Abstract:
Modular print engines and print engine components that are usable in desktop card printers for personalizing plastic cards such as financial cards including credit and debit cards, identification cards, driver&#39;s licenses, and other personalized plastic cards. The modular nature of the print engines and print engine components permit alteration in the specific functionality of the desktop card printers depending upon, for example, the personalization requirements of the plastic cards and intended applications of the desktop card printers. In addition, the modular print engine components can be completely tested prior to installation into the modular print engines to ensure that the modular print engine components are working correctly prior to installation. Furthermore, the modular print engine components add flexibility to the desktop card printers as upgraded functionality and features can be introduced by developing new modular components.

Description:
FIELD 
       [0001]    This disclosure describes modular print engines and modular print engine components that can be used with the modular print engines to personalize plastic cards such as financial cards including credit and debit cards, identification cards, driver&#39;s licenses, and other personalized plastic cards. 
       BACKGROUND 
       [0002]    Plastic cards such as financial cards including credit and debit cards, identification cards, driver&#39;s licenses, and other personalized plastic cards are typically personalized with personal information of the intended card holder. Examples of personalization include, but not are limited to, names, addresses, photographs, account numbers, employee numbers, or the like. The personal information may be applied to the card in a number of different ways including, but not limited to, printing on a surface of the document, storing the information on a magnetic stripe disposed on the card, and storing the information on an integrated circuit chip or smart chip embedded in the card. 
         [0003]    In some cases, the plastic cards are personalized using a desktop card printer that has a relatively small footprint intended to permit the desktop card printer to reside on a desktop and that is designed to personalize cards in relatively small volumes, for example measured in tens or low hundreds per hour. An example of a desktop printer is the CD800 Card Printer available from Entrust Datacard Corporation of Shakopee, Minn.. 
         [0004]    Desktop card printers are typically designed to be relatively small so that the printers can fit onto a desk or table. The desktop card printer 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 printer (i.e., its “footprint”) should be minimized. 
         [0005]    At the same time, it is desirable that a desktop card printer be able to perform multiple card processing operations, thereby increasing the performance capability of the desktop card printer. 
         [0006]    Additionally, desktop card printers should be easy to operate and maintain with only a minimal amount of specialized training. Desktop card printers 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 printer should thus be relatively intuitive and straightforward. Furthermore, the cards that are output from the card printer must be of the highest quality, attractive, and durable. 
       SUMMARY 
       [0007]    Modular print engines and modular print engine components useable with the modular print engines are described. The modular print engines and print engine components are usable in desktop card printers for personalizing, for example, plastic cards such as financial cards including credit and debit cards, identification cards, driver&#39;s licenses, and other personalized plastic cards. The modular nature of the print engines and print engine components described herein permit alteration in the specific functionality of the desktop card printers depending upon, for example, the personalization requirements of the plastic cards and intended applications of the desktop card printers. In addition, the modular print engine components can be completely tested prior to installation into the modular print engines to ensure that the modular print engine components are working correctly prior to installation. Furthermore, the modular print engine components add flexibility to the desktop card printers as upgraded functionality and features can be introduced by developing new modular components. 
         [0008]    In one embodiment, the modular print engine can be removably mounted on top of a lower module that performs one or more card processing operations including, but not limited to, embossing, laminating, or both embossing and laminating. The functionality of the desktop card printer can be selectively altered by installing different ones of the modular print engine components into and/or onto the module print engine. Before or after printing in the modular print engine, a plastic card can be directed from the modular print engine into the lower module to perform the processing operation(s) of the lower module. Thereafter, the plastic card can be output from the lower module or directed back into the modular print engine for further processing and/or output of the personalized card. 
         [0009]    The modular print engine can include a card input at a front end of a housing, as well as a card input hopper which is in communication with the card input to input cards into the modular print engine for personalization. A card reorienting mechanism is in the housing adjacent to a rear end thereof, and the card reorienting mechanism is configured to receive a plastic card and rotate the card to redirect the card along a desired card travel path in the housing. A first card travel path extends between the card input and the card reorienting mechanism with cards being transported along the first card travel path by a card transport mechanism. A print engine that is configured to print on a card is disposed along the first card travel path. The print engine can perform any type of printing including, but not limited to, retransfer printing, direct to card printing, ink jet printing, laser marking, laser engraving, and any other type of printing performed on cards. 
         [0010]    The modular print engine also includes a second card travel path extending from the card reorienting mechanism. A removable option module is disposed along the second card travel path. The removable option module includes at least one personalization mechanism that is configured to perform a personalization operation on a card. The removable option module can be removed and replaced with a different option module that is configured to have a different functionality. A plurality of different option modules, each having different functionality, can be created. Each option module is configured to be individually and separately removably installed in the housing along the second card travel path, and each option module is configured to perform a different personalization operation on a plastic card received thereby. One option module can be removed and replaced with a different option module to change the functionality of the modular print engine. 
         [0011]    The modular print engine includes a first card opening in the bottom of the housing. A third card travel path extends from the card reorienting mechanism to the first card opening to permit a card to be output from the modular print engine and into the lower module. In some embodiments, after processing in the lower module, the plastic card can be input back into the modular print engine through the first card opening for further processing and/or output from the modular print engine. 
         [0012]    In one embodiment, a second card opening can be provided in the rear end of the housing, and a fourth card travel path extends from the card reorienting mechanism to the second card opening. In this embodiment, a second option module can be attached to the rear end of the housing for receiving a card from the second card opening. The second option module can include at least one processing mechanism that is configured to perform a processing operation on a card. 
         [0013]    In another embodiment, a second card opening can be provided in the top of the housing, and the second card travel path extends from the card reorienting mechanism to the second card opening. An upper expansion module can be attached to the top of the housing and can receive a plastic card from the modular print engine through the second card opening, with the card then being directed to an output of the upper expansion module through which the plastic card can be output from the upper expansion module. 
         [0014]    In one embodiment, a modular print engine useable in a desktop card printer that personalizes cards includes a housing having a front end, a rear end, a top and a bottom. A card input is at the front end of the housing, and a card input hopper is disposed at the front end of the housing that is in communication with the card input. A card reorienting mechanism is disposed in the housing adjacent to the rear end, with the card reorienting mechanism being configured to receive a card and rotate the card to redirect the card along a desired card travel path. A first card travel path extends between the card input and the card reorienting mechanism. In addition, a second card travel path extends from the card reorienting mechanism. A print engine that is configured to print on a card is disposed along either the first card travel path or the second card travel path, and a removable option module is disposed along either the first card travel path or the second card travel path. The removable option module includes at least one personalization mechanism that is configured to perform a personalization operation on a card. In addition, a first card opening is formed in the bottom of the housing, and a third card travel path extends from the card reorienting mechanism to the first card opening. 
         [0015]    In another embodiment, a desktop card printer system that personalizes cards includes a housing having a front end, a rear end, a top and a bottom. A card input is at the front end of the housing, and a card input hopper is in communication with the card input. A card reorienting mechanism is disposed in the housing adjacent to the rear end, with the card reorienting mechanism being configured to receive a card and rotate the card to redirect the card along a desired card travel path. A first card travel path extends between the card input and the card reorienting mechanism. In addition, a second card travel path extends from the card reorienting mechanism. A print engine that is configured to print on a card is disposed along either the first card travel path or the second card travel path. The system also includes a plurality of option modules, where a single one of the option modules is configured to be removably installed in the housing along either the first card travel path or the second card travel path. Each option module is configured to perform a different personalization operation on a plastic card received thereby. Therefore, by changing the option module that is installed, the functionality of the desktop card printer can be changed. 
         [0016]    As used herein, a processing mechanism is intended to encompass a mechanism that performs a processing operation on a card that can involve personalization or not involve personalization. For example, applying a transparent protective laminate, perhaps even including a hologram or other non-personalized security feature, is an example of a card processing operation that does not involve personalization. Applying a name, address, photograph, account number, employee number, signature, or the like to a card are examples of processing operations that involve personalization. A personalization mechanism is intended to encompass a mechanism that performs a processing operation on a card that involves personalization. The term processing operation therefore encompasses both personalization and non-personalization operations performed on a card, while the term personalization operation encompasses personalization operations performed on a card. 
     
    
     
       DRAWINGS 
         [0017]      FIG. 1  schematically illustrates a modular print engine described herein removably mounted on top of a lower module. 
           [0018]      FIG. 2  schematically illustrates an example of a re-transfer print engine that can be used with the modular print engine of  FIG. 1 . 
           [0019]      FIGS. 3A-D  schematically illustrate examples of different option modules that can be installed one at a time in the modular print engine of  FIG. 1 . 
           [0020]      FIG. 4  schematically illustrates another embodiment of a modular print engine with an upper expansion module. 
           [0021]      FIG. 5  schematically illustrates another embodiment of a modular print engine with a second option, or rear expansion, module. 
           [0022]      FIGS. 6A-C  schematically illustrates examples of different second option modules that can be used with the modular print engine of  FIG. 5 . 
           [0023]      FIG. 7  schematically illustrates another embodiment of a modular print engine with an option module located below the print engine. 
           [0024]      FIG. 8  schematically illustrates another embodiment of a modular print engine with a removable option module located between the input and the card reorienting mechanism. 
       
    
    
     DETAILED DESCRIPTION 
       [0025]    As described further below, in some embodiments, a modular print engine  10  can include a card reorienting mechanism that is disposed at the intersection of four distinct card travel paths. In one embodiment, the four card travel paths are located at 90 degree intervals around the card reorienting mechanism and the card travels paths extend either horizontally or vertically. However, the four card travel paths can be positioned at other spaced intervals about the card reorienting mechanism, and the card travel paths need not extend horizontally or vertically. 
         [0026]    In addition, the modular print engine  10  described further below can include a card input at a front end thereof and a card opening through a rear end thereof. In some embodiments, there can also be a card opening through a bottom of the modular print engine  10 . In other embodiments, there can also be a card opening through a top of the modular print engine. Depending upon the desired card travel path through the desktop card printer, the card openings can be card inputs or both inputs and outputs. 
         [0027]    Referring to  FIG. 1 , a first embodiment of a modular print engine  10  is illustrated as being detachably and removably mounted on top of a lower module  12 . Together, the modular print engine  10  and the lower module  12  form a desktop card printer that in use is configured to personalize, for example, plastic cards such as financial cards including credit and debit cards, identification cards, driver&#39;s licenses, and other personalized plastic cards. The desktop card printer is designed to have a relatively small horizontal (i.e. front to back) footprint intended to permit the desktop card printer to reside on a desktop or table and that is designed to personalize cards in relatively small volumes, for example measured in tens or low hundreds per hour. 
         [0028]    The connection between the modular print engine  10  and the lower module  12  can be any form of non-permanent connection that permits the modular print engine  10  to be detachably mounted on top of the lower module  12  and that permits the modular print engine  10  to be non-destructively detached from the lower module  12  without destroying any portion of the modular print engine  10  or the lower module  12 . An example of a suitable detachable mounting between a print engine and a lower module is the detachable mounting used in the CD800 print engine that interfaces with a lower laminator module or the CE870 print engine that interfaces with a lower embosser module, both of which are available from Entrust Datacard Corporation of Shakopee, Minn.. 
         [0029]    The lower module  12  is of conventional construction and operation and as shown in  FIG. 1  generally includes a lower module housing  14  illustrated in dashed lines with a front end  16 , a rear end  18  opposite the front end  16 , a top  20 , and a bottom  22  opposite the top  20 . A main card transport path  24  is defined in the housing  14  along which a plastic card is transported generally in a horizontal direction or generally parallel to the top  20  and the bottom  22 . A slot  26  is defined in the top  20  of the housing  14  through which a card can be input into the housing  14  from the modular print engine  10  and, in some embodiments, output from the housing  14  back into the modular print engine  10 . A secondary card transport path  28  leads from the slot  26  to a card reorienting mechanism  30  that is disposed adjacent to the rear end  18  of the housing  14 . In one embodiment, the secondary card transport path  28  can be generally vertical or perpendicular to the main card transport path  24  which can be generally horizontal. 
         [0030]    The card reorienting mechanism  30  is rotatably disposed in the housing  14  for rotation both clockwise and counterclockwise as indicated by the arrow on the card reorienting mechanism  30 . When a card is being input into the lower module  12  from the modular print engine  10 , the card reorienting mechanism  30  is configured to receive a card along the secondary card transport path  28  and rotate the card so as to direct the card along the main transport path  24 . Likewise, when a card is being output from the lower module  12  back into the modular print engine  10 , the card reorienting mechanism  30  can receive a card from the main transport path  24 , and rotate the card so as to direct the card along the secondary card transport path  28  for transport out of the lower module  12 . Examples of suitable card reorienting mechanisms are described in U.S. 2013/0220984 and U.S. Pat. No. 7,398,972 each of which is incorporated herein by reference in its entirety. A card is transported along the main card transport path  24  and the secondary card transport path  28  by suitable card transport mechanisms, such as rollers  32 ,  34 . In some embodiments, the card transport mechanisms are reversible to allow a card to be transported in forward (i.e. during card input) and reverse (i.e. during card output back through the slot  26 ) directions along each card transport path  24 ,  28  as shown by the arrows in  FIG. 1 . In other embodiments where the card is to be output directly from the lower module  12  after processing in the lower module  12 , the card transport mechanisms need not be reversible. 
         [0031]    The lower module  12  includes at least one card processing mechanism  36  disposed along the main card transport path  24  that is configured to perform a processing operation on the card. In one embodiment, a single card processing mechanism  36  can be provided. In another embodiment, two or more card processing mechanisms  36  can be provided one after the other along the main card transport path  24 . Examples of card processing mechanisms  36  that can be used include, but are not limited to, a card embosser or a card laminator. The lower module  12  can also include an output  38  at the end of the transport path  24  through which a card can be output from the lower module  12  after processing by the processing mechanism(s)  36 . In some embodiments, the lower module  12  may also include a card de-bowing mechanism (not shown) that is used to eliminate a bow that may occur on the card as a result of processing by the processing mechanism(s)  36 . An example of a suitable de-bowing mechanism that can be used is described in US 2014-0345787 the entire contents of which are incorporated herein by reference. A suitable lower module with a card embosser or a card laminator is available from Entrust Datacard Corporation of Shakopee, Minn.. 
         [0032]    In operation of the lower module  12 , a card enters the lower module  12  from the modular print engine  10  through the slot  26 . The card is transported along the secondary card transport path  28  and into the card reorienting mechanism  30  which is then rotated to bring the card in line with the main card transport path  24 . The card is then directed along the main card transport path  24  to the card processing mechanism(s)  36  which performs the one or more processing operations on the card. In one embodiment, the card is then transported along the transport path  24  to the output  38  and output from the lower module  12 , for example into a hopper that can collect multiple cards. In other embodiments, after processing by the card processing mechanism(s)  36 , the card can be transported in the reverse direction along the main card transport path  24  back to the card reorienting mechanism  30  which receives the card and rotates the card to bring the card in line with the secondary card transport path  28 . The card is then transported along the secondary card transport path  28  and back out of the lower module  12  through the slot  26  and back into the modular print engine  10 . 
         [0033]    With continued reference to  FIG. 1 , the modular print engine  10  includes a housing  50  having a front end  52 , a rear end  54 , a top  56  and a bottom  58 . A main card input  60  is located at the front end  52  of the housing  50  through which plastic cards to be processed by the modular print engine  10  and/or by the lower module  12  (i.e. processed by the desktop card printer) are input. In some embodiments, the card input  60  can also form a card output through which processed cards can be output from the modular print engine  10 . In other embodiments, a card output that is separate from the card input  60 , but also located at the front end  52  like the card input  60 , can be provided through which processed cards can be output from the modular print engine  10 . 
         [0034]    A card input hopper  62  can be mounted at the front end  52  of the housing  50  that is in communication with the card input  60 . The card input hopper  62  is designed to hold a number of plastic cards waiting to be processed which are fed one-by-one into the housing  50  by a suitable card feed mechanism  64  known in the art. In embodiments where a card output is also located at the front end  52 , a card output hopper  66  can also be mounted at the front end  52  of the housing  50  that is in communication with the card output for receiving finished processed cards. The card output hopper  66  is designed to hold a number of finished processed cards after they have been processed which are fed out of the housing through a suitable card outlet, which can coincide with or be separate from the card inlet  60 , and dropped into the card output hopper  66  in a manner known in the art. In one embodiment, the card input hopper  62  and the card output hopper  66  form an integral, single unit where the input hopper  62  and the output hopper  66  are combined together into a common structure that is mountable and removable as a single unit from the housing  50 . In another embodiment, the input hopper  62  (as well as the output hopper  66  or both the input hopper  62  and the output hopper  66 ) can be configured with a multihopper configuration where the input hopper  62  is configured to simultaneously hold different card stock (for example, Visa® and Mastercard® branded card stock; driver&#39;s license card stock from different states; identification card stock having different security levels; etc.) waiting to be personalized. Each type of card stock can be selectively input into the modular print engine from the input hopper  62  as selected by the printer controller based on the type of card to be created. 
         [0035]    A main or first card travel path  68  extends through the housing  50  from the input  60 . In the illustrated example, the card travel path  68  extends substantially horizontally through the housing  50  substantially parallel to the bottom  58 . Cards are transported along the card travel path  68  by a card transport mechanism, such as sets of rollers  70 . In some embodiments, the card transport mechanism can be reversible to allow the cards to be transported in forward (for example during card input or during printing) and reverse (for example, if a card is to be output from the modular print engine  10  through the front end  52  or to transport a card upstream of a printer before, during or after printing) directions along the travel path  68  as shown by the arrow in  FIG. 1 . 
         [0036]    A card reorienting mechanism  72  is disposed in the housing  50  along the card travel path  68  adjacent to the rear end  54 . The card reorienting mechanism  72  is rotatably disposed in the housing  50  for rotation both clockwise and counterclockwise as indicated by the arrow on the card reorienting mechanism  72 . The card reorienting mechanism  72  is configured to receive a card along the card travel path  68  and rotate the card so as to direct the card in a different direction along a desired card travel path. Examples of suitable card reorienting mechanisms are described in U.S. 2013/0220984 and U.S. Pat. No. 7,398,972 each of which is incorporated herein by reference in its entirety. 
         [0037]    A print engine  74  is disposed along the card travel path  68  that is configured to print on a card disposed on the card travel path  68 . In one embodiment, the print engine  74  can be configured to perform retransfer printing as described further below with respect to  FIG. 2 . However, the print engine  74  can be configured to perform direct to card printing, ink jet printing, laser marking, laser engraving, and any other type of printing performed on cards. 
         [0038]    With continued reference to  FIG. 1 , a second card travel path  76  can extend upwardly from the card reorienting mechanism  72 . In one embodiment, the second card travel path  76  extends substantially vertically upward from the card reorienting mechanism  72 . However, the second card travel path  76  is not limited to extending vertically and can instead extend upwardly at an angle to vertical. Cards are transported along the card travel path  76  by a card transport mechanism, such as sets of rollers  78 . In some embodiments, the card transport mechanism can be reversible to allow the cards to be transported in forward and reverse directions along the travel path  76  as shown by the arrow in  FIG. 1 . 
         [0039]    A removable option module  80  is disposed along the second card travel path  76  and above the first card travel path  68 . The removable option module  80  includes at least one card processing mechanism that is configured to perform a processing operation on a plastic card. As discussed further below with respect to  FIGS. 3A-D , the removable option module  80  is one of a plurality of removable option modules  80  that can be installed one at a time in the modular print engine  10  to permit changes to the functionality of the modular print engine  10 . Each option module  80  is configured to be individually and separately removably installed in the housing  50  along the second card travel path  76  and above the first card travel path  68 , and each option module  80  is configured to perform a different processing operation on a plastic card received thereby. One option module  80  can be removed and replaced with a different option module  80  to change the functionality of the modular print engine  10 . 
         [0040]      FIG. 3A  illustrates that in one embodiment, the option module  80  can include a magnetic stripe reader and/or writer  82  that can read data on a magnetic stripe of a card and/or write data onto the magnetic stripe. Magnetic stripe readers and/or writers are well known in the art.  FIG. 3B  illustrates that in another embodiment, the option module  80  can include a smart card reader and/or writer  84  that can read data stored on an integrated circuit chip (i.e. smart card chip) on the card and/or write data to the chip. The smart card reader and/or writer  84  can be configured for contact or contactless reading and/or writing. Smart card readers and/or writers, both contact and contactless, are well known in the art. In another embodiment illustrated in  FIG. 3C , the option module  80  can include both the magnetic stripe reader and/or writer  82  and the smart card reader and/or writer  84  arranged in any order. In another embodiment illustrated in  FIG. 3D , the option module  80  can include two smart card readers and/or writers  84 . The card processing mechanism(s) in the option modules  80  is not limited to a magnetic stripe reader and/or writer  82  and a smart card reader and/or writer  84 . Other card processing mechanisms can be included in the option modules  80  in combination with or separately from the magnetic stripe reader and/or writer  82  and the smart card reader and/or writer  84 . Examples of other card processing mechanisms that can be included in the option modules  80  can include, but are not limited to, a scanner that can read a one dimensional bar code on a card surface, a camera that can be used to read a one or two dimensional bar code on a card surface or capture an image of a card surface, a hole puncher that punches one or more holes in the card, and other card processing mechanisms. In one embodiment, the camera, if used, can be arranged to capture one or more images of a card surface while the card is held by the card reorienting mechanism  72 . 
         [0041]    Depending upon the desired functionality of the modular print engine  10 , one can install the appropriate option module  80  in the modular print engine  10 . Because each option module  80  is modular, each option module  80  can be completely tested prior to installation into the modular print engine  10  to ensure that the option module  80  is working correctly prior to installation. Further, to change functionality of the modular print engine  10 , the user can replace one option module  80  with another option module  80  having the desired functionality. 
         [0042]    Returning to  FIG. 1 , a third card travel path  86  can extend downwardly from the card reorienting mechanism  72 . In one embodiment, the third card travel path  86  extends substantially vertically downward from the card reorienting mechanism  72  substantially in-line with the card travel path  76 . However, the third card travel path  86  is not limited to extending vertically and can instead extend downwardly at an angle to vertical. Cards are transported along the card travel path  86  by a card transport mechanism, such as rollers  88 . In some embodiments, the card transport mechanism can be reversible to allow the cards to be transported in forward and reverse directions along the travel path  86  as shown by the arrow in  FIG. 1 . 
         [0043]    The third card travel path  86  extends to a card opening  90  in the bottom  58  of the housing  50 . When the modular print engine  10  is correctly mounted on the lower module  12 , the third card travel path  86  and the card opening  90  are aligned with the card transport path  28  and the slot  26  of the lower module  12  so that a card can be transferred between the modular print engine  10  and the lower module  12 , i.e. transferred out of the modular print engine  10  and into the lower module  12 , and in some embodiments, transferred out of the lower module  12  and back into the modular print engine  10 . 
         [0044]    In some embodiments, the modular print engine  10  can further include a fourth card travel path  92  that can extend rearwardly from the card reorienting mechanism  72  as discussed further below with respect to  FIG. 5 . In one embodiment, the fourth card travel path  92  can extend substantially horizontally from the card reorienting mechanism  72  in-line with the card travel path  68 . However, the fourth card travel path  92  is not limited to extending horizontally and can instead extend at an angle to horizontal. When the fourth card travel path  92  is present, the travel path  92  extends to a card opening  94  formed in the rear  54  of the housing  50  to permit cards to exit and enter the card opening  94  through the rear  54  of the housing  50 . 
         [0045]    The modular print engine  10  can therefore include a card input at the front end  52  thereof and the card opening  94  through the rear  54  thereof. In some embodiments, there can also be the card opening  90  through the bottom of the modular print engine  10 . In other embodiments, there can also be the card opening  202  discussed in  FIG. 4 . 
         [0046]    Returning to  FIG. 1 , in some embodiments a card de-bowing mechanism  100  can be provided in the travel path  68  after the print engine  74 . The de-bowing mechanism  100  is configured to bend the card after printing to remove a bend in the card that may develop as a result of the printing of the card, especially with retransfer printing. The de-bowing mechanism  100  can be any mechanism that is suitable for eliminating a bend that may develop in the card. An example of a suitable de-bowing mechanism  100  that can be used is described in US 2014-0345787 the entire contents of which are incorporated herein by reference. 
         [0047]    A card reject hopper  102  is also located in the modular print engine  10 , for example above the travel path  68 , above the de-bowing mechanism  100 , and adjacent to the card reorienting mechanism  72 . The card reject hopper  102  is positioned to receive cards that one may wish to store and not output from the modular print engine  10 , for example cards that are determined to be defective for some reason. For example, a card may be determined to be defective by failing to read and/or write data using the magnetic stripe reader and/or writer  82  or using the smart card reader and/or writer  84  of the option module  80 . In such a case, the card is transported to the card reorienting mechanism  72  which rotates the card so that it is aligned with an input into the card reject hopper  102 , and the card reorienting mechanism  72  then discharges the defective card into the card reject hopper  102  using transport rollers on the card reorienting mechanism  72 . Optionally, the card reject hopper  102  can be located at any other suitable location in the modular print engine  10 , and cards to be stored in the card reject hopper  102  can be transported to the card reject hopper  102  using a suitable transport mechanism. 
         [0048]    In one exemplary operation of the modular print engine  10  of  FIG. 1 , a card can be initially input from the input hopper  62  through the input  60 . In one embodiment, the card is initially transported along the card travel path  68  to the card reorienting mechanism  72 , which redirects the card onto the second card travel path  76  where the card is transported into the option module  80 . The option module  80  determines whether the magnetic stripe and/or the chip on the card are working correctly, and if they are, data is written onto the magnetic stripe and/or onto the chip. If they are not working correctly, the card can be transported back along the second card travel path  76  to the card reorienting mechanism  72  which then directs the card into the card reject hopper  102 . After the data has been written, the card is transported back along the second card travel path  76  to the card reorienting mechanism  72  which then directs the card back onto the first card travel path  68 . The card is then transported back toward the front end  52  upstream of the print engine  74  for printing. The card is then printed on by the print engine  74 . After printing, if it is anticipated that the printing caused the card to bend, the card is transported to the de-bowing mechanism  100  which removes the bend in the card. The card is then transported to the card reorienting mechanism  72  which redirects the card to the third card travel path  86 . The card is then transported out of the modular print engine  10  and into the lower module  12  through the aligned card opening  90  and the slot  26 , and to the card reorienting mechanism  30  in the lower module  12 . The card reorienting mechanism  30  redirects the card onto the card transport path  24  where the card is transported to the card processing mechanism(s)  36 . After the card is processed in the card processing mechanism(s)  36 , the card can then be output from the lower module  12  via the output  38 . 
         [0049]    In other embodiments, after the card is processed in the card processing mechanism(s)  36 , the card can then be redirected back to the card reorienting mechanism  30  via the card transport path  24 , and redirected out of the lower module  12  and back into the card reorienting mechanism  72  of the modular print engine  10 . The card reorienting mechanism  72  can reorient the card for transport back along the card travel path  68  and into the output hopper  66 . Alternatively, if the card opening  94  in the rear  54  is used, the card can be redirected by the card reorienting mechanism  72  to the fourth card travel path  92  for discharge out the card opening  94 . Alternatively, as discussed further below, the card can be directed upwardly for discharge out of a card opening in the top of the modular print engine  10 . 
         [0050]    Many other operational sequences of the modular print engine  10  of  FIG. 1  are possible including, but not limited to, directing the card first to the lower module  12 , and then back into the modular print engine  10  for processing by the option module  80  and the print engine  74 . In addition, the card can be initially printed by the print engine  74  prior to the card being directed to the option module  80  and/or to the lower module  12 . In addition, the card can be initially directed into the option module  80 , followed by processing in the lower module, followed by printing by the print engine  74 . 
         [0051]    As illustrated in  FIG. 1 , the print engine  74  is disposed above the card travel path  68 . Applicant has discovered that locating the card travel path  68  below the print engine  74  improves the resulting print process by the print engine  74 . For example, card handling is more reliable. For print engines that rely upon heat in the printing process, for example using one or more heated transfer rollers in the case of retransfer printing, the improved card handling is believed to result from heat rising upward in a direction away from the card during printing. 
         [0052]    As described above, in one embodiment the print engine  74  can be configured to perform retransfer printing. Retransfer printing is well known in the art.  FIG. 2  illustrates an example of the print engine  74  configured for retransfer printing. The illustrated retransfer printing configuration includes a print side that includes print ribbon supply  150  from which a supply of monochrome or multi-color print ribbon  152  is supplied, and a print ribbon take-up  154  that takes-up used print ribbon  152 . The print ribbon is directed past a print head  156 , which in the illustrated example can be stationary, which transfers dye or pigment ink from the print ribbon  152  onto a retransfer film  158 . After printing, the used print ribbon  152  is then wound onto the take-up  154 . 
         [0053]    The retransfer film  158  is supplied from a film supply  160  on a retransfer side, and after retransfer the remaining film is wound onto a film take-up  162  also on the retransfer side. The retransfer film  158  is directed past a platen roller  164  positioned opposite the print head  156  and which in the illustrated example can be moved toward and away from the print head  156  to press the retransfer film  158  and the print ribbon  152  between the print head  156  and the platen roller  164  during printing onto the retransfer film  158 . The retransfer side can also include a capstan roller  166  that is also movable toward and away from the print side. 
         [0054]    Once a desired image is printed onto the retransfer film  158 , the retransfer film  158  with the printed image is advanced to a transfer section  168  where the printed image on the retransfer film  158  is transferred onto a surface of the card. The transfer section  168  includes a heated transfer roller  170  that is movable toward and away from a fixed platen  172  positioned on the opposite side of the travel path  68 . The heated transfer roller  170  presses the portion of the retransfer film  158  containing the printed image against the surface of the card which is backed by the platen  172 , with the retransfer film  158  and the card then being transported together past the heated transfer roller  170  to transfer the layer of the retransfer film  158  containing the printed image onto the card surface. The remainder of the retransfer film  158  is then wound onto the film take-up  162 . 
         [0055]    The specific construction and operation of retransfer printers, including the print ribbon, the retransfer film, printing an image on the retransfer film, and transferring the printed image onto a surface of a card, is well known in the art. One example of retransfer printing is disclosed in U.S. Pat. No. 6,894,710 among many others. U.S. Pat. No. 6,894,710 is incorporated herein by reference in its entirety. 
         [0056]    Referring now to  FIG. 4 , another embodiment of a modular print engine  200  is illustrated. Elements of the modular print engine  200  that are similar in construction and function to corresponding elements in the modular print engine  10  of  FIG. 1  are referenced using the same reference numerals. The lower module  12  is not illustrated in  FIG. 4 , but the modular print engine  200  would be mounted onto a lower module, which can be similar to or different than the lower module  12  in  FIG. 1 . 
         [0057]    In the embodiment in  FIG. 4 , the second card travel path  76  extends from the card reorienting mechanism  72  to a card opening  202  that is formed in the top  56  of the housing  50 . An upper expansion module  204  is attached to the top  56  of the housing  50 . The upper expansion module  204  can be selectively added to and removed from the modular print engine  200  to permit alteration in where cards are output. 
         [0058]    The upper expansion module  204  includes an input  206  that, when the upper expansion module  204  is correctly mounted on the housing  50 , is aligned with the card opening  202  for receiving a card therein. The upper expansion module  204  further includes a rotatable card reorienting mechanism  208  and an output  210  through which a card can be output from the modular print engine in a rearward direction. A card that enters the upper expansion module  204  is received in the card reorienting mechanism  208 , which redirects the card approximately 90 degrees and outputs the card through the output  210  aided if necessary by transport rollers  212 . The output  210 , or a separate output, could be formed at the front of the upper expansion module  204  to allow front discharge of cards separately from or in addition to outputting cards to the rear through the output  210 . If the upper expansion module  204  is not used, cards can still be output at the top  56  of the modular print engine  200  through the card opening  202 , or the card opening  202  can be closed to prevent card travel therethrough. 
         [0059]    Alternatively, instead of outputting cards from the upper expansion module  204 , the cards can be output from the lower module  12  or through the card opening  94  as discussed above in  FIG. 1 . Or a user may select to output one or more cards from the upper expansion module  204 , while selecting to output other cards from other locations of the desktop card printer. In this manner, the upper expansion module  204  expands the functionality of the modular print engine  200  by allowing a user to configure and select how cards are output from the modular print engine  200 . 
         [0060]    Referring now to  FIG. 5 , another embodiment of a modular print engine  250  is illustrated. Elements of the modular print engine  250  that are similar in construction and function to corresponding elements in the modular print engine  10  of  FIG. 1  are referenced using the same reference numerals. The lower module  12  is not illustrated in  FIG. 5 , but the modular print engine  250  would be mounted onto a lower module, which can be similar to or different than the lower module  12  in  FIG. 1 . 
         [0061]    In the embodiment in  FIG. 5 , the fourth card travel path  92  is present that extends substantially horizontally from the card reorienting mechanism  72  to the card opening  94  formed in the rear  54  of the housing  50 . A second option, or rear expansion, module  252  is removably attached to the rear end  54  of the housing  50  that permits a user to change the functionality of the modular print engine  250 . The second option module  252  includes at least one processing mechanism that is configured to perform a processing operation on, for example, a plastic card. The removable second option module  252  is one of a plurality of different removable second option modules  252 . Each second option module  252  is configured to be individually and separately removably installed on the rear  54  of the housing  50 , and each second option module  252  is configured to perform a different processing operation on a plastic card received thereby. One second option module  252  can be removed and replaced with a different second option module  252  to change the functionality of the modular print engine  250 . 
         [0062]    In general, each second option module  252  includes a card opening  254  that, when the second option module  252  is correctly mounted on the housing  50 , is aligned with the card opening  94  for receiving a card therein. In addition, each second option module  252  includes a housing  255  (seen in  FIGS. 6A-C ) that houses at least one processing mechanism that is configured to perform a processing operation, for example a personalization operation, on a plastic card. 
         [0063]      FIGS. 6A-6C  illustrate different examples of the second option modules  252 . Many other examples of second option modules  252  are possible including any combinations of the concepts illustrated in  FIGS. 6A-C . 
         [0064]    In  FIG. 6A , the second option module  252  includes a card travel path  256  that extends from the card opening  254  substantially in-line with the travel paths  68  and  92 . The travel path  256  can extend to an output  258  in the rear of the housing  255  through which cards can be selectively output. Cards are transported along the travel path  256  by a suitable reversible or non-reversible transport mechanism, such as transport rollers  260 . One or more card processing mechanisms  262  are provided along the travel path  256 , for example above the travel path  256 , for performing one or more additional processing operations on the card. The processing mechanism  262  can be, for example, a personalization mechanism such as a magnetic stripe reader and/or writer or a smart card reader and/or writer. The processing mechanism  262  can be any one or more mechanisms that perform one or more processing operations, such as personalization or non-personalization operations, on a card. After the processing mechanism  262  finishes processing the card, the card can be output through the output  258  or transported back into the modular print engine  250 . 
         [0065]      FIG. 6B  illustrates the second option module  252  as being similar to the second option module  252  of  FIG. 6A , but including a card reorienting mechanism  264  that can reorient a card onto a new travel path  266  up to the card processing mechanism  262 . After processing by the processing mechanism  262 , the card can be directed back to the card reorienting mechanism  264 , which then directs the card back onto the travel path  256  for output through the output  258  or transport back into the modular print engine  250 . 
         [0066]      FIG. 6C  illustrates the second option module  252  as including the travel path  256  but no output  258 . Instead, the travel path  256  ends at the processing mechanism  262 . In  FIG. 6C , after processing by the processing mechanism  262 , the card is transported back into the modular print engine  250 . 
         [0067]    Referring now to  FIG. 7 , another embodiment of a modular print engine  300  is illustrated. Elements of the modular print engine  300  that are similar in construction and function to corresponding elements in the modular print engine  10  of  FIG. 1  are referenced using the same reference numerals. For sake of simplicity, the lower module  12  is not illustrated in  FIG. 7 , but the modular print engine  300  would be mounted onto a lower module, which can be similar to or different than the lower module  12  in  FIG. 1 . In addition, the transport mechanism, such as the rollers  70 , and the card de-bowing mechanism  100  are not illustrated in  FIG. 7  for sake of simplicity, although a transport mechanism would be included for transporting a card along the various card travel paths described below, and the card de-bowing mechanism  100  can optionally be included. 
         [0068]    In the embodiment illustrated in  FIG. 7 , the removable option module  80  is physically located below the print engine  74 . A card travels along the card travel path  68  to the card reorienting mechanism  72  which can reorient the card downward along another card travel path  302  that extends to the card opening  90  in the bottom  58  of the housing  50  that communicates with the lower module  12  (not illustrated in  FIG. 7 ). A second card reorienting mechanism  304  is located along the card travel path  302  that can redirect the card onto a card travel path  306  along which the removable option module  80  is disposed. The option module  80  can be removable and replaceable with another, differently configured option module  80  as discussed above for  FIGS. 1 and 3A -D. The option module  80  in  FIG. 7  can have the same configuration and operation as the option modules  80  described above with respect to  FIGS. 1 and 3A -D. The card travel path  306  is illustrated as being parallel to the card travel path  68 , although the card travel path  306  can extend at an angle to the card travel path  68 . 
         [0069]    In addition, the card reject hopper  102  can be located in the same position as shown in  FIGS. 1, 4, and 5 . Alternatively, as shown in  FIG. 7 , the card reject hopper  102  can be located between the second card reorienting mechanism  304  and the rear end  54  of the housing  50 . Cards to be rejected can be directed into the card reject hopper  102  by the second card reorienting mechanism  304 , by the first card reorienting mechanism  72 , or by both of the card reorienting mechanisms  72 ,  304 . 
         [0070]    The modular print engine  300  can also include a card imaging device  308  that is separate from the option module  80  and adjacent to the card reorienting mechanism  72 . The imaging device  308  can be, for example, a scanner that can read a one dimensional bar code on a card surface or a camera that can be used to read a one or two dimensional bar code on a card surface or capture an image of a card surface. In one embodiment, the camera can be arranged to capture one or more images of a card surface while the card is held by the card reorienting mechanism  72 . 
         [0071]    Although not illustrated in  FIG. 7 , the modular print engine  300  can also include the card opening  94  in the rear end  54  thereof that leads to one of the second option modules  252  described above with respect to  FIGS. 5 and 6A -C and/or can include the card opening  202  in the top  56  that leads to the upper expansion module  204  described above with respect to  FIG. 4 . 
         [0072]    Referring now to  FIG. 8 , another embodiment of a modular print engine  350  is illustrated. Elements of the modular print engine  350  that are similar in construction and function to corresponding elements in the modular print engine  10  of  FIG. 1  are referenced using the same reference numerals. For sake of simplicity, the lower module  12  is not illustrated in  FIG. 8 , but the modular print engine  350  would be mounted onto a lower module, which can be similar to or different than the lower module  12  in  FIG. 1 . In addition, the transport mechanism, such as the rollers  70 , and the card de-bowing mechanism  100  are not illustrated in  FIG. 8  for sake of simplicity, although a transport mechanism would be included for transporting a card along the various card travel paths described below, and the card de-bowing mechanism  100  can optionally be included. 
         [0073]    In the embodiment illustrated in  FIG. 8 , the removable option module  80  is physically located along the card travel path  68  between the input  60  and the card reorienting mechanism  72 . In addition, the print engine  74  is positioned along a card travel path  352  that extends downwardly from the card reorienting mechanism  72  to the card opening  90  in the bottom  58  of the housing  50  that communicates with the lower module  12  (not illustrated in  FIG. 8 ). The print engine  74  can be oriented in a direction so that printing on the card occurs along the card travel path  352 . However, the print engine  74  can be located along other card travel paths extending from the card reorienting mechanism  72  so that printing occurs along any other card travel path. In the case of the print engine  74  being configured for retransfer printing, the heated transfer roller  170  would be located adjacent to the card travel path  352  as illustrated. A card travels along the card travel path  68  to or through the option module  80  and then to the card reorienting mechanism  72  which can reorient the card and direct the card downward along the card travel path  352 . The option module  80  can be removable and replaceable with another, differently configured option module  80  as discussed above for  FIGS. 1 and 3A -D. The card travel path  352  is illustrated as being perpendicular to the card travel path  68 , although the card travel path  352  can extend at an angle to the card travel path  68 . 
         [0074]    In addition, the card reject hopper  102  can be located in the same position as shown in  FIGS. 1, 4, and 5 . Alternatively, as shown in  FIG. 8 , the card reject hopper  102  can be located adjacent to the card reorienting mechanism  72  between the card travel path  352  and the rear end  54  of the housing  50 . Cards to be rejected can be directed into the card reject hopper  102  by the card reorienting mechanism  72 . 
         [0075]    In one embodiment, the modular print engine  350  can also include a card imaging device  354  that is separate from the option module  80  and adjacent to the card reorienting mechanism  72 . The imaging device  354  can be, for example, a scanner that can read a one dimensional bar code on a card surface or a camera that can be used to read a one or two dimensional bar code on a card surface or capture an image of a card surface. In one embodiment, the camera can be arranged to capture one or more images of a card surface while the card is held by the card reorienting mechanism  72 . In another embodiment, the card can be output from the card reorienting mechanism  72  onto a platform structure  355  that holds the card while being imaged by the imaging device  354 . 
         [0076]    In another embodiment, the modular print engine  350  can also include a smart card reader and/or writer  356  that is separate from the option module  80  and is located adjacent to the card reorienting mechanism  72  so that the card reorienting mechanism  72  can reorient and direct a card into the smart card reader and/or writer  356  for reading and/or writing on an integrated circuit chip (i.e. smart card chip) on the card. Like the option module  80 , the smart card reader and/or writer  356  can also be removable and replaceable with a mechanism having different functionality. For example, a contact type smart card reader and/or writer  356  can be replaced with a contactless type smart card reader and/or writer  356 , or the smart card reader and/or writer  356  can be replaced with a magnetic stripe reader and/or writer or other card processing mechanism. 
         [0077]    Although not illustrated in  FIG. 8 , the modular print engine  350  can also include the card opening  94  in the rear end  54  thereof that leads to one of the second option modules  252  described above with respect to  FIGS. 5 and 6A -C and/or can include the card opening  202  in the top  56  that leads to the upper expansion module  204  described above with respect to  FIG. 4 . 
         [0078]    All of the individual features and elements in the embodiments in  FIGS. 1-8  can be used separately from one another or in any combinations together. 
         [0079]    The examples disclosed in this application are to be considered in all respects as illustrative and not limitative. The scope of the invention is indicated by the appended claims rather than by the foregoing description; and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.