Abstract:
A desktop card processor having increased card processing capabilities without increasing the horizontal footprint of the card processor. The card processor utilizes multiple card processing levels stacked in vertically separated levels to minimize the horizontal footprint of the card processor.

Description:
FIELD OF THE INVENTION 
   The invention relates to plastic card processing equipment, particularly desktop processing equipment, that perform at least one processing operation on a plastic card, such as a credit card, driver&#39;s license, identification card and the like. More particularly, the invention relates to desktop card processing equipment having at least two vertically separate card processing levels. 
   BACKGROUND OF THE INVENTION 
   Plastic cards are used in a number of applications, such as identification cards, security badges, employee badges, driver&#39;s licenses, credit cards, membership cards, and the like. The use of card processing equipment for processing these types of plastic cards is well known. In such equipment, a plastic card to be processed is input into the processing equipment, at least one processing operation is performed on the input card, and the card is then output from the processing equipment. The processing operation(s) performed on the plastic card by known processing equipment includes one or more of printing, laminating, magnetic stripe encoding, programming of a chip embedded in the card, card cleaning, and the like. 
   The processing equipment is often configured in the form of a desktop unit. An example of a popular desktop plastic card processing unit is a desktop plastic card printer which performs monochromatic or multi-color printing on a card that is input into the printer. Examples of desktop units that perform printing are disclosed in U.S. Pat. Nos. 5,426,283; 5,762,431; 5,886,726; 6,315,283; 6,431,537; and 6,536,758. Of these, U.S. Pat. No. 5,426,283 describes a unit that performs chip programming in addition to printing. 
   Desktop card processing equipment is designed to be relatively small, so that the equipment can fit onto a desk or table. The desktop card processor may be positioned on a support surface with other office machines and workspace, so that table and desk space is at a premium. Therefore, the amount of desk or table space required for the desktop card processor (i.e., its “footprint”) should be minimized. 
   At the same time, it is desirable that a piece of desktop card processing equipment be able to perform multiple card processing operations, thereby increasing the performance capability of the equipment. 
   Additionally, desktop card processors should be easy to operate and maintain with only a minimal amount of specialized training. Desktop card processors are often operated by personnel for whom producing cards is only an incidental portion of their job, such as a security guard or a desk clerk, and not by personnel who have special training in such equipment. The operation and maintenance of the card processor should thus be relatively intuitive and straightforward. Furthermore, the cards that are output from the card processor must be of the highest quality, attractive, and durable. 
   While existing desktop card processing equipment has proven adequate, there is a continuing need for further improvements. In particular, there is a need for desktop card processing equipment that can perform multiple card processing operations on a card while maintaining a relatively compact footprint for the processing equipment. 
   SUMMARY OF THE INVENTION 
   The invention relates to plastic card processing equipment for processing data bearing plastic cards, such as credit cards, driver&#39;s licenses, identification cards, loyalty cards and the like. More particularly, the invention relates to a desktop card processor that is capable of performing multiple processing operations on a card while maintaining a compact footprint. The card processor is configured so that cards to be processed and processed cards are positioned on one side of the card processor. This allows the card processor to be positioned on a desk against a wall or in a corner for more efficient utilization of space. 
   The card processor maintains a compact footprint on account of having multiple card processing levels stacked in vertically separated levels. The cards are loaded into the card processor and processed on an upper card processing level, then are flipped and lowered to a lower card processing level for additional processing. 
   The upper card processing level can comprise a printing mechanism and one or more other card processing mechanisms, and the lower card processing level can comprise one or more laminating mechanisms and one or more other card processing mechanisms. This arrangement allows the card processor to incorporate dual laminating mechanisms to laminate both sides of a card in a single pass without significantly increasing the footprint of the card processor. 
   Further, the card processor is configured to allow the lamination foil, which is consumed by the card processor during operation and must be replaced when the supply is depleted, or other consumable foil used by the card processing equipment, to be replaced without opening the machine cover. The lamination foil cartridge(s) is directly accessible from the outside of the card processor. This allows the lamination foil to be replaced by an operator without having to open any portion of the processor housing. 
   The card processor also includes a space-saving output hopper that holds a relatively large number of processed cards without increasing the overall height of the card processor. The space-saving output hopper is configured so that it may be positioned over the edge of a table or desk or act as a support for the front end of the card processor. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIGS. 1A-1E  are schematic illustrations of variations of a card processor according to the invention. 
       FIG. 2  is a perspective view of a card processor according to the invention. 
       FIG. 3  is a schematic cross-sectional view of the card processor according to the invention. 
       FIG. 4  is a schematic view of a card reorienting mechanism used in the card processor. 
       FIG. 5A  is a cross-sectional detail view of an output hopper of the card processor where the output hopper overhangs a table. 
       FIG. 5B  is a side view of the card processor showing the output hopper acting as a support leg for the card processor. 
       FIG. 6A  is front perspective view of the card processor with the output hopper removed. 
       FIG. 6B  is a rear perspective view of the output hopper. 
       FIG. 7  is a perspective view of a lamination foil cartridge loaded with the foil and with the foil separate. 
       FIG. 8  is a perspective view of a lamination foil cartridge loaded with a roll of lamination foil. 
       FIG. 9  is a perspective view of a card processor with a laser-engraving mechanism. 
       FIG. 10  is a cross-sectional view of a card processor with a laser-engraving mechanism. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
   Improvements to plastic card processing equipment, particularly desktop card processing equipment, for processing data bearing plastic cards, such as credit cards, driver&#39;s licenses, identification cards, loyalty cards and the like, are described herein. Desktop card processing equipment described herein have enhanced space utilization, while having enhanced card processing capabilities. 
   A desktop card processor according to the invention will be described as performing operations on a plastic card. For example, the plastic card can be ID1-sized plastic card, but the concepts described herein could be used with cards of other sizes or made of material compositions other than plastic. A card generally has two substantially flat faces that may be referred to as the front side and back side of the card. 
   In addition, the desktop card processor according to the invention is configured to perform multiple processing operations on a card. Processing operations that can be performed on the card includes multiple ones of at least the following exemplary processing operations: multi-color printing, monochromatic printing, laminating, card cleaning, magnetic stripe encoding, laser printing, embedded computer chip programming, card de-bowing, indenting and embossing. Other card processing operations would be encompassed by the concepts of the invention was well. 
   The desktop card processor described herein has multiple card processing levels stacked in generally vertically separated levels, and input and output hoppers on the same end of the processor. The card processor will be described with respect to a card traveling initially along an upper card processing level and thereafter being transported downward to a lower card processing level which transports the card along the lower processing level to the output hopper. However, as an alternative, the card could initially travel along the lower card processing level after being fed from a lower input hopper, then be transported upward to the upper card processing level which transports the card along the upper level to an output hopper located above the input hopper. 
     FIGS. 1A-1E  are schematic illustrations of exemplary variations of card processors that incorporate concepts of the invention. Common to each of the illustrated variations is a card input hopper H 1  that is capable of holding a plurality of cards to be processed and a card output hopper H 2  that is capable of holding a plurality of processed cards where the hoppers H 1 , H 2  are located at what will be referred to as the front end region of the card processor, an upper card processing level L 1 , a lower card processing level L 2 , a plurality of card processing mechanisms M on each level and each of which is configured to perform a processing operation on a card, a card transport T 1  for the upper card processing level and a card transport T 2  for the lower card processing level for transporting cards along the processing levels L 1 , L 2 , and at least one reorienting mechanism R for transporting cards between the card processing levels L 1 , L 2 . 
   In the card processor  5 A shown in  FIG. 1A , the card processing mechanisms M of the upper level L 1  include a cleaning mechanism for cleaning the front and/or back of the card, a color printing mechanism, a smart card mechanism for programming an integrated circuit chip on a card, a magnetic stripe encoding mechanism, and an optional other processing mechanism. The card processing mechanisms M of the lower level L 2  include two lamination mechanisms for laminating the front and back of the card, a debowing mechanism for removing any bowing in the card that may have occurred, and any other processing mechanism that my be desired. The transport T 1  takes a card from the input hopper H 1  and transports the card to and through the card processing mechanisms M of the upper level L 1 . The card is then fed into the reorienting mechanism R which reorients the card to permit it to be transported downward to a second reorienting mechanism R associated with the lower level L 2 . The second mechanism R reorients the card suitable for card processing at the level L 2 , and the transport T 2  transports the card to and through the card processing mechanisms M and ultimately to the output hopper H 2 . 
   The card processor  5 B shown in  FIG. 1B  is similar to the card processor  5 A shown in  FIG. 1A , but also includes an additional card processing mechanism M in the form of a laser engraving mechanism associated with the level L 1  and an optical laser mechanism associated with the level L 2 . The laser engraving and optical laser mechanisms are disposed generally at the rear of the card processor. 
   The card processor  5 C shown in  FIG. 1C  is similar to the processor  5 B shown in  FIG. 1B , but includes a third card processing level L 3  between the levels L 1  and L 2 . 
   The card processor  5 D shown in  FIG. 1D  is similar to the processor  5 A shown in  FIG. 1A , but includes card processing levels on each side of the card reorienting mechanisms R, as well as hoppers H 1  and H 2  at the rear of the card processor. 
   The card processor  5 E shown in  FIG. 1E  includes two card processing levels L 1 , L 2  but uses a single reorienting mechanism R that services both levels L 1 , L 2 . 
   Attention is now directed to  FIG. 2  which illustrates a specific implementation of a card processor  20  in perspective view. Card processor  20  includes a housing  26  having an input/output end  21  with a card input hopper  22  adjacent to input/output end  21  for staging cards to be processed and a card output hopper  24  for receiving processed cards from the card processor. Card processor  20  also includes a user display and input  28  at the input/output end  21  where relevant information concerning the status and operation of the card processor can be communicated to the operator and the operator can enter commands, a manual card recovery knob  30  adjacent a side surface  23  that allows a card to be manually advanced through a lower processing level of the processor (a similar knob is located on the non-visible side of the processor for manually advancing a card through an upper processing level), and an access lid  36  adjacent a top surface  25  of the housing  26  for accessing the internal mechanisms of the card processor. The side surface  23  defines a pair of lamination foil cartridge cavities  32 ,  34  each of which receives a lamination foil cartridge  40 , shown in  FIGS. 2 ,  6  and  7 . The lamination foil cartridges  40  will be discussed in greater detail below. 
   For convenience in describing the figures, the input/output end  21  of the card processor  20  will be described as being at a front end region of the processor, while the opposite end of the processor will be referred to as being a back end region  17  of the processor. Furthermore, the card processor has an upper end region and a lower end region  9 . 
     FIG. 3  illustrates a schematic cross-sectional view of the card processor  20 . The card processor  20  comprises a plurality of card processing mechanisms  42   a ,  42   b;  card transports  44   a ,  44   b ; and card reorienting mechanisms  46   a ,  46   b . Card transport  44   a  can be called an upper card transport and card transport  44   b  can be called a lower card transport. Similarly, card reorienting mechanism  46   a  can be called an upper card reorienting mechanism, and card reorienting mechanism  46   b  can be called a lower card reorienting mechanism. 
   The group of components comprising the card processing mechanisms  42   a , the upper card transport  44   a , and the upper card reorienting mechanism  46   a  defines an upper or first card processing level  15 . The group of components comprising the card processing mechanisms  42   b , the lower card transport  44   b , and the card reorienting mechanism  46   b  define a lower or second card processing level  13 . 
   Card processing mechanisms  42   a ,  42   b  can perform any of a number of types of card processing operations. For example, the card processing mechanisms  42   a ,  42   b  may perform multi-color printing, monochromatic printing, laminating, card cleaning, magnetic stripe encoding, laser printing, embedded computer chip programming, card de-bowing, indenting, embossing, etc. 
   Card transports  44   a ,  44   b  are used to transfer cards from the input hopper  22  to the first card processing mechanism, from one card processing mechanism to the next card processing mechanism, and from the last processing mechanism to the output hopper. These card transports  44   a ,  44   b  are capable of imparting generally linear motion to a card and may comprise any of a number of types of mechanisms for imparting motion to cards. For example, card transports  44   a ,  44   b  may comprise a series of rollers driven by electric motors and a suitable drive train. Examples of a suitable transport mechanism for transporting cards in a desktop card processor are disclosed in U.S. Pat. Nos. 5,762,431 and 5,886,726, each of which is hereby incorporated herein by reference in its entirety. 
   When a card reaches the end of the card transport  44   a , the card is transferred from the upper card processing level  15  to the lower card processing level  13  by means of card reorienting mechanisms  46   a ,  46   b . The card reorienting mechanisms  46   a ,  46   b —also known as duplexers—may be of the type disclosed in U.S. patent application Ser. No. 10/716,579 filed on Nov. 17, 2003, which is hereby incorporated herein by reference in its entirety. 
     FIG. 4  illustrates one possible embodiment of a card reorienting mechanism  46   a ,  46   b  of the type disclosed in U.S. patent application Ser. No. 10/716,579. In operation, upper card transport  45   a  feeds a card into upper card reorienting mechanism  46   a . In the disclosed configuration, cards are transported in a generally horizontal orientation. Upper card reorienting mechanism  46   a  rotates the card to an approximately vertical orientation so that the card points downward toward the lower card reorienting mechanism  46   b . The card is then fed from the upper card reorienting mechanism  46   a  to lower card reorienting mechanism  46   b , which then rotates the card back to its approximately horizontal orientation with either the front or back surface facing upward depending upon whether the front or back surface of the card is to be processed next. The card is then transferred to lower card transport  44   b , which transports the card to the processing mechanisms in the lower card processing level  13 . Other examples of duplex mechanisms for reorienting a card are disclosed in U.S. Pat. Nos. 5,806,999; 5,771,058; 5,768,143; and 6,279,901. 
   Some cards may require certain processing operations to be performed on both sides of the card. For example, a card may require information to be printed on both sides of the card and/or both sides of the card need to be laminated. This may be accomplished in several ways. The necessary card processing mechanisms could be located on both sides of the card transport  44   a ,  44   b  to allow processing operations to be performed on both sides of the card as the card makes a single pass along a card transport  44   a ,  44   b . As an alternative, a card can also be processed on both sides of the card by transporting it through one card processing level in opposite orientations. For example, on the upper card processing level  15  this can be accomplished by feeding the card into upper card transport  44   a , flipping the card 180 degrees in the upper card reorienting mechanism  46   a , transferring the card back into upper card transport  44   a,  operating upper card transport  45   a  in the reverse direction so that the card moves toward the front end region of the processor, reversing the direction of the upper card transport  45   a  again so that the card moves through the processing mechanism(s)  42   a  toward the back end region of the processor, and processing the card as it passes through the appropriate card processing mechanisms  42   a.    
   Referring now to  FIGS. 5A and 5B , the card output hopper  24  is configured to allow a large storage capacity without increasing the height of the processor. Cards are discharged from the card processor into the card output hopper  24  at the end of the lower card transport  44   b  nearest the front end of the processor. As can be seen in  FIG. 5A , the card output hopper  24  extends below the lower end region  9  of the card processor. This allows the card processor operator to position the card output hopper  24  over the edge of a table or a desk  100 , thereby causing the card processor to sit flush on the flat bottom surface of the processor. Alternatively, as shown in  FIG. 5B , the card output hopper  24  can rest on the table or desk  100  and act as a support leg or a “kickstand” for the front end of the card processor, adding slightly to the height of the processor. 
     FIGS. 6A and 6B  illustrate how the output hopper  24  attaches to the card processor. The hopper  24  includes a pair of spaced resilient arms  270  that extend from the rear thereof, as shown in  FIG. 6B . The arms  270  each include an angled ramp section  272  and a curved retention section  274 . The arms  270  are designed to snap-fit connect with a shaft  276  (shown in  FIG. 6A ) adjacent the front end of the card processor  20 , as shown in  FIG. 5A . A pair of flanges  271  are associated with the arms  270  and are disposed above the shaft  276  when the hopper  24  is connected to the card processor as shown in  FIG. 5A  to prevent downward movement of the hopper  24 . Similarly, a pair of flanges  273  are disposed underneath the shaft  276  to prevent upward movement of the hopper  24 . 
   The output hopper  24  also includes a structure  278  that acts as the support leg in  FIG. 5B . The structure  278  extends beyond the sides of the output hopper  24 , and raised bosses  279  are defined at the top of the structure  278 . With reference to  FIG. 6A , a pair of resilient fingers  280  are defined adjacent the bottom of the card processor and project toward the front of the processor (only one finger  280  is visible in  FIG. 6A ; the second finger is hidden behind element  281 ). The fingers  280  include detents  282  defined on the bottom thereof that snap fit engage with the raised bosses  279  of the structure  278  as shown in  FIG. 5A . This connection between the hopper  24  and card processor allows the hopper  24  to support the card processor when the hopper acts as the support leg in  FIG. 5B . 
   In one embodiment, the upper card processing level  15  has a single card processing mechanism  42   a  in the form of a multi-color printer, while the lower card processing level  13  has two card processing mechanisms  42   b  each of which is a laminator. Preferably one laminating mechanism  42   b  is positioned above lower card transport  44   b  and the second laminating mechanism  42   b  is positioned below lower card transport  44   b . This configuration facilitates one-pass lamination of the front and back of the card. 
   Referring to  FIG. 7 , the laminating mechanisms utilize lamination foil cartridges  40  that are inserted through the openings  32 ,  34  in the outside of the housing  26 . The cartridges  40  are accessible to the operator without the operator being required to open a cover of the housing  26  or removing any portion of the housing  26 . As a result, access to, and replacement of, the lamination foil on the cartridges  40  is made easier. 
   As shown in  FIGS. 7 and 8 , each lamination foil cartridge  40  comprises an exterior housing  200  and a base plate  201  fixed to the housing  200 . A supply spindle  202  and an uptake spindle  203  are rotatably affixed to the base plate  201 . Affixed to uptake spindle  203  is a gear  206  that engages a drive gear  250 . The drive gear  250  is connected to a nip roller  226  which has a boss  252  on the end thereof. The boss  252  engages with a drive mechanism (not shown) inside the card processor when the cartridge  40  is inserted into the processor. 
   A gate mechanism  254  is pivotally connected to a fixed shaft  256  on the base plate  201 . The gate mechanism  254  is pivotable between a first, open position shown in  FIGS. 7 and 8 , and a second, closed position shown in  FIG. 2  where the gate mechanism  254  is disposed over the lamination foil. The gate mechanism  254  includes an idler roller  258  rotatably mounted thereon that opposes the nip roller  226  when the gate mechanism  254  is at the second position. Further, the gate mechanism  254  includes a large rectangular opening  260  that permits access to the lamination foil when the gate mechanism is closed, as shown in  FIG. 2 . 
   A lamination foil  208  to be used is disposed on a supply roll  204  that is inserted onto the supply spindle  202  and the take-up end of the foil  208  is pre-attached to an uptake roll  205  that is disposed on the uptake spindle  203 . When properly positioned and with the gate mechanism  254  closed, the lamination foil  208  runs over guide bar  210 , under the guide bar  216  on the gate mechanism  254 , over the top of guide bars  212  and  214 , and between the nip formed by the nip roller  226  and roller  258 . In addition, the lamination foil is guided along its edges by means of a channel formed between tabs  218 ,  220  affixed to guide bars  212 ,  214  and steps  222 ,  224  formed at the ends of the guide bars  212 ,  214 . A suitable lamination foil for use in the card processor is disclosed in commonly owned, copending application Ser. No.11/051,125, titled SHEET MATERIAL WITH INDEX OPENINGS AND METHOD FOR MAKING AND USING A SHEET MATERIAL WITH INDEX OPENINGS, and filed on Feb. 4, 2005. 
   In operation, the lamination foil is advanced to expose a new section of lamination foil between guide bar  212  and guide bar  214  each time a card is to be laminated. Advancement of the lamination foil is achieved by driving the nip roller  226 . The nip formed between the nip roller  226  and the idler roller  258  is sufficient to advance the foil in the direction of the arrow in  FIG. 8  when the nip roller  226  is driven. When this occurs, the gear  250  drives the gear  206  which causes the take-up roll  205  to take-up slack foil. 
   The drive mechanism that drives the nip roller  226  preferably includes a clutch mechanism that prevents overdriving of the foil. The card to be laminated is driven at a slightly faster speed than the foil. Therefore, the movement of the card may cause the foil to advance at a faster rate than desired. The clutch mechanism prevents this and ensures that the foil is advanced at a constant rate. 
   When the foil is used up and the end of the foil is reached, the foil pulls away (i.e. detaches) from the supply roll  204 . Referring to  FIG. 8 , a chopper wheel  230  is connected to and rotates with the supply spindle  202 . The chopper wheel  230  includes a plurality of spaced teeth separated by gaps. A sensing mechanism (not shown) is positioned to sense rotation of the chopper wheel  230  by sensing the alternating teeth and gaps. When the chopper wheel  230  fails to rotate when rotation is expected, the card processor knows that the end of the foil has been reached and has pulled away from the supply roll  204 . 
   Referring now to  FIGS. 9 and 10 , the card processor  20  may include a laser engraving mechanism  50  for performing laser personalization on the card. The laser engraving mechanism  50  may be located as an add-on mechanism toward the rear  17  of the card processor  20 , with portions of the mechanism  50  extending under the card processor as shown in  FIG. 10 . 
   With reference to  FIG. 9 , the laser engraving mechanism  50  comprises a power supply  66  for powering the laser and a printed circuit assembly (PCA) board  64  for controlling the laser and/or portions or all of the processor  20 . A laser head  62  generates a laser beam, which is expanded by beam expander  60 . The transmission of the laser beam is regulated by a beam shutter and solenoid  58 , which is controlled by the PCA board  64 . Proximate the beam shutter and solenoid  58  is a beam deflector  56  for deflecting the beam to create a useful pattern on the card. The beam is then transmitted to a F-Theta lens  54  which focuses the beam to a focal point. 
   To engrave a card, the card is transferred from the upper card reorienting mechanism  46   a  into a card stage  52 . The card stage  52  is configured to orient the card at various angles with respect to the direction of the laser beam and configured to translate the card up and down as shown by the arrows in  FIG. 10  to keep the card surface being engraved at the focal point. A suitable card stage  52  is used in the DCL30 Desktop Card Laser Personalization System available from DataCard Corporation of Minnetonka, Minn. 
   Further, as indicated in  FIGS. 1B and 1C , the card processor may also include an optical laser that is capable of writing and reading data to and from a surface of an optical memory card. Optical laser structure for writing and reading data on optical data cards is known in the art, including the LaserCard® 600-Q optical card read/write drive available from LaserCard Corporation of Mountain View, Calif. 
   The above specification and examples provide a complete description of the invention. Many embodiments of the invention, not explicitly described herein, can be made without departing from the spirit and scope of the invention.