Abstract:
Improvements relating to identification tags on consumable supply items used in identity document production equipment. The use of identification tags on the consumable supply items allows the document production equipment to recognize the consumable supply items that are loaded into each piece of equipment. The equipment can then initiate a variety of activities that are based on the loaded supply item. The activities are designed to enhance the operation of the equipment for the equipment operator and to provide added value to those customers who utilize consumable supply items that are recognized by the equipment.

Description:
PRIORITY DATA 
     This application is a Continuation application of application Ser. No. 10/308,244 filed Dec. 2, 2002, now U.S. Pat. No. 6,963,351, which application is incorporated by reference herein in its entirety, and which claims the benefit of U.S. Provisional Application No. 60/342,781 filed Dec. 21, 2001, and U.S. Provisional Application No. 60/400,331 filed Jul. 31, 2002. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to consumable items in printers and related equipment. More particularly, the invention relates to a system for tagging consumable supply items that are used in equipment, such as printers, used to produce data bearing identity documents, including cards such as identification cards, drivers licenses, credit cards and the like, and booklets such as passports and the like, as well as to methods resulting from the use of tagged consumables. 
     BACKGROUND OF THE INVENTION 
     The use of radio frequency (RF) identification tags on consumable supply items of printers is known in the art. U.S. Pat. Nos. 5,455,617; 6,099,178; 6,227,643; and WO 00/43932 are examples. Each of these documents disclose the use of read/write memory fixed onto a consumable item of a printer, and from which data is read and/or written to by a radio frequency circuit. 
     There is, however, a continuing need for improvements relating to the use of memory tags on consumable items that are used in the production of data bearing identity documents. 
     SUMMARY OF THE INVENTION 
     The invention provides improvements relating to the use of identification tags on consumable supply items used in identity document production equipment. The use of identification tags on the consumable supply items allows the document production equipment to recognize the consumable supply items that are loaded into each piece of equipment. The equipment can then initiate a variety of activities that are based on the loaded supply item. The activities are designed to enhance the operation of the equipment for the equipment operator and to provide added value to those customers who utilize consumable supply items that are recognized by the equipment. 
     In one aspect of the invention, a consumable supply item for a piece of data bearing document production equipment is provided. The supply item comprises a core, a ribbon material wound onto the core, and a memory element attached to the core. 
     In another aspect of the invention, a printer is provided which comprises a ribbon material supply roll disposed on a spindle, a read/write memory element fixed to the supply roll, and a read/write unit for reading data from and writing data to the read/write memory element. 
     In yet another aspect of the invention, a method of operating a piece of data bearing document production equipment is provided. The method includes loading a consumable supply item containing a memory element having stored data into the piece of equipment, using the piece of equipment to read data from the memory element, determining whether the loaded consumable supply item is a recognized supply item based upon the data that is read from the memory element, and initiating an activity in the piece of equipment that is different from a normal operating activity of the piece of equipment when the loaded consumable supply item is a recognized supply item. 
     In another aspect of the invention, the read/write memory element is fixed to the take-up core upon which used print ribbon is wound, instead of being fixed to the supply core. In this embodiment, it is also preferred that ribbon amount data stored in the memory element pertaining to how much ribbon remains on the supply roll, is decremented based on print jobs performed by the printer. Print job information is available from the printer controller which controls operation of the printer in which the take-up core is used. 
     For a better understanding of the invention, its advantages and objects obtained by its use, reference should be made to the drawings which form a further part hereof, and to the accompanying description, in which there is described a preferred embodiment of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a print ribbon supply roll and spindle arrangement for a printer incorporating the radio frequency identification tag according to the present invention. 
         FIG. 2  is a cross sectional view of the core and spindle arrangement. 
         FIG. 3  is a top view of the radio frequency identification tag of the present invention. 
         FIG. 4  illustrates an identification code that can be stored on the memory element. 
         FIG. 5  illustrates an alternate embodiment of the invention utilizing a memory element on the take-up core. 
         FIG. 6  illustrates a printer in which the ribbon supply and ribbon take-up of  FIG. 5  can be used. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The invention relates to the use of memory tags on consumables items, preferably consumable items provided in the form of rolls, that are used in the production of data bearing identity documents, including cards such as identification cards, drivers licenses, credit cards and the like, and booklets such as passports and the like. Examples of consumable items to which the invention applies includes, but is not limited to, printing ribbons, cleaning tape, indent foil, labels, topping foil, holographic topcoats, polyester laminates, ink cartridges for ink jet printers, and toner cartridges. The printing ribbons can have multi-color panels, or they can be a single color. The types of equipment that utilize these consumables includes printers and laminators, as well as peripheral equipment utilized with printers and laminators. In addition, the memory tags of the invention can be used on equipment that form part of large scale document production units, or on table top units. 
     The invention includes a memory element that is provided on the consumable item so that data pertaining to the consumable item, and other data, can be stored thereon. The memory element is preferably a read/write memory element that allows data to be read from and written to the memory element. In addition, a suitable read/write unit is provided that interacts with the memory element in order to read data from, and write data to, the memory element. 
     In order to describe the inventive concept, the invention will be described herein in relation to a print ribbon roll on a printer that is used in the production of data bearing identity documents. It is to be understood, however, that the invention is applicable to other types of consumables in other types of identity document production equipment as well. 
       FIG. 1  illustrates a print ribbon supply roll  10  and a spindle  12  for use in a printer. The ribbon supply roll  10  includes a ribbon core  14  and a print ribbon  16  wound onto the core  14 . The print ribbon  16 , which is illustrated in dashed lines in  FIG. 1 , preferably comprises a series of differently colored panels, such as cyan, yellow, magenta, and black. Alternatively, the print ribbon  16  comprises a single, solid color, i.e. monochromatic. The spindle  12  is mounted so as to be rotatably driven by a shaft  18  via a motor, such as a stepper motor (not shown), in known fashion. The ribbon core  14  and ribbon  16  are designed to be placed onto the spindle  12  whereby the ribbon core  14  is driven by the spindle  12  to unwind ribbon  16  therefrom during use of the printer. The ribbon  16  is taken up on a take-up core ( FIG. 5 ) within the printer. 
     Affixed to the core  14  is an identification tag  20  (see  FIGS. 2 and 3 ). The tag  20  comprises an antenna  22  and a read/write memory element  24 . In the preferred embodiment, the tag  20  is fixed to an end  26  of the core  14 . In addition, a radio frequency read/write unit  28  is positioned on structure  30  adjacent the end  26  of the core  14  for reading data from, writing data to, and providing power to, the tag  20 . The present invention utilizes radio frequency signals to read data from and write data to the memory element  24 , as well as to provide power for the tag  20 . The use of radio frequency signals to read and write data, and to provide power to identification tags, is well known in the art, such as from WO 00/43932 and U.S. Pat. No. 6,099,178. As the use of radio frequency identification tags is known, a description of how data is read from and written to the tags, and how the tags are powered by the radio frequency signals, is not provided herein. 
     The identification tag  20 , details of which are shown in  FIG. 3 , is generally circular, and is designed to fit within the end  26  of the core  14 . The core  14  is slightly recessed adjacent the end  26  to allow the tag  20  to fit completely within the interior of the core  14 . The tag  20  is preferably fastened to the core  14 , for example by using an adhesive material. Therefore, the tag  20  is fixed to the core  14  to prevent its easy removal. Other fastening mechanisms could be used to secure the tag  20  to the core  14 , such as a snap fastening system in which the tag  20  snaps into place on the core  14 . If desired, the tag  20  could be mounted to the core  14  so as to allow non-destructive removal of the tag  20 . The inner diameter d 1  of the tag  20  is slightly greater than the outer diameter of the spindle  12  to allow the tag  20  to slide over the spindle  12  as the core  14  is introduced onto the spindle  12 . The outer diameter d 2  of the tag  20  is slightly less than the interior diameter of the core  14  to allow the tag  20  to fit within the recessed end  26  of the core  14 . The antenna  22  is circular and is formed on the tag  20  between the inner and outer diameters. A tab  32  projects from the outer edge of the tag  20 , and the memory element  24  is disposed on the tab  32 . In use, the tab  32  is preferably bent upward toward the middle of the core  14  when the tag  20  is mounted within the core  14 . The tab  32  could also be bent downward toward the open end of the core  14 , in which the size of the tab  32  must be selected so that the end of the tab does not project beyond the end of the core  14 . 
     Returning now to  FIG. 1 , the read/write unit  28  includes an antenna  34  that is housed within a plastic cover  36  forming part of the structure  30 . The antenna  34  is generally circular, and has a diameter that is greater than the spindle  12 . Other known components of the read/write unit  28  that cooperate with the antenna  34  for reading and writing data to the tag  20  are also housed within the plastic cover  36 . 
     The structure  30  also includes a metal plate  38 . The metal plate  38  can be steel or aluminum, and have any thickness. However, to provide optimum performance, it has been discovered that the metal plate  38  must cover a diameter of at least about 2.375 inches around the shaft  18 . By using a metal plate  38  of at least this size, it has been discovered that the inductance of the antenna can be made constant which results in the radio frequency signals being made constant, thereby improving the performance. The diameter of the shaft  18  should also be no more than 0.375 inches in diameter. It is to be realized that both the plastic cover  36  and the metal plate  38  are provided with apertures to allow passage of the shaft  18 . Bearings permit rotation of the shaft  18  relative to the plastic cover  36  and metal plate  38 . 
     The spindle  12  is preferably molded from a plastic material. As illustrated in  FIG. 2 , a ferrite core  40  is molded inside the spindle  12  during formation of the spindle, and the core  40  and spindle  12  are molded around the shaft  18 . At present, RF identification tag technology is such that the tag  20  should be as close as possible to the read/write unit to provide optimal performance. Normally, the core  14  is disposed on the spindle  12  so that the tag  20  is disposed at the bottom of the core  14  adjacent the antenna  34  of the read/write unit  28 . However, if the core  14  is reversed and is placed on the spindle  12  so that the tag  20  is at the top of the core  14 , the tag  20  is further away from the antenna  34 . The ferrite core  40  that is molded in the spindle helps direct the lines of flux of the RF signal to the top of the core  14 . Therefore, if the tag  20  is disposed at the top end of the core  14 , the RF signals from the read/write unit  28  are still effectively transmitted to the top end of the core and the tag  20 , to allow effective reading and writing of data. This also reduces interference with other tags that may be adjacent the tag  20 . For topping foil, which is normally mounted in a horizontal orientation, the tag would generally be provided at one end only. 
     An important aspect of the RF identification tag system of the present invention is the data that is stored on the memory element  24 , and how that data is utilized. It is preferred that the data identify the type of supply material that is present on the core  14 . In addition, the data should include a unique identifier that identifies the specific roll. Preferably, reading of the data on the tag  20  is automatically performed every time a ribbon is loaded into the printer, as well as each time the printer is re-started. 
       FIG. 4  illustrates an exemplary identification code  50  that is stored in the memory element  24 . The code  50  is preferably an eleven digit numeric ID code. However, it is contemplated that the code  50  could be formed from alphabetic characters, alphanumeric characters, symbolic characters, and combinations thereof. 
     The first three digits of the code  50  represent a particular supply item identifier number  52 . The use of three digits allows up to 999 supply items to be identified. For example, one type of print-ribbon roll from a particular manufacturer could be assigned the identifier number  123 , while a second, different type of print ribbon roll from the same manufacturer could be assigned the identifier number  423 . A look-up table within the equipment&#39;s operating system stores information, such as by supply item identifier number, for each supply item supported by the equipment. By reading the supply item identifier number  52 , information pertaining to the supply item can thus be accessed. The supply item identifier number  52  could be formed by a larger or smaller number of digits, depending upon the number of supply items that need to be identified. 
     The code  50  also includes a date identifier portion  54  which identifies the year the supply item was produced. The last digit of the year in which the supply item was produced is preferably used. For example, if the supply item was produced in the year 2001, the digit used in the date identifier  54  would be “1”. The date identifier  54  could utilize a larger number of digits to represent the year if desired. It is also contemplated that the code  50  could be used without the date identifier  54 . 
     The last portion of the code  50  is an individual supply item identification number  56  that is unique to the individual supply item. The use of seven digits allows up to 9,999,999 individual supply item ID numbers to be used. The identification number  56  allows the equipment&#39;s operating system to store information for each individual supply item, so that each individual supply item can be tracked and monitored. The supply item identification number  56  could be represented by a larger or smaller number of digits, depending upon how many individual supply items are to be tracked and monitored. 
     In addition to the identification code  50 , additional data that can be stored on the memory element  24  of the tag  20  includes, but is not limited to:
         1) Data indicating how much useable ribbon remains on the roll, i.e. ribbon amount data. This data can be continuously updated in known fashion during equipment use by tracking ribbon use and decrementing the ribbon amount data based upon use. An alternative, as discussed below, is to decrement the ribbon amount data based upon-print jobs, with this information being provided by the printer controller.   2) Data pertaining to the offsets to be applied to the equipment based upon the particular ribbon; i.e. system offset data.   3) Data pertaining to the use history of the ribbon, i.e. use history data. The data can include information relating to the type(s) of equipment (if any) the roll has been previously used in; the times and/or dates of previous uses and roll loading/unloading events, both in previous equipment and in the equipment the roll is presently loaded in; the operator(s) of the equipment; how many data bearing identity documents have been produced using the roll, for each use and/or total; and information as to whether any problems with the roll or the equipment occurred during roll use.   4) Manufacturer data.   5) Promotional/Marketing data.       

     Some of this data can be stored in a look-up table(s) in the system memory of the equipment, rather than being stored in the memory element  24 , with the data being accessed by reading the supply item identifier number  52  and/or the individual supply item identification number  56  from the code  50 . This would minimize the storage requirements of the memory element  24 . However, in some instances it is preferred to store as much of this data as possible on the memory element, which would allow the ribbon roll to be used in equipment that do not have, or have access to, look-up tables containing the needed data. 
     As a result of the tag  20 , the operation of the equipment with which the supply item is used can be enhanced based upon the particular supply item that is loaded into the equipment. A specific implementation of this concept will be described in relation to the use of print ribbon rolls in a printer. When a print ribbon roll that is loaded into the-printer is determined by the operating system of the printer to be from a first pre-determined group of print ribbon rolls, as determined by reading the supply item identifier number  52  from the code  50  or by a failure to read any data, e.g. the print ribbon roll does not have a tag, the printer operates in its usual fashion which will be referred to hereinafter as the printer&#39;s “normal mode”. However, when a print ribbon roll loaded into the printer is determined by the operating system of the printer to be from a second pre-determined group of print ribbon rolls, as determined by reading the supply item identifier number  52  from the code  50 , the operation of the printer can be enhanced via the printer&#39;s operating system initiates various system activities that are based on the loaded print ribbon roll. This enhanced operation will be referred to hereinafter as the printer&#39;s “enhanced mode”. The supply item identifier number(s) belonging to the first and second predetermined groups can be stored in look-up tables in the printer&#39;s operating system. A print ribbon roll without a tag will default to the printer normal mode operation. 
     Numerous enhancements can be realized in the printer enhanced mode. These enhancements include enhanced printer operation, data tracking and reporting, error proofing, and inventory management. 
     Printer Operation 
     In current print ribbon rolls without an RF ID tag, in order to determine the type of print ribbon on the roll, it is necessary for the operator to manually identify the ribbon type to the printer by entering the ribbon type using a printer user interface unit. This process is time consuming and inconvenient for the operator. It also requires a printer operator with sufficient skill to enter the ribbon type. Alternatively, it is known to automatically identify a print ribbon by advancing the print ribbon a certain distance to enable the printer to determine the print ribbon type. Because the print ribbon is advanced for identification purposes, this process wastes ribbon that could have been used for printing. 
     Because of the tag  20 , the printer knows the type of ribbon on the roll by reading the code  50 . Therefore, the printer can automatically optimize its operation based upon the loaded ribbon type. Further, ribbon useage is reduced since the ribbon is not advanced for identification purposes. This minimum advancement feature is applicable in the printer normal mode, for those rolls belonging to the first pre-determined group. As an added benefit in the enhanced mode for those rolls determined to be in the second pre-determined group, ribbon useage can be maximized by backing-up the ribbon so that previously used portions of the ribbon are re-used. 
     Further, for those rolls determined to be in the second pre-determined group, printer servicing operations can be optimized. For example, when the printer shuts down as a result of a sensed problem, and the operator completes all validation checks resulting from the shut down, the printer can be set-up to automatically resume operation without requiring the operator to send the printer an acknowledgement, provided the loaded roll is determined to be from the second pre-determined group. For a loaded roll determined to be from the first pre-determined group, the printer would require that an acknowledgement from the operator be input, prior to resuming operation. In addition, for impending servicing needs, such as a low print ribbon, the printer can be set-up to provide an indicator to the operator of the impending servicing need, and indicate to the operator the location of the servicing need. 
     An additional benefit provided to the second pre-determined group is that the printer can be set-up to display an icon that provides a graphical display of the amount of ribbon remaining on the roll. For example, the icon can be a thermometer bar, an odometer, or the like. Text can accompany the icon to indicate the percent of ribbon remaining. In addition, the icon can be colored to match the color of the ribbon. In contrast, for the first pre-determined group, the printer can be set-up to simply provide an indication as to whether the print ribbon is loaded or not. 
     Data Tracking and Reporting 
     For a roll determined to be from the second pre-determined group, the printer can be set-up to perform a variety of data tracking, data analyzing, and data reporting functions. For example, when a print ribbon is loaded, data from the memory element or from a look-up table, such as the offsets required by the ribbon, can be read and applied to the printer, and data, such as the time and date, can be written to the memory element or look-up table. 
     During use of the ribbon, data, such as the number of documents produced and operating time to allow determination of throughput rate, can be stored in the memory element or a look-up table. The throughput rate can then be displayed and/or analyzed. 
     Similarly, when the ribbon roll is unloaded from the printer, data pertaining to the unloaded ribbon is stored in the memory element or in a look-up table. 
     Error Proofing 
     For a roll determined to be from the second pre-determined group, certain error proofing features will result. For example, the printer is set-up to perform a check of the ribbon to determine ribbon compatibility with the printer by checking a material compatibility look-up table stored in the printer operating system. The printer determines whether there are any compatibility issues and displays recommendations to the operator. The operator can also be given a choice whether to proceed or not. Further, if the ribbon type is improper (e.g. cleaning tape is loaded instead of a print ribbon), a warning message and/or indicator can be displayed. 
     In addition, the printer is preferably set-up to automatically apply the system offset data for ribbons from the second pre-determined group. For ribbons from the first pre-determined group, the offset information for a particular ribbon must be manually entered by the operator after being prompted for the offset information. 
     For the second pre-determined group, the printer is also set-up to verify that the loaded print ribbon is suitable for the current document production job. If it is not, a warning message will be provided and the printer will pause until the error has been corrected. Once corrected, the printer will automatically resume operation. 
     Also for the second pre-determined group, the printer will detect if the loaded roll is from a re-called lot (determined from the code  50 ), and provide a warning message on a suitable display as well as instructions on how to deal with the issue. The instructions can be updated as needed by updating the re-call information stored in the printer&#39;s operating system. 
     Inventory Management 
     A further enhancement is that data reports can be generated for the printer detailing information on the ribbons that have been loaded into the printer per time period. This enhancement is available for the second pre-determined group. In addition, the printer preferably tracks and counts each time a roll from the second pre-determined group is loaded into the printer. In more advanced applications, the printer can track the detailed useage of a ribbon roll from the second pre-determined group, as well as generate reports detailing the ribbons that have been consumed over a pre-determined time period. 
     In each of the enhancements described herein, it is contemplated that the operating system of the printer can access and communicate with a remote or host controller via a modem, a network, or other suitable communication technology. The look-up tables and other data storage capacity necessary to implement the enhancements can thus be provided by the remote controller, rather than locally at the printer. 
     The tag has so far been described as being attached to a ribbon supply core. However, other tag locations are possible.  FIG. 5  illustrates a print ribbon supply item  60  that includes a print ribbon  62 , preferably a multi-color print ribbon, that supplies the dye or ink used in the printing process. The ribbon  62  is wound onto a supply core or cylinder  64  that is cylindrical in shape. The ribbon  62  includes a take-up end that is attached to a take-up core or cylinder  66  that is cylindrical in shape and upon which used ribbon is wound. In  FIG. 5 , the ribbon  62  is illustrated as being unused, with substantially the entire extent thereof wound onto the supply cylinder  64 , and the end of the ribbon  62  being attached to the take-up cylinder  66  ready to take-up used ribbon. 
     The supply item  60  is intended to be mounted on a carrier  68  that includes a rotatable supply spindle  70  that receives the supply cylinder  64  thereon and a rotatable take-up spindle  72  that receives the take-up cylinder  66  thereon. A cap  74  is attached to the end of the take-up cylinder  66 , and fixed to the cap  74  in a suitable manner is an RF identification tag  76 . In this embodiment, a suitable RF read/write unit for reading data from and to the tag  76  will be positioned adjacent the end of the take-up cylinder  66 . 
       FIG. 6  illustrates the supply item  60  positioned within a desktop thermal printer  80 . The printer  80  is related to the printer disclosed in U.S. Pat. No. 5,762,431, the entire disclosure of which is incorporated by reference. The printer  80  is used to print data and/or graphics onto plastic cards, for example financial (e.g. credit and debit) cards, drivers&#39; licenses, national identification cards, and other cards. The printer  80  can also be provided with features to perform additional processing operations on the cards, including laminating the cards, printing bar codes, reading from and/or writing to magnetic stripes on the cards, and reading from and/or writing to an integrated circuit chip on the card. After positioning the supply item  60  on the carrier  68 , the carrier  68  is then inserted into the printer  80  which positions the print ribbon  62  for subsequent printing. 
     The tag  76  can store data that is the same as, or different from, the data stored in the tag  20 . Preferably, the tag  76  permits the printer  80  to operate with the same enhancements as described above. 
     It is preferred that the tag  76  store at least data concerning the amount of ribbon remaining on the supply cylinder  64 . This data is preferably decremented during use of the printer, so that the tag  76  contains information on how much ribbon remains. Preferably, the ribbon remaining data on the tag  76  is decremented based upon the print jobs performed by the printer  80  using information provided by the printer controller. 
     For most print jobs, the printer controller can determine approximately how much ribbon will be needed to complete each print job. Therefore, the ribbon remaining data can be decremented by the amount of ribbon expected to be used for each print job. An excess margin, if needed, can be factored into the expected ribbon use determination to account for discrepancies and errors. Thus, as each print job is completed, or sometime thereafter, the ribbon remaining data on the tag  76  is updated by the information provided by the printer controller. 
     Other ways for determining the amount of ribbon used can be used. For example, an encoder could be used in association with the supply cylinder  64  or on the supply side of the supply item  60  to directly track ribbon use. Alternatively, an encoder could ride on the surface of the ribbon on the supply cylinder to rotate in proportion to the amount of ribbon that gets unspooled from the supply cylinder  64 . A capstan encoder or other encoder device downstream from the supply cylinder  64  and in engagement with the print ribbon could also be used to directly track ribbon use. 
     In one implementation, the tag  76  also preferably stores an encryption string to make the tag  76  difficult to reproduce. The tag  76  can also store one or more of the following: a part number, information on the ribbon type, a date code, a manufacturers lot code, a manufacturers code, and copyright information. The tag  76  can also store a count that is decremented, for example after each print job, to enable the tag  76  to expire once the count reaches zero or other chosen value. 
     In addition, the tag could be positioned to hang off the end of the supply or take-up cylinders and not rotate with the cylinder during use. In such an embodiment, the tag would be fixed in position relative to the cylinder during printer operation, such as by the tag cooperating with a slot in the printer upon inserting the carrier into the printer. The tag could also be separate from the supply and take-up cylinders, and instead be placed by a user into the printer when the supply item is replaced. 
     The above specification, examples and date 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.