. The printer controls the
feeding of the ribbon over the printhead from the supply spool to
the take-up spool.
[0006] There is a never-ending demand for improvements to ribbon
cartridges for use in identification card printers, including
forming the ribbon cartridge such that it allows the card printer
to be formed more compactly, providing roller cleaning features,
and other desirable features.
SUMMARY OF THE INVENTION
[0007] The present invention is generally directed to a ribbon
cartridge for use in an identification card printer. One embodiment
of the ribbon cartridge includes a cartridge housing, a supply
spool, a take-up spool, a supply of ribbon, and a supply circuit.
The cartridge housing includes a supply spool enclosure and a
take-up spool enclosure. The supply spool is contained in the
supply spool enclosure and the take-up spool is contained in the
take-up spool enclosure. The supply of ribbon extends from the
supply spool to the take-up spool. The supply circuit includes a
memory containing supply information relating to the ribbon
cartridge.
[0008] These and other features will become apparent with a careful
review of the drawings and the corresponding detailed
description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of an identification card
printer in accordance with various embodiments of the
invention.
[0010] FIG. 2 is a schematic diagram of a printer in accordance
with various embodiments of the invention.
[0011] FIG. 3 is a schematic diagram of an identification card
printer in accordance with various embodiments of the invention
with selected components illustrated in cross-section.
[0012] FIG. 4 is a perspective exploded view of an identification
card printer and a ribbon cartridge, in accordance with various
embodiments of the invention.
[0013] FIG. 5 is a cross-sectional view of the printer of claim 4
taken generally along line 5-5.
[0014] FIGS. 6 and 7 are exploded and assembled views of a bushing
and a side wall of an identification card printer, in accordance
with various embodiments of the invention.
[0015] FIGS. 8 and 9 are top and side schematic views,
respectively, of a printhead, a thermal print ribbon and ribbon
sensors, in accordance with various embodiments of the
invention.
[0016] FIG. 10 is a front plan view of an identification card
printer with an open front cover, in accordance with various
embodiments of the invention.
[0017] FIGS. 11 and 12 are schematic diagrams respectively
illustrating misalignment and alignment between active print
elements of a printhead and a card.
[0018] FIG. 13 is an exploded perspective view of a ribbon
cartridge in accordance with various embodiments of the
invention.
[0019] FIG. 14 is a perspective view of a cartridge housing in
accordance with various embodiments of the invention.
[0020] FIG. 15 is a cross-sectional view of the cartridge housing
of FIG. 14 taken generally along line 15-15.
[0021] FIG. 16 is a rear perspective view of a ribbon cartridge
with a cleaner roller exploded therefrom, in accordance with
embodiments of the invention.
[0022] FIG. 17 is a rear perspective view of a ribbon cartridge and
an actuating member in accordance with various embodiments of the
invention.
[0023] FIGS. 18 and 19 are exploded and assembled views of a ribbon
spool and supply circuit, respectively, in accordance with various
embodiments of the invention.
[0024] FIG. 20 is a flowchart illustrating a method of operating an
identification card manufacturing device with a ribbon supply in
accordance with various embodiments of the invention.
[0025] FIG. 21 is schematic diagram of an identification card
printer in accordance with the prior art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] An identification card printer 100, with which the ribbon
cartridge of the present invention can be used, is shown in FIG. 1.
As will be discussed in greater detail below, the ribbon cartridge
can operate with an inverted printhead of printer 100 whose
resistive heating elements or print elements face upward. This
configuration allows printer 100 to be formed more compactly than
conventional identification card printers that utilize printheads
that are vertically oriented with the print elements facing
downward, as illustrated in FIG. 21. In such a conventional card
printer 600, cards 602 are fed along a print path 604 below the
print elements 606 of the printhead 608. Thermal print 611 ribbon
is fed between the print elements 606 and a top surface 612 of card
602, on which an image is to be printed by the printhead 608. A
card supply 614 can be provided at a card input 616 where a bottom
card 618 from a stack of cards 620 is fed along print path 604. A
card hopper 622 can be positioned opposite the card input 616 to
collect processed cards 602. Due to the relatively flat print path
604, a base 624 of card hopper 622 must be positioned well below
print path 604 in order to collect stack of cards 620. Due to the
orientation of printhead 608 above print path 604 and the location
of card hopper 622 below print path 604, such conventional
identification card printers 600 must be formed relatively tall
compared to printer 100 of the present invention.
[0027] A general description of identification card printer 100 in
accordance with embodiments of the present invention will be
initially provided with reference to FIGS. 2 and 3. FIG. 2 is a
schematic diagram of printer 100 and FIG. 3 is a simplified front
view of printer 100 with selected components depicted in
cross-section. In general, printer 100 includes a card input 102, a
card transport 104, a printhead 106, and a card output 108. Cards
110 are received by card transport 104 at card input 102. Card
transport 104 feeds cards 110 individually along a print path 112.
Print path 112 is preferably substantially flat between card input
102 and card output 108 to avoid substantially bending the rigid or
semi-rigid card substrates 110 that could damage cards 110.
[0028] Card transport 104 includes card feed rollers 114 that are
driven by a motor 116 through gear and pulley arrangements. It
should be understood that separate motors can be used in different
stages of card delivery through printer 100. For example, one motor
116 can be used to drive the feeding of card 110 through input 102,
and another motor 116 can be used to drive the feeding of card 110
thereafter through printer 100. Card feed rollers 114 drive card
110 along print path 112. Card support plates or rails (not shown)
can also be used to provide support to card 110 during transport
along print path 112 by card transport 104.
[0029] Printhead 106 is positioned below print path 112 and
includes upwardly facing print elements 118. A supply of thermal
print ribbon 120 extends between a supply spool 122 and a take-up
spool 124, across a gap 126, in which printhead 106 is positioned,
and over print elements 118. Supply and take-up spools 122 and 124
are preferably positioned adjacent opposite sides of printhead 106
and below print path 112. As will be discussed in greater detail
below, print ribbon 120 can be contained in a removable ribbon
cartridge 130 illustrated in partial cross-section in FIG. 3.
[0030] During a printing operation, card 110 is fed by card
transport 104 between print ribbon 120 and a platen 132. Pressure
is applied to print ribbon 120 and a bottom-facing print surface
134 of card 110 by platen 132 and printhead 106. Print elements 118
are selectively energized to heat portions of print ribbon 120 in
contact therewith to cause print material or dye from print ribbon
120 to transfer to surface 134 of card 110 to form the desired
image thereon. The printed card 110 can then be discharged through
card output 108.
[0031] Printer 100 includes a controller 140 that is configured to
control the operations of printer 100 including one or more motors
116 driving card feed rollers 114 of card transport 104, one or
more motors 142 controlling feeding of print ribbon 120 between
supply and take-up spools 122 and 124, the selective energization
of print elements 118 of printhead 106, and other components of
printer 100, in response to a print job provided by a card
producing application 144. It should be understood that motors 116
and 142 of FIG. 2 provide a simplified illustration of the means by
which card transport 104 and supply and take-up rolls 122 and 124
are driven. Fewer or additional motors can be used as desired.
Additionally, motors 116 and 142 can operate to drive different
components than those depicted in FIG. 2. For example, motor 142
can be configured to drive take-up roll 124 rather than supply roll
122.
[0032] Card producing application 144 can run on a computer 146, or
be contained in printer memory 148 for execution by controller 140.
The print job typically includes card processing instructions, such
as print instructions, data writing instructions, data reading
instructions, and other card processing instructions in accordance
with normal methods.
[0033] Additional instructions and input signals can be provided to
controller 140 from input 150 (FIG. 2), which can be input controls
152 in the form of buttons 154 or 156 (FIG. 1) or other input
device. Controller 140 can also provide information to a user on a
display 158 of control panel 156.
[0034] Firmware 160 for printer 100 is preferably stored in memory
148 of printer 100, such as flash memory, and is executed by
controller 140 to operate printer 100. Firmware 160 can be upgraded
periodically with revised versions. In accordance with one
embodiment of the invention, encrypted firmware upgrades are
downloaded into memory 148 of printer 100 through, for example,
computer 146. A loader program 162 stored in memory 148 of printer
100, such as flash memory, is configured to decrypt the encrypted
firmware upgrade and load the decrypted firmware upgrade into
memory 148 of printer 100 to complete the upgrade of firmware
160.
[0035] Individual cards 110 can be provided to card input 102 in a
stack 164 of cards 110 that is contained in a card hopper 166,
embodiments of which are depicted in FIGS. 3-5. FIG. 4 is a
perspective view of printer 100 including hopper 166, and FIG. 5 is
a cross-sectional view of hopper 166 generally taken along line 5-5
of FIG. 4, but with the addition of card stack 164. Cards 110 of
card stack 164 are oriented with surface 134, on which an image is
to be printed, facing downward. Unlike conventional printers that
stack cards with the print surface facing upward, the orientation
of cards 110 of card stack 164 of the present invention assists in
preventing dust from accumulating on print surface 134 over time.
This results in a cleaner print surface 134, which enhances the
quality of the image that can be printed thereon. Additional dust
protection for card stack 164 can be provided by a cover 168, shown
open in FIG. 4.
[0036] Stack of cards 164 is supported by a base member 170 of
hopper 166 that connects to a rod 172 through an arm 174. Arm 174
includes a cylindrical portion 176 through which rod 172 extends.
Cylindrical portion 176 is configured to slide along rod 172 to
allow base member 170 to move up and down relative to card input
102.
[0037] A biasing mechanism 178, depicted as a coil spring, applies
an upwardly directed force to the base member, which in turn
applies the force to card stack 164. Biasing mechanism 178 directs
a top card 180 of card stack 164 against a card feed roller 182 of
card transport 104 at card input 102, as shown in FIG. 3. Top card
180 can then be fed by card transport 104 from card input 102 and
along print path 112.
[0038] Additional biasing mechanism can be provided to ensure
proper contact with card feed roller 182 of card transport 104. For
example, base member 170 can include a leaf spring 184, or other
suitable spring or biasing mechanism, that is configured to apply
an additional force to a front portion 186 of card stack 164. This
causes front portion 186 of card stack 164 to lift slightly from
base member 170, which assists in the feeding of top card 180
through card input 102 by card transport 104.
[0039] In accordance with one embodiment of the invention, base
member 170 can be temporarily latched in a loading position by
pushing down on lever 187 (FIG. 4), which is connected to base
member 170 and arm 174, to lower base member against the bottom 188
(FIG. 5) of hopper 166. A suitable latching mechanism temporarily
holds base 170 in the loading position. The latching mechanism
preferably automatically releases base member 170 from the loading
position when cover 186 (FIG. 4) is closed due to actuation of the
latching mechanism by, for example, latch 189 of cover 186. Biasing
mechanism 178 then moves base member to the card feeding position
shown in FIG. 5.
[0040] As mentioned above, card transport 104 preferably includes a
plurality of feed or drive rollers 114 that are configured to
transport top card 180 along print path 112. Feed rollers 114
generally include a shaft 190 that extends through a larger
diameter card gripping member 192 and is supported by side walls of
printer 100, as shown in FIG. 5. In accordance with one embodiment
of the invention, card feed rollers 114 are mounted to a side wall
194 of printer 100 by a twist-lock bushing 196, as shown in FIGS. 3
and 5. A perspective exploded view of bushing 196 displaced from
side wall 194 is provided in FIG. 6 and a perspective view of
bushing 196 attached to side wall 194 is provided in FIG. 7. Side
wall 194 includes a large opening 198 through which shafts 190 of
feed rollers 114 of card transport 104 can extend. In accordance
with one embodiment of the invention, card gripping member 192 is
capable of extending through opening 198 of side wall 194. This
feature simplifies assembly of printer 100 by allowing card feed
rollers 114 to be installed through a single side wall 194 rather
than having to extend each end of shaft 190 through the side walls
of the printer from within the interior of the printer.
[0041] Once feed roller 114 is in position with shaft 190 extending
through opening 198 of side wall 194, an end 200 of shaft 190 is
received by central bore 202 of bushing 196. Bushing 196 is then
secured to side wall 194 to complete the mounting of end 200 of
feed roller 114 to side wall 194.
[0042] In accordance with one embodiment of the invention, bushing
196 includes tab members 204 that extend from cylindrical portion
206. Two of the preferably at least three tab members 204 are
configured to be received in slots 208 and 210 adjacent opening 198
in side wall 194, while the third tab member 204 is allowed to fall
within opening 198 in side wall 194. In accordance with one
embodiment of the invention, tab members 204 have different sizes
and/or shapes such that each can only be inserted into one of the
corresponding slots 208 and 210 to ensure proper orientation of
bushing 196 during installation. Once tab members 204 are inserted
in slots 208 and 210, a shoulder 212 of bushing 196 engages outside
surface 214 of side wall 194 and prevents further insertion of
cylindrical portion 206 through side wall 194. Bushing 196 can be
locked into place on side wall 194 by twisting or rotating bushing
196 about an axis that is concentric to central bore 202, which
causes side wall 194 to be pinched between shoulder 212 and tab
members 204.
[0043] Bushing 196 can also include an arm 216 that includes a
protrusion 218 that is received by an aperture 220 in side wall 194
when bushing 196 is properly oriented to side wall 194. In addition
to providing an alignment feature, arm 216 and protrusion 218 also
operate to further lock bushing 196 in the desired position
relative to side wall 194.
[0044] As mentioned above, thermal print ribbons 120 are typically
divided up into different color frames or panels along its length.
The frames or panels repeat in a sequence or group consisting of a
yellow panel, followed by a magenta panel, which is followed by a
cyan panel. In addition, a black resin frame or panel can be
provided in sequence of the color panels, if desired. Printhead 106
selectively prints image lines to surface 134 of card 110 from the
panels of ribbon 120 to form color images on card 110 in a
conventional manner under control of controller 140.
[0045] One embodiment of printer 100 includes a ribbon sensor 222,
shown in FIGS. 2 and 3, that is positioned adjacent print ribbon
120 and is configured to detect the ribbon panels. Ribbon sensor
222 is preferably positioned adjacent printhead 106 within gap 126
and includes an emitter 224 and a receiver 226 that are positioned
on opposite sides of print ribbon 120, as shown in FIG. 3 and in
the top and side schematic views of FIGS. 8 and 9, respectively. In
accordance with one embodiment of the invention, a component of
ribbon sensor 222, such as emitter 224, is mounted to printhead
106, as shown in FIG. 3. Alternatively, receiver 226 can be mounted
to printhead 106. This positioning of ribbon sensor 222 in close
proximity to printhead 106 assists in providing accurate
positioning of individual panels of ribbon 120 relative to
printhead 106, which allows for efficient use of the ribbon
120.
[0046] Emitter 224 preferably includes a light emitting diode
(LED). Light produced by the LED passing through print ribbon 120
is detected by receiver 126. A signal from receiver 126 in response
to the detected light, indicates the color of the panel through
which the light has passed. The signal is provided to controller
140, as indicated by line 228 of FIG. 2. Controller 140 controls
the feeding of print ribbon 120 through control of bi-directional
motor 142 in response to the signal 228 to align the desired panel
with printhead 106. In accordance with one embodiment of the
invention, the LED of emitter 224 emits blue light having a
wavelength of approximately 470 nanometers (nm), which has proved
to provide the widest dispersion of the resultant signal from
receiver 226 between the different panels of ribbon 120 for
accurate panel detection.
[0047] In accordance with another embodiment of the invention,
printer 100 includes a plurality of ribbon sensors 222, such as
sensors 222A and 222B illustrated in FIGS. 8 and 9. Sensor 222A can
include an emitter 224A and a receiver 226A, and sensor 222B can
include an emitter 224B and a receiver 226B, which operate as
described above. Alternatively, sensor 222B can include only a
receiver 226B (i.e. without emitter 224B shown in phantom lines)
that is positioned in close proximity to emitter 224A, such that it
can utilize the light emitting from emitter 222A to provide the
desired panel detection.
[0048] Sensors 222A and 222B are preferably positioned to allow for
detection of a location of a transition 230 between separate panels
232 and 234 of ribbon 120. For example, sensors 222A and 222B are
preferably positioned such that when sensor 222A detects panel 232
of one color and sensor 222B detects panel 234 of another color, it
is known that transition 230 is positioned immediately between
sensors 222A and 222B. If necessary, controller 140 can feed ribbon
120 in either a forward or backward direction to detect the
location of transition 230 using sensors 222A and 222B. Once the
position of transition 230 is determined, controller 140 can align
printhead 106 as desired relative to a particular panel of ribbon
120. This allows printer 100 to utilize the entire ribbon panel,
which reduces waste and extends the life of ribbon 120. This is
particularly useful when printer 100 is powered on, which allows
printer 100 to locate the transition 230 and position the panels of
ribbon 120 relative to printhead 106 as desired.
[0049] Printer 100 can also include a card sensor 240 that is
positioned adjacent print path 112, as shown in FIG. 2. Card sensor
240 is configured to detect the feeding of a card 110 by card
transport 104 along print path 112. Card sensor 240 includes an
output signal represented by arrow 242, which is provided to
controller 140. Controller 140 uses signal 242 to position card 110
as desired using card transport 104 relative to printhead 106 and
other components of printer 100.
[0050] Printer 100 can also include internal and/or external
expansion modules 244 and 246, respectively, as illustrated
schematically in FIG. 3. Internal expansion module 244 is
positioned in line with print path 112 between printhead 106 and
card output 108 or between printhead 106 and card input 102.
Internal expansion module 244 can be received in an expansion
module bay 248 of a housing 250 of printer 100, shown in the front
plan view of FIG. 10.
[0051] External expansion module 246 preferably attaches to an end
252 of printer 100 adjacent card output 108. External expansion
module 246 includes a card receiver 254 in card hand-off alignment
with card output 108.
[0052] Each expansion module 244 and 246 generally includes a card
processing component 256, as illustrated in external expansion
module 246 of FIG. 3. Card processing component 256 provides
additional card processing functions for printer 100. Card
processing component 256 can be, for example, a data encoder
configured to write data to a memory chip embedded in card 110, a
magnetic stripe reader configured to read data on a magnetic stripe
of card 110, a magnetic stripe writer configured to write data to a
magnetic stripe of card 110, a card flipper configured to flip card
110 to allow for processing of both sides of card 110, a card
laminator configured to apply an overlaminate material to the
surface of card 110, or other card processing component. Card
processing component 256 can be controlled by controller 140 or by
a separate controller of the expansion module.
[0053] Printer 100 can also include an output hopper 260 at end
252, as shown in FIG. 3. A removable cover 261 can substantially
enclose output hopper 260 as shown in FIG. 10. Output hopper 260 is
generally positioned below card output 108 and is configured to
collect cards 110 discharged therethrough. One advantage of the
present invention is that the collection of cards 110 in output
hopper 260 is in the form of first-in-first-out order. In other
words, each card 110 is preferably collected in output hopper 260
with the print surface 134 on which an image was printed by
printhead 106 facing downward. As a result, bottom card 264 in the
stack 262 of cards 110, which was the first card 110 processed by
printer 100, will be the top card in the stack 262 having its print
surface 134 facing upward when the stack 262 is removed from output
hopper 260 and turned over. As a result, the cards 110 in the stack
262 are presented to the user in first-in-first-out order. This is
preferred over the last-in-last-out order of conventional card
printers, such as printer 600 shown in FIG. 21, where the printed
surface 612 of the first card processed by printer 600 is located
at the bottom of stack of cards 626 collected in hopper 622 with
the printed surface 612 facing upward. As a result, the
last-in-last-out card stack 626 must be reorganized to place the
cards 602 in first-in-first-out order with the print surface 612 of
the first processed card 602 in view or facing upward.
[0054] The print job provided by application 144 generally includes
print image data that provides instructions for controlling
printhead 106 through controller 140 to print the image on surface
134 of card 110. The instructions determine which print elements
118 of printhead 106 are active during the printing process. For
proper printing of the image on surface 134 of card 110, the active
print elements 118 of printhead 106 that are to be energized to
print the image must extend across a width of the card 110. If they
do not, the printed image will generally not be properly aligned
with surface 134 of card 110. Additionally, it will not be possible
to provide full edge-to-edge printing of the image over surface 134
of card 110.
[0055] Typically, each printer 100 must be factory tested to ensure
that print elements 118 and card 110 are properly aligned during
printing operations. If they are misaligned, a mechanical
adjustment to the position of printhead 106 relative to card 110 is
typically required. This may involve moving the position of
printhead 106, or adjusting card transport 104 to change the
position of card 110 at printhead 106.
[0056] The present invention provides a method of aligning print
elements 118 of printhead 106 with card 110 without mechanical
adjustment to printer 100, as shown in FIG. 2. Instead, an offset
value 270 is determined and stored in memory 148 (e.g., flash
memory) of printer 100, shown in FIG. 2. Offset value 270 provides
an adjustment to print elements 118 of printhead 106 that will be
set as active and thus, be energized during print operations to
print the image to surface 134 of card 110. FIG. 11 is a simplified
top view of print elements 118 of printhead 106 relative to a card
110 (shown in phantom). The initially active print elements 118 are
represented by shaded boxes 272, whereas the non-shaded boxes 274
represent non-active print elements 118. Accordingly, FIG. 11
illustrates a misalignment between active print elements 272 and
card 110 of approximately four print elements 118. Accordingly, an
offset value 270 of minus four would be set for the example of FIG.
11 to shift the active print elements 272 to the left by four print
elements 118 resulting in the alignment of active print elements
272 with card 110, as illustrated in FIG. 12. Accordingly, offset
value 270 adjusts the print elements 118 that are used by printhead
106 to process a print job such that the active print elements 118
are properly aligned with card 110 to ensure full edge-to-edge
printing capability and proper alignment of the printed image and
card 110.
[0057] During a print operation, the print job is received from the
card processing application 144, from which print image data is
generated that designates the active print elements 272. Next,
offset value 270 is received from printer 100. Offset value 270 is
then used to designate a modified set of active print elements 118,
such as elements 272 shown in FIG. 12. Finally, the modified set of
active print elements 118 are used to process the print job
resulting in printing of the image represented by the print job in
proper alignment with surface 134 of card 110 due to the proper
alignment between active print elements 118 of printhead 106 and
card 110.
[0058] In accordance with another embodiment of the invention, the
original active print elements 118 designated by the print image
data generated from the print job, such as elements 272 shown in
FIG. 11, are initially left unmodified. Next, offset valued 270 is
received from printer 100 immediately prior to processing the print
job from application 144 with printer 100. Finally, the print image
data is re-generated to designate the modified set of active print
elements 118 (elements 270 of FIG. 12) of printhead 106 that are
offset from the original set of active print elements by the offset
value 270.
[0059] As mentioned above, print ribbon 120 can be contained in a
removable ribbon cartridge 130 (FIG. 4) that contains the supply
and take-up spools 122 and 124. Ribbon cartridge 130 is received in
a cartridge receiver 280 of printer housing 250, as shown in FIGS.
4 and 10. Cartridge receiver 280 is preferably accessed through a
front face 282 of housing 250 to provide front-loading of cartridge
130 in printer 100. A front cover 284 of housing 250 can cover
cartridge receiver 280, as shown in FIGS. 1 and 4.
[0060] FIGS. 13-17 provide various views of ribbon cartridge 130.
Ribbon cartridge 130 includes a cartridge housing 300 that is
preferably formed of a single piece of semi-flexible plastic.
Housing 300 generally includes a supply spool enclosure 302
containing supply spool 122 and a take-up spool enclosure 304
containing take-up spool 124. Supply and take-up spool enclosures
302 and 304 each include an interior side wall 306 and 308,
respectively, that are joined together by a front plate 310, as
shown in FIG. 14. Openings 312 and 314 in front walls 316 and 318
of the supply and take-up spool enclosures 302 and 304, shown in
FIG. 14, respectively receive front portions 320 of spool cores 322
and 324 of supply and take-up spools 122 and 124, as shown in FIGS.
13 and 17. Similarly, openings 326 and 328 and rear walls 330 and
332 of supply and take-up spool enclosures 302 and 304,
respectively receive rear portions 334 of cores 322 and 324 of
supply and take-up spools 122 and 124, as shown in FIGS. 16 and
17.
[0061] Front core support walls 336 and 338 are provided in supply
and take-up spool enclosures 302 and 304 to provide support of the
front portion 320 of cores 322 and 324 of supply and take-up spools
122 and 124, respectively, as shown in FIGS. 14 and 15. Print
ribbon 120 is wound on cores 322 and 324 of supply and take-up
spools 122 and 124 between front and rear ribbon guides 340 and
342. Ribbon guides 340 and 342 also limit axial movement of supply
and take-up spools 122 and 124 between rear walls 330 and 332 and
front core support walls 336 and 338 of cartridge housing 300.
[0062] One problem encountered with ribbon cartridges of the prior
art is that they require delicate handling to avoid unintentional
unwinding of the print ribbon. Ribbon cartridge 130 of the present
invention avoids this problem by providing spool rotation
inhibitors 344 and 346, shown in FIGS. 14 and 15, that provide at
least some resistance to the rotation of supply and take-up spools
122 and 124, respectively, while ribbon cartridge 130 is not
installed in cartridge receiver 280 of printer 100.
[0063] In accordance with one embodiment of the invention, spool
rotation inhibitors 344 and 346 are formed by tab members 348 and
350 that respectively extend from between front core support walls
336 and 338 and front walls 316 and 318 of supply and take-up
spools enclosures 302 and 304 of cartridge housing 300. Tab members
348 and 350 are positioned to engage front portions 320 of spool
cores 322 and 324 and provide frictional resistance to the rotation
of supply and take-up spools 122 and 124. Ridges 352 can be formed
on tab members 348 and 350 to provide the desired rotational
resistance. The rotational resistance to supply and take-up spools
122 and 124 provided by rotation inhibitors 344 and 346 is overcome
by motor 142 that drives the rotation of supply and take-up spools
122 and 124 when ribbon cartridge 130 is installed in cartridge
receiver 280. Additionally, housing 300 includes a finger hold 353
to allow for the installation of ribbon cartridge 130 in cartridge
receiver without touching ribbon 120.
[0064] Supply and take-up spool enclosures 302 and 304 of cartridge
housing 300 are preferably shaped such that ribbon cartridge 130
can only be received by cartridge receiver 280 in the proper
orientation. Thus, cartridge receiver 280 preferably includes a
first chamber 354 that is configured to receive supply spool
enclosure 302, and a second chamber 356 that is configured to
receive take-up spool enclosure 304. First and second chambers 354
and 356 also preferably substantially conform to the exterior shape
of supply and take-up spool enclosures 302 and 304, which are shown
in the cross-sectional view of ribbon cartridge 130 of FIG. 3.
[0065] During installation of ribbon cartridge 130 and cartridge
receiver 280, first and second drive shafts 360 and 362 (FIGS. 3
and 4) are respectively received within rear openings 364 and 366
of supply and take-up spools 122 and 124, shown in FIG. 16. Once
ribbon cartridge 130 is installed in cartridge receiver 280, drive
shafts 360 and 362 provide support for supply and take-up spools
122 and 124 and align them in the desired position.
[0066] Drive shafts 360 and 362 are driven by motor 142 under
control of controller 140 to rotate supply and take-up spools 122
and 124 as desired to control the position of ribbon 120 and its
panels relative to printhead 106, as well as to provide tension in
ribbon 120. Drive shafts 360 and 362 each preferably includes
longitudinal ridges 369 (FIG. 4) that are received between
corresponding longitudinal ridges 367 of supply and take-up spool
cores 322 and 324, shown in FIG. 16. Ridges 369 intermesh with
ridges 367 to prevent slippage between shafts 360 and 362 and
supply and take-up spools 122 and 124.
[0067] Cartridge receiver 280 can also include at least one
cartridge receiving guide 368 that is configured to receive a
corresponding cartridge loading guide 370 of ribbon cartridge 130
to provide vertical support of a front portion 372 of ribbon
cartridge 130, as shown in FIG. 10. In accordance with one
embodiment of the invention, cartridge receiving guide 368 includes
a channel 373 and cartridge loading guide 370 includes a protrusion
374 (FIG. 3) extending from supply spool enclosure 302 of cartridge
housing 300. During loading of ribbon cartridge 130 in cartridge
receiver 280, protrusion 374 slides in channel 373 and provides
vertical support to front portion 372 of ribbon cartridge 130.
Other types of cartridge receiving guides 368 and cartridge loading
guides 370 can also be used.
[0068] Gap 126 (FIG. 3) is defined by interior side walls 306 and
308 and ribbon guides 380 and 382 (FIGS. 13 and 16) that are
positioned between and above supply and take-up spools 122 and 124.
The distance between ribbon guides 380 and 382 is preferably less
than approximately 0.75 inches, but at least wide enough to
accommodate printhead 106. Printhead 106, is covered by front cover
plate 384 (FIG. 4) and is received within gap 126 (FIG. 3) as
ribbon cartridge 130 is installed in cartridge receiver 280.
[0069] In order to facilitate easy installation and removal of
ribbon cartridge 130 in cartridge receiver 280, printhead 106 is
preferably movable in a vertical direction, as illustrated in FIG.
3. This vertical movement of printhead 106 is provided in part by
slidably mounting printhead within printer 100. Preferably,
printhead 106 includes a full-down position represented by dashed
outline 400, in which printhead 106 is positioned during loading of
ribbon cartridge 130 and cartridge receiver 280. In full-down
position 400, printhead 106 is lowered below ribbon guides 380 and
382 to prevent interference between printhead 106 and print ribbon
120, which extends over ribbon guides 380 and 382 during
installation of ribbon cartridge 130 and cartridge receiver 280.
Once ribbon cartridge 130 is installed in cartridge receiver 280
(FIGS. 3 and 10), printhead 106 can be raised from full-down
position 400 to an idle position represented by dashed outline 402,
shown in FIG. 3. Prior to printing to surface 134 of card 110,
printhead 106 is moved to a print position 404, which is
illustrated in the solid lines of FIG. 3. When in print position
404, printhead 106 is raised relative to idle position 402 such
that print elements 118 and print ribbon 120 overlaying print
elements 118, are raised to a position that is adjacent print path
112 to allow for printing to surface 134 of card 110.
[0070] The raising and lowering of printhead 106 between the
full-down position 400 and print position 404 is provided by cam
mechanism 410, shown schematically in FIG. 2. Cam mechanism 410 is
driven by motor 412 under control of controller 140. Cam mechanism
410 can take on many configurations. In accordance with one
embodiment of the invention, cam mechanism 410 includes first and
second cam members 414 and 416, shown in FIG. 3. First cam member
414 is rotatably driven by motor 412 (FIG. 2). Second cam member
416 is attached to printhead 106 at end 418 and engages first cam
member 414 at end 420. The rotation of first cam member 414 by
motor 412 causes second cam member 416 to pivot about axis 422,
which in turn raises or lowers printhead 106 depending upon the
direction of rotation of first cam member 414.
[0071] A printhead position sensor 424, shown schematically in
FIGS. 2 and 3, can detect the position of printhead 106 and provide
position information to controller 140. Controller 140 uses the
position information to position printhead 106 as desired through
control of motor 412 driving first cam member 414.
[0072] A printhead biasing mechanism 426, depicted as a spring, can
be provided to resist raising of printhead 106 from full-down
position 400. Additionally, base 428 of printer housing 250, shown
in FIG. 3, includes an opening 430, through which adjustments to
cam mechanism 410 can be made and printhead 106 can be removed.
[0073] One embodiment of printer 100 includes a card cleaner roller
440 that is positioned immediately below print path 112 between
printhead 106 and card input 102, as shown in FIG. 3. Printer card
cleaner roller 440 preferably operates as a feed roller 114 of card
transport 104 and includes a debris-collecting surface 442.
Debris-collecting surface 442 engages print surface 134 of card 110
as it is fed along print path 112 and removes dust and other debris
from surface 134 prior to printing thereon by printhead 106.
Printer card cleaner roller 440 can be cleaned periodically by a
user of the printer 100.
[0074] One embodiment of card cartridge 130 includes a cleaner
roller 444, shown in FIGS. 3, 13, 16 and 17, which operates to
clean card cleaner roller 440 by removing debris from
debris-collecting surface 442, which eliminates the need to clean,
remove, or replace card cleaner roller 440. Cleaner roller 444 of
ribbon cartridge 130 includes a debris-collecting surface 446 that
is preferably more tacky than debris-collecting surface 442 of card
cleaner roller 440. In accordance with one embodiment of the
invention, debris-collecting surface 446 of cleaner roller 444 can
include double-sided tape or an adhesive applied to a removable
sleeve that is mounted to a core 448. Debris-collecting surface 446
can be renewed periodically, or cleaner roller 444 of ribbon
cartridge 130 can be periodically replaced with another card
cleaner roller 444 as needed.
[0075] Cleaner roller 444 includes front and rear ends 450 and 452
that respectively extend through apertures 454 and 456 in front and
rear walls 316 and 330 of supply spool enclosure 302 of cartridge
housing 300. Cleaner roller can be easily inserted and removed from
cartridge housing 300 by simply bending cartridge housing
slightly.
[0076] In accordance with one embodiment of the invention,
cartridge housing 300 includes a removable cover 460 that covers a
top portion of supply spool enclosure 302 and protects ribbon 320
from contact with debris-collecting surface 446 of cleaner roller
444, as shown in FIGS. 4, 15 and 16. Cover 460 preferably includes
tab members 462 each having a protrusion 464 that is configured to
be received within a corresponding aperture 466 of front and rear
walls 316 and 330 of supply spool enclosure 302, as shown in FIGS.
14, 16 and 17.
[0077] Cleaner roller 444 is preferably actuated for contact with
card cleaner roller 440 following installation of ribbon cartridge
130 and cartridge receiver 280. In accordance with one embodiment
of the invention, rear end 452 of cleaner roller 444 includes an
opening 470 that is configured to receive a rod 472 of an actuating
member 474, shown in FIG. 17. Actuating member 474 generally
operates to maintain cleaner roller 444 in contact with card
cleaner roller 440 during operation of printer 100 when ribbon
cartridge 130 is installed in cartridge receiver 280, as
illustrated in FIG. 3. The phantom representations of rod 272 of
actuating member 474 and cleaner roller 444, shown in FIG. 3,
illustrate a receiving position for actuating member 474, in which
rod 472 is positioned to extend through opening 470 of cleaner
roller 444 as ribbon cartridge 130 is received in cartridge
receiver 280.
[0078] One embodiment of actuating member 474 includes a ring
member 476 that is rotatably mounted around a rear side of drive
shaft 360. Actuating member 474 rotates about drive shaft 360 from
the receiving position to a card cleaning position, where debris
collecting surface 446 of cleaner roller 444 engages
debris-collecting surface 442 of card cleaner roller 440, as shown
in FIG. 3.
[0079] Movement of actuating member 474 between the receiving and
card cleaning positions is preferably triggered by the closing of
front cover 284 of printer housing 250. In accordance with an
embodiment of the invention, this is accomplished by protrusion 478
that is mounted to an inside surface 480 of front cover 284, as
shown in FIG. 4. Preferably, actuating member 474 is biased toward
the receiving position. When front cover 284 is fully closed,
protrusion 478 extends through opening 482 of housing 250 and
engages a suitable linkage that moves actuating member 474 from the
receiving position to the full card cleaning position thereby
causing debris-collecting surface 446 of roller cleaner roller 444
to engage debris-collecting surface 442 of card cleaner roller 440
and rotate therewith during printing operations.
[0080] In accordance with another embodiment of the invention, a
supply circuit 500 having a memory 502 is mounted to ribbon
cartridge 130, as illustrated schematically in FIG. 2. One suitable
supply circuit is the I-CODE1 produced by Philips. Memory 502 of
supply circuit 500 contains information relating to print ribbon
120, such as a lot code identifying a lot of the ribbon 120, a
supplier code identifying a supplier of ribbon 120 or ribbon
cartridge 130, a ribbon type identifying parameters of print ribbon
120, a security code that can be used to prevent unauthorized use
of ribbon cartridge 130, a printer configuration setting used to
optimize printer settings such as printhead settings including
those affecting image color and intensity, a number of prints
completed by print ribbon 120, and/or a number of prints remaining
or that can be printed by print ribbon 120.
[0081] In accordance with one embodiment of the invention, supply
circuit 500 can be mounted to either supply spool 122 or take-up
spool 124, as illustrated in FIGS. 18 and 19. FIG. 18 is an
exploded perspective view of supply circuit 500 mounted to supply
spool 122, and FIG. 19 is an assembled view of supply circuit 500
mounted to supply spool 122. In accordance with one embodiment of
the invention, supply circuit 500 is formed as a ring member 504
that is mounted to a rear-facing surface 506 of rear ribbon guide
342.
[0082] Printer 100 includes a supply circuit reader 510, shown
schematically in FIG. 2. Controller 140 is configured to access or
read the supply information contained in memory 502 of supply
circuit 500 using supply circuit reader 510. The supply information
is preferably accessed prior to feeding card 110 by card transport
104. Additionally, controller 140 can write data to memory 502 of
supply circuit 500 through supply circuit reader 510. Supply
circuit reader 510 communicates with memory 502 using conventional
techniques including radio frequency (RF) communication
methods.
[0083] Communications between controller 140 and supply circuit 500
through supply circuit reader 510 are preferably securely made
using various encryption methods to protect the supply information.
In accordance with one embodiment of the invention, the supply
information contained in memory 502 of supply circuit 500 is
encrypted in accordance with a first encryption method. In
accordance with one embodiment of the invention, the supply
information contained in memory 502 of supply circuit 500 is
encrypted in a form that can be decrypted by controller 140. In
accordance with another embodiment of the invention, supply circuit
reader 510 includes a processor that is configured to decrypt the
encrypted supply information and re-encrypt the supply information
in accordance with a second encryption method. The first encryption
method is preferably different from the second encryption method.
Finally, the re-encrypted supply information is communicated to
controller 140, which is configured to decrypt the re-encrypted
supply information.
[0084] Another embodiment of the invention is directed to a method
of operating printer 100, which is illustrated in the flowchart of
FIG. 20. At step 520 of the method, a value is stored in memory 502
of supply circuit 500. Preferably, the value is representative of a
number of prints remaining or that can be printed by print ribbon
120. Accordingly, the value can correspond to a length of print
ribbon 120 that remains and is still useful for printing, for
example. Next, at step 522, the value contained in memory 502 is
decremented in response to use of print ribbon 120 with printer
100. Thus, as print ribbon 120 is used to print images on cards
110, the value is decremented accordingly to represent the
depletion of the usable print ribbon 120 such that the value
continues to represent the amount of usable print ribbon 120 that
remains. This decrementing of the value is typically performed by
controller 140 through supply circuit reader 510. Memory 502 is
preferably disabled when the value reaches a predetermined end
value, as indicated at step 524. Typically, the end value would be
set such that it is likely that the print ribbon 120 is no longer
usable by printer 100. The disablement of memory 502 can be
performed by controller 140 and prevents further writing to memory
502. Finally, at step 526, controller 140 prevents use of print
ribbon 120 with printer 100 when it is determined that memory 502
has been disabled. Preferably, a check is made by controller 140 to
determine whether memory 502 has been disabled prior to processing
a card 110 with printer 100. In this manner, ribbon cartridge 130
is given a limited life span over which it can be used with printer
100.
[0085] In accordance with one embodiment of the above-described
method, memory 502 of supply circuit 500 is divided into a
plurality of memory banks. Each bank is provided with a value
representing a portion of the prints remaining in ribbon 120.
During use of print ribbon 120, the value stored in the banks are
selectively decremented to represent the use of the print ribbon
120 as the value in each bank reaches a predetermined end value,
controller 140 disables the bank of memory 502 rendering the bank
unusable. Once the values in all of the banks of memory 502 reach
the predetermined end value, the controller 140 can prevent further
use of the print ribbon 120 with printer 100.
[0086] Although the present invention has been described with
reference to preferred embodiments, workers skilled in the art will
recognize that changes may be made in form and detail without
departing from the spirit and scope of the invention.
* * * * *