Patent Description:
Card production systems include processing devices that process card substrates (hereinafter "cards") to form the final card product. Such processes may include a printing process, a laminating or transfer process, a data reading process, a data writing process, and/or other process used to form the desired credential. An ink jet card printer is a form of card production system that utilizes an ink jet print head to print images to cards.

<CIT> describes an automatic desktop printer for security booklet documents. <CIT> describes an apparatus having a plurality of transport elements spaced apart and moving with different velocities.

The invention is related to an ink jet card printer according to claim <NUM> and a method of printing images to cards according to claim <NUM>. According to the invention, the ink jet card printer includes a card transport and a print unit. The card transport includes a first belt, a first motor configured to drive the first belt to feed a card along a processing axis, a second belt, and a second motor configured to drive the second belt to feed a card along the processing axis. The print unit includes an ink jet print head and a gantry. The ink jet print head is configured to perform a print operation simultaneously on a card supported in a print position on the first belt and on a card supported in a print position on the second belt. The gantry is configured to move the ink jet print head along a fast scan axis that is parallel to the processing axis and a slow scan axis that is perpendicular to the processing axis.

According to the invention, the method of printing images to first and second cards uses an ink jet printer having a card transport including first and second belts, and a print unit including an ink jet print head and a gantry, the first card is supported in a print position on the first belt and the second card is supported in a print position on the second belt. A first image is printed on the first card and a second image is printed on the second card using the ink jet print head including moving the ink jet print head in a fast scan direction across the first and second cards and moving the ink jet print head in a slow scan direction that is perpendicular to the fast scan direction using the gantry. The first card is discharged from the first belt by feeding the first card in a first direction along a processing axis that is parallel to the fast scan direction using the first belt.

According to the invention, the card transport includes first and second belts, each of which is configured to feed a card along a processing axis. The first belt is driven by a first motor, and the second belt is driven by a second motor. The first and second belts each include an input/output end and a passing end. The passing ends of the first and second belts are configured to simultaneously engage a card fed between the first and second belts.

This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the invention which is defined by the appended claims.

Embodiments of the present disclosure are generally directed to a card feeder of an ink jet card printer that is configured to facilitate the feeding individual cards to a print position for printing by an ink jet print head that is moved through a print zone using a gantry during printing operations. The card feeder has a raised position, in which at least a portion of the card feeder extends into the print zone. As a result, the card feeder would obstruct printing operations if left in the raised position. This issue is avoided by moving the card feeder to a lowered position during printing operations, in which the card feeder is displaced from the print zone, using a lift mechanism.

These and other embodiments of the present disclosure are described more fully hereinafter with reference to the accompanying drawings. Elements that are identified using the same or similar reference characters refer to the same or similar elements. The various embodiments of the present disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the present disclosure to those skilled in the art.

<FIG> and <FIG> are simplified side and top views of an ink jet card printer <NUM> in accordance with embodiments of the present disclosure. In some embodiments, the printer <NUM> includes a print unit <NUM>, and a card transport <NUM>. The card transport <NUM> is configured to feed individual cards <NUM> along a processing axis <NUM>. The print unit <NUM> includes an ink jet print head <NUM> and a gantry <NUM>. The print head <NUM> is configured to perform a printing operation on individual cards <NUM> supported by the card transport <NUM> in a print position <NUM> along the processing axis <NUM>. The gantry <NUM> is configured to move the print head <NUM> through a print zone <NUM> during printing operations.

In some embodiments, the printer <NUM> includes a controller <NUM>, which represents one or more distinct controllers of the printer <NUM>, each of which includes at least one processor that is configured to execute program instructions stored in a computer-readable media or memory of the printer <NUM>, which may also be represented by the controller <NUM>, or another location. Any suitable patent subject matter eligible computer readable media or memory may be utilized including, for example, hard disks, CD-ROMS, optical storage devices, flash memory, magnetic storage devices, or other suitable computer readable media or memory that do not include transitory waves or signals. The execution of the instructions by the controller <NUM> controls components of the printer <NUM> to perform functions and method steps described herein.

As discussed in greater detail below, the card printer <NUM> may include one or more card feeders <NUM>, such as card feeders 120A and 120B, that are each configured to deliver cards <NUM> to, and receive cards <NUM> from, the card transport <NUM>. The printer <NUM> may also include one or more conventional card flippers <NUM>, such as flippers 122A and 122B, that are configured to invert the cards <NUM>. A conventional card supply <NUM>, such as a card cartridge containing a stack of cards, may be provided to supply cards <NUM> for processing by the printer <NUM>, and processed cards may be discharged and collected by a suitable card collector (e.g., a hopper) <NUM>.

The ink jet print head <NUM> may be any suitable conventional ink jet print head that is configured to perform a direct printing operation to individual cards <NUM> supported in the print positions <NUM> along the processing axis <NUM>. The gantry <NUM> includes a conventional gantry for moving the print head <NUM> along a fast scan axis <NUM> that is substantially parallel to the processing axis <NUM>, and a slow scan axis <NUM> that is substantially perpendicular to the processing axis <NUM>, as shown in <FIG>, during printing operations. As used herein, the term "fast scan axis" refers to the axis along which the print head <NUM> is moved by the gantry <NUM> during an active printing phase of the operation, during which ink is discharged from the print head <NUM> to form the image on the card <NUM>. The term "slow scan axis" refers to the axis along which the print head <NUM> is moved by the gantry <NUM> during an inactive printing phase (ink is not discharged from the print head) to position the print head <NUM> for the next active printing phase.

In some embodiments, the gantry <NUM> and the print head <NUM> may occupy the print zone <NUM> during printing operations, which is indicated by dashed boxes in <FIG> and <FIG>. The print zone <NUM> generally extends from the processing axis <NUM>, or immediately above the processing axis <NUM>, into the space above the card transport <NUM> and the card feeders <NUM>. The print zone <NUM> may also surround the card transport <NUM> and the card feeders <NUM>, as shown in <FIG>.

In some embodiments, the card feeders <NUM> each include a lift mechanism <NUM> to move the card feeders <NUM> to a lowered position <NUM>, in which the card feeders <NUM> are displaced from the print zone <NUM>, such as below the print zone <NUM>, as indicated by card feeder 120A in <FIG>, and the card feeders 120A and 120B in <FIG>. <FIG> is an isometric view of exemplary card transport <NUM> and card feeders <NUM> in their lowered positions <NUM>, <FIG> is a side view of an exemplary printer <NUM> with the card feeders <NUM> in their lowered positions <NUM>, and <FIG> is a side view of the printer <NUM> of <FIG> with frame side walls removed, in accordance with embodiments of the present disclosure.

The lift mechanisms <NUM> may also move the card feeders <NUM> to a raised position <NUM>, in which at least a portion of the card feeders <NUM> extend into the print zone <NUM>, and the card feeders <NUM> are positioned to feed cards <NUM> to, or receive cards <NUM> from, the card transport <NUM>, as indicated by the card feeder 120B in <FIG> and the card feeders 120A and 120B in <FIG> and <FIG>. <FIG> is a side view of the exemplary printer <NUM> of <FIG> with the card feeders <NUM> in their raised positions, and <FIG> is a side view of the printer <NUM> of <FIG> with frame side walls removed, in accordance with embodiments of the present disclosure. Thus, the card feeders <NUM> may be moved to their raised positions <NUM> by the lift mechanisms <NUM> to facilitate feeding cards <NUM> to, or receiving cards <NUM> from the card transport <NUM>.

Thus, the lift mechanisms <NUM> may be used to move the card feeders <NUM> from their raised positions <NUM>, in which at least a portion of the card feeders <NUM> would obstruct a printing operation, to their lowered positions <NUM>, in which the card feeders <NUM> do not obstruct the print zone <NUM>, to enable the print head <NUM> to be moved through the print zone <NUM> by the gantry <NUM> and perform a printing operation.

In some embodiments, the card transport <NUM> includes belts <NUM>, such as first and second belts 140A and 140B (i.e., belt feeders or conveyors), that are each supported by rollers <NUM> for movement along a belt path. In one example, the first and second belts 140A and 140B are each supported by four rollers <NUM>, which are supported by a belt frame <NUM>, such as side walls 146A and 146B of the belt frame <NUM> (<FIG>). The belts <NUM> include exposed portions <NUM> adjacent the processing axis <NUM>. The exposed portion <NUM> of each of the belts <NUM> is used to feed the cards <NUM> along the processing axis <NUM> and support the cards <NUM> in the print positions <NUM>.

Motors 154A and 154B are respectively configured to independently drive the first and second belts 140A and 140B along their belt paths. Thus, the exposed portion <NUM> of the first belt 140A may independently feed a card <NUM> along the processing axis <NUM> in a direction toward the second belt 140B or in a direction toward the card feeder 120A using the motor 154A, and the exposed portion <NUM> of the second belt 140B may independently feed a card <NUM> along the processing axis <NUM> in the direction toward the first belt 140A, or in the direction toward the card feeder 120B using the motor 154B.

The belts <NUM> of the card transport <NUM> may take on any suitable form. In some embodiments, the belts <NUM> are conventional vacuum belts that are coupled to a vacuum source <NUM> (i.e., a source of negative pressure), such as a regenerative vacuum blower. The vacuum source <NUM> may be shared by the belts <NUM>, as shown in <FIG>, or separate vacuum sources 158A and 158B may respectively be used by the belts 140A and 140B, as shown in <FIG>. Chambers <NUM> couple the negative pressure generated by the vacuum source <NUM> to the exposed portions <NUM> of the belts <NUM>. The negative pressure is communicated to a top side of the exposed portions <NUM> through apertures <NUM> in the belts, which are shown in <FIG> and <FIG>, and is used to secure cards <NUM> to the exposed portions <NUM> during card feeding and printing operations. Thus, when a card <NUM> engages the top surface of the exposed portion <NUM> of one of the belts <NUM>, the negative pressure generated by the vacuum source <NUM> or sources 158A and 158B adheres the card <NUM> to the belt <NUM>. When the belts <NUM> are driven by the corresponding motor <NUM>, the adhered card <NUM> is driven along the processing axis <NUM>.

During a printing operation, with the card feeders <NUM> in their lowered positions <NUM>, each of the belts <NUM> may feed a card <NUM> along the processing axis <NUM> to the corresponding print position <NUM>, in which the exposed top surfaces <NUM> of the cards <NUM> are at the border of the print zone <NUM>, as shown in <FIG>, <FIG>, <FIG> and <FIG>. The print head <NUM> may perform a print operation on the top surfaces <NUM> of the cards <NUM> supported in the print positions <NUM>. Thus, the print head <NUM> may print an image to the exposed surface <NUM> of the card <NUM> supported in the print position <NUM> on the belt 140A, print an image to the surface <NUM> of the card <NUM> supported in the print position <NUM> on the belt 140B, and/or simultaneously print images to the surfaces <NUM> of both cards <NUM> supported in the print positions <NUM> on the belts 140A and 140B during a single printing operation.

For example, referring to <FIG>, with the card feeders <NUM> in their lowered positions <NUM>, and the cards <NUM> held in the print positions <NUM> against the exposed portions <NUM> of the belts 140A and 140B due to the negative pressure generated by the vacuum source <NUM> or sources 158A and 158B (<FIG>, <FIG>, <FIG> and <FIG>), the gantry <NUM> may move the print head <NUM> along the fast scan axis <NUM> (processing axis <NUM>) over the cards <NUM>, while the print head <NUM> prints image lines to the surfaces <NUM>, as indicted by arrow <NUM>. After the print head <NUM> is moved past the end of the card <NUM> adjacent the card feeder 120B, the gantry <NUM> shifts the print head <NUM> along the slow scan axis <NUM>, as indicated by arrow <NUM>. The gantry <NUM> then moves the print head <NUM> back along the fast scan axis <NUM> (arrow <NUM>), during which the print head <NUM> prints image lines to the surfaces <NUM> of the cards <NUM>. The gantry <NUM> again shifts the position of the print head <NUM> along the slow scan axis <NUM> (arrow <NUM>), and the print head <NUM> prints image lines as the gantry <NUM> moves the print head <NUM> along the fast scan axis <NUM> (arrow <NUM>). These steps of printing image lines while moving the print head <NUM> along the fast scan axis <NUM> and shifting the position of the print head <NUM> along the slow scan axis <NUM>, are repeated until the images have been printed to the surfaces <NUM> of the cards <NUM>. Accordingly, a single print operation may simultaneously print images to two cards <NUM> supported on the belts <NUM>.

To print a full edge-to-edge image on a card <NUM>, the print head <NUM> may be configured to print an image that is slightly larger than the surface <NUM> of the card <NUM>. As a result, some ink will overspray the edges of the card <NUM>.

In some embodiments, the exposed surface <NUM> of each belt <NUM> has a smaller surface area than the card <NUM>. That is, the width and length of the exposed belt surfaces <NUM> are selected such that they are less than the corresponding width and length of the cards <NUM>, as generally shown in <FIG> with the cards <NUM> shown in phantom lines. Thus, when a card <NUM> is in the print position <NUM>, the entirety of the exposed belt surface <NUM> is covered by the card <NUM>, and a perimeter portion <NUM> of the card <NUM> extends beyond the edges of the exposed belt surface <NUM>. This allows the print head <NUM> to print images that extend to the edges of the surfaces <NUM> of cards <NUM> while protecting the exposed belt surface <NUM> from ink contamination.

In some embodiments, the printer <NUM> includes an ink overspray collector <NUM> that surrounds a perimeter of the exposed belt surface <NUM> and extends beyond the edges of the cards <NUM> when in their print positions <NUM>, as shown in <FIG>. Thus, the collector <NUM> is positioned to receive ink that is sprayed over the lengthwise and widthwise edges of the cards <NUM> during a printing operation. In some embodiments, the ink overspray collector <NUM> is a disposable component that may be periodically removed and replaced by an operator of the printer <NUM>. The collector <NUM> may be formed of plastic, paper, cardboard, or another suitable material. In some embodiments, the collector <NUM> is a single piece of material having an opening 184A for the exposed belt surface <NUM> of the belt 140A, and an opening 184B for the exposed belt surface <NUM> of the belt 140B.

As mentioned above, the card feeders <NUM> are each configured to deliver cards <NUM> to, and receive cards <NUM> from the card transport <NUM> when in their raised positions <NUM> (<FIG> and <FIG>). The card feeders <NUM> may also receive cards <NUM> for processing from the card supply <NUM>, such as using card feeder 120A, and discharge processed cards <NUM> to the collector <NUM>, such as using the card feeder 120B, as indicated in <FIG>.

In some embodiments, the card feeders <NUM> each include at least one pinch roller pair <NUM>, such as pinch roller pairs 190A and 190B, as shown in <FIG>, <FIG> and <FIG>. In some embodiments, at least a portion of one or both of the pinch roller pairs <NUM> extends into the print zone <NUM> when the card feeder <NUM> is in the raised position <NUM>, as shown in <FIG>. The pinch roller pairs 190A and 190B are respectively positioned adjacent ports <NUM> and <NUM> of the card feeder <NUM>, with the port <NUM> being positioned adjacent an input/output end <NUM> of the corresponding belt <NUM>, as shown in <FIG>. Each pinch roller pair <NUM> may include an idler roller <NUM> and a motorized feed roller <NUM> (<FIG> and <FIG>) that are supported by a card feeder frame <NUM>, such as between side walls 201A and 201B of the frame <NUM>, as shown in <FIG>. While the idler roller <NUM> is illustrated as being the top roller in the provided examples, it is understood that the positions of the rollers <NUM> and <NUM> may be reversed. A cover <NUM> may be positioned between the pinch roller pairs 190A and 190B to cover a portion of the path through which cards <NUM> are fed through the card feeder <NUM>, as shown in <FIG>.

The card feeders 120A and 120B respectively include motors 204A and 204B (<FIG>) for driving the motorized rollers <NUM> to feed a card <NUM> supported between one or both of the pinch roller pairs 190A and 190B along a card feed axis <NUM>. The separate motors <NUM> of the feeders <NUM> allow the controller <NUM> to independently control the card feeders <NUM>. As a result, the card feeder 120A may be used to deliver a card <NUM> to the belt 140A while the card feeder 120B delivers a card <NUM> to the collector <NUM>, for example.

The card feed axis <NUM> of each feeder <NUM> is substantially parallel to a vertical plane extending through the processing axis <NUM>. Thus, as shown in the top view of <FIG>, the card feed axes <NUM> of the feeders <NUM> are oriented substantially parallel (e.g., ±<NUM> degrees) to the processing axis <NUM> within a horizontal plane.

In some embodiments, the lift mechanisms <NUM> pivot the frame <NUM> of the card feeders <NUM> about a pivot axis <NUM> (<FIG>) during movement of the card feeders <NUM> between their raised and lowered positions <NUM> and <NUM>. As a result, the orientation of the card feed axis <NUM> relative to the processing axis <NUM> in a vertical plane changes with movement of the card feeders <NUM> between their raised and lowered positions <NUM> and <NUM>. When the card feeder <NUM> is in its lowered position <NUM>, the card feed axis <NUM> is at an oblique angle (e.g., <NUM>-<NUM> degrees) to the processing axis <NUM> in the vertical plane, as shown in <FIG>. When the card feeder <NUM> is in its raised position, the card feed axis <NUM> is substantially parallel to the processing axis <NUM> in the vertical plane, as shown in <FIG>, allowing the card feeder <NUM> to deliver a card <NUM> to the adjacent belt <NUM>, or receive a card <NUM> from the adjacent belt <NUM> using one or more of the pinch roller pairs <NUM>.

In some embodiments, the pivot axis <NUM> is defined by a pivotable connection <NUM> between the card feeder frame <NUM> and the belt frame <NUM>, as indicated in <FIG>. In one embodiment, the pivotable connection or hinge <NUM> is formed between the side walls 201A and 201B of the card feeder frame <NUM> and the corresponding side walls 146A and 146B of the belt frame <NUM>.

In one exemplary embodiment, each lift mechanism <NUM> includes a cam <NUM>, a cam follower <NUM> and a motor <NUM>, as shown in <FIG> and <FIG>. The separate motors <NUM> allow the controller <NUM> to independently control each lift mechanism <NUM>. In one example, each cam <NUM> is supported by the belt frame <NUM> for rotation about an axis <NUM> (<FIG>), and each cam follower <NUM> is supported by the card feeder frame <NUM> and pivots with the card feeder frame <NUM> about the pivot axis <NUM>. Alternatively, the positions of the cam <NUM> and the cam follower <NUM> may be reversed where the cam <NUM> is supported by the belt frame <NUM> and the cam follower <NUM> is supported by the card feeder frame <NUM>. In some embodiments, the cam follower <NUM> is biased to engage the cam <NUM> using a suitable biasing mechanism, such as a spring.

During an exemplary lift operation, in which the card feeder <NUM> is moved from the lowered position <NUM> (<FIG>) to the raised position <NUM> (<FIG>), the controller <NUM> activates the motor <NUM> of the lift mechanism <NUM> to drive rotation of the cam <NUM> about the axis <NUM> in the direction indicated by arrow <NUM> in <FIG>. As the cam <NUM> rotates, it slides and presses against a cam surface <NUM> (<FIG>) of the cam follower <NUM>. This drives the card feeder frame <NUM> to pivot about the pivot axis <NUM> until the card feeder <NUM> reaches the raised position <NUM> shown in <FIG>. The operation is reversed to move the card feeder <NUM> back to its lowered position <NUM>. That is, the controller activates the motor <NUM> of the lift mechanism <NUM> to drive rotation of the cam <NUM> about the axis <NUM> in the direction opposite arrow <NUM> (<FIG>). During this rotation of the cam <NUM>, the cam surface <NUM> of the cam follower <NUM> slides along the cam <NUM> and the card feeder frame <NUM> pivots about the pivot axis <NUM> until the card feeder <NUM> reaches the lowered position <NUM> shown in <FIG>.

Alternative lift mechanisms <NUM> may also be employed. For example, different lift mechanisms may be used to pivot the card feeders <NUM> between their raised and lowered positions <NUM> and <NUM>, such as a screw drive, or another suitable lift mechanism. Additionally, the lift mechanisms <NUM> may be configured to move the card feeders <NUM> linearly between the raised and lowered positions <NUM> and <NUM>.

In some embodiments, a lateral stabilizer <NUM> is used in connection with each of the card feeders <NUM> to ensure substantial coaxial alignment in the horizontal plane between the card feed axis <NUM> and the processing axis <NUM> of the adjacent belt <NUM>, as shown in <FIG>, when the card feeders <NUM> are in their raised positions <NUM>. One example of a suitable lateral stabilizer <NUM> is shown in <FIG>, which are front and top isometric views of a portion of the printer <NUM> at the interface between the card feeder 120A and the belt 140A with the ink collector <NUM> removed. In some embodiments, the lateral stabilizer <NUM> is positioned between the pinch roller pair 190A at the port <NUM> and the input/output end <NUM> of the adjacent belt 140A, as shown in <FIG>.

In one embodiment, the lateral stabilizer <NUM> includes a first stabilizing member <NUM> connected to the card feeder frame <NUM>, and a second stabilizing member <NUM> connected to the belt frame <NUM>. Thus, the first stabilizing member <NUM> moves with movement of the card feeder frame <NUM> about the pivot axis <NUM> relative to the second stabilizing member <NUM>. The first stabilizing member <NUM> engages with the second stabilizing member <NUM> in a cooperating manner when the card feeder <NUM> is moved from the lowered position <NUM> to the raised position <NUM> to provide the desired lateral alignment of the card feed axis <NUM> and the processing axis <NUM>. In some embodiments, the first and second stabilizing members <NUM> and <NUM> are displaced from each other when the card feeder <NUM> is in the lowered position <NUM>.

In one exemplary embodiment, the first stabilizing member <NUM> is in the form of a rib member and the second stabilizing member is in the form of a groove <NUM>, as shown in <FIG>. Alternatively, the positions of the rib member and groove may be reversed. The groove <NUM> may be formed in a bar <NUM> extending between the side walls 146A and 146B of the belt frame <NUM>. As the card feeder <NUM> is moved from the lowered position <NUM> to the raised position <NUM>, the rib member <NUM> is received within the groove <NUM>, as shown in <FIG>, to align the card feed axis <NUM> with the processing axis <NUM> and maintain the alignment during card feeding operations between the card feeder 120A and the belt 140A.

Ideally, each card feeder <NUM> supports a received card <NUM> such that a central axis of the card <NUM> is aligned with the card feed axis <NUM>. This ensures that the card <NUM> is fed to the adjacent belt <NUM> in alignment with the processing axis <NUM>, which allows for accurate positioning of the card <NUM> in the print position <NUM> on the belt <NUM> and accurate printing of an image to the card surface <NUM>.

In some embodiments, each card feeder <NUM> includes a card alignment mechanism <NUM>, an example of which is illustrated in the top view of a portion of the printer <NUM> provided in <FIG> with the cover <NUM> removed. The card alignment mechanism <NUM> is configured to prevent misalignment between a card <NUM> supported by the one or more pinch roller pairs <NUM> of the card feeder <NUM> and the card feed axis <NUM>. One embodiment of the card alignment mechanism <NUM> includes a reference wall <NUM>, a pusher wall <NUM> and a biasing mechanism <NUM>. The reference wall <NUM> is aligned parallel to the card feed axis <NUM> and has a fixed position relative to the card feeder frame <NUM>. The pusher wall <NUM> is moveable relative to the card feeder frame <NUM> and the reference wall <NUM>. The biasing mechanism <NUM> is configured to bias the pusher wall <NUM> toward the reference wall <NUM>. Embodiments of the biasing mechanism <NUM> include a spring or another conventional biasing mechanism.

As a card <NUM> is received by the card feeder <NUM> with the central axis of the card <NUM> being offset from the card feed axis <NUM> or non-parallel to the card feed axis <NUM>, the pusher wall <NUM> pushes the card <NUM> toward the reference wall <NUM> due to the bias produced by the biasing mechanism <NUM>. This causes an edge of the card <NUM> to engage the reference wall <NUM>. As the card <NUM> continues to be fed into the card feeder <NUM> by the pinch roller pairs <NUM>, the edge of the card <NUM> engaging the reference wall <NUM> aligns with the reference wall <NUM> and aligns the central axis of the card <NUM> with the card feed axis <NUM>.

The printer <NUM> may include one or more sensors <NUM> to facilitate various card feeding operations, such as receiving a card <NUM> in the card feeders <NUM> and positioning a card <NUM> in the print position <NUM> on the belts <NUM>. In one embodiment, the printer <NUM> includes a card sensor <NUM> for detecting the presence or absence of a card at each side of the card transport <NUM>, as indicated in <FIG>. In some embodiments, the card sensors <NUM> are positioned between the pinch roller pair 190A and the adjacent belt <NUM>. In some embodiments, the card sensors <NUM> are supported by the card feeder frame <NUM>, as shown in <FIG> and <FIG>. The card sensors may take on any suitable form, such as an optical card sensor having an emitter <NUM> and a receiver <NUM>, as shown in <FIG>.

During reception of a card <NUM> by a card feeder <NUM> in its lowered position <NUM>, the sensor <NUM> may be used to detect the leading edge of the card <NUM> being fed toward the card transport belt <NUM>, which may indicate that the card <NUM> is fully received in the card feeder <NUM>. The card feeder <NUM> may then be moved from the lowered position <NUM> to the raised position <NUM>. After the card feeder <NUM> is moved to the raised position <NUM>, the corresponding card sensor <NUM> may be used to detect the trailing edge of the card <NUM> as the card is fed to the adjacent belt <NUM>. The controller <NUM> may use this detection of the trailing edge of the card <NUM> to control the belt <NUM> to position the card <NUM> in the desired print position <NUM>.

The card sensors <NUM> may also be used by the controller <NUM> to control the reception of cards <NUM> fed from the belts <NUM> by the card feeders <NUM>. For example, as a card <NUM> is fed from the belt <NUM> toward the card feeder <NUM>, the card sensor <NUM> may detect the leading edge of the card <NUM>. This detection may be used by the controller <NUM> to control the pinch roller pairs <NUM> to receive the card <NUM> in the card feeder <NUM>. The card <NUM> may then be fed into the card feeder <NUM> using the pinch roller pairs <NUM> until the sensor <NUM> detects the trailing edge of the card <NUM> indicating that the card <NUM> has been fully received within the card feeder <NUM> and that the card feeder <NUM> is ready to be moved to its lowered position <NUM>.

As mentioned above, the printer may optionally include one or more card flippers <NUM> that may be used to invert cards <NUM> to facilitate printing operations on both sides of the cards <NUM>. Each card flipper <NUM> may be configured to receive a card <NUM> from the adjacent card feeder <NUM>, the card supply (flipper 122A) or the card collector (flipper 122B), rotate the card <NUM> about a flipping axis <NUM> to invert the card <NUM>, and pass the inverted card <NUM> back to the adjacent card feeder <NUM>, which can deliver the inverted card <NUM> to the card transport <NUM> and the print unit <NUM> for a printing operation. The card flippers <NUM> may each be conventional card flippers. One suitable card flipper <NUM> which may be used by the printer is described in <CIT>.

In some embodiments, each flipper <NUM> includes a pinch roller pair <NUM> that is configured to hold the card <NUM> during rotation about the flipping axis <NUM>. One or more motors <NUM> (<FIG> and <FIG>) are used to drive rotation of a gear <NUM>, that supports the pinch roller pair <NUM> and a card <NUM> supported by the pinch roller pair, about the flipping axis <NUM>. In some embodiments, the card feed axis <NUM> of each flipper <NUM> is configured to rotate into alignment with the card feed axis <NUM> of the adjacent card feeder <NUM> when it is in the lowered position <NUM>. The motor <NUM> may also drive the pinch roller pair <NUM> to feed a card <NUM> supported by the pinch roller pair <NUM> to the pinch roller pair 190B at the port <NUM> of the adjacent card feeder <NUM>, such as shown in <FIG>. The adjacent card feeder <NUM> may then move to the raised position <NUM> and feed the card <NUM> to the adjacent belt <NUM>, as shown in <FIG>.

Some embodiments of the present disclosure are directed to methods of printing an image to one or more cards <NUM> using the ink jet card printer <NUM>. In one embodiment of the method, a card <NUM>, which may have been received from the supply <NUM> and fed to the card feeder 120A by the card flipper 122A, is supported by the pinch roller pairs <NUM> of the card feeder 120A while in its lowered position <NUM>, as shown in <FIG>. The card feeder 120A is moved to its raised position <NUM> using the corresponding lift mechanism <NUM>, and the card <NUM> is discharged from the card feeder 120A to the belt 140A using the pinch roller pair 190A. The card feeder 120A is then moved to the lowered position <NUM> (<FIG> and <FIG>) and out of the print zone <NUM> using the lift mechanism <NUM>, and the card <NUM> is fed along the processing axis <NUM> by the belt 140A to the print position <NUM> (<FIG>). An image is then printed to the surface <NUM> of the card <NUM> using the print head <NUM>, which involves moving the print head <NUM> with the gantry <NUM> through the print zone <NUM>, as indicated in <FIG> and <FIG>.

Some embodiments of the method involve performing a print operation using the ink jet card printer <NUM> to print images on two cards <NUM> simultaneously. One example of such a method will be described with reference to <FIG>, which are simplified top views of the card transport <NUM> and the card feeders 120A and 120B during various stages of the method. Initially, a pair of cards <NUM> may be fed from the supply <NUM> to the card transport <NUM> with the card feeders <NUM> in their lowered positions <NUM>. This may involve feeding a first card <NUM> from the supply <NUM> through the card flipper <NUM> to the card feeder 120A, as shown in <FIG> and <FIG>. The card feeder 120A may then be moved to its raised position <NUM> using the lift mechanism <NUM>, and the first card 106A is fed to the belt 140A by the pinch roller pair 190A, as shown in <FIG>. The card feeder 120A may then return to its lowered position <NUM>, and a second card <NUM> may be fed from the supply <NUM> through the flipper 122A to the card feeder 120A in the same manner as the first card. During the feeding of the second card 106A to the card feeder 120A, the first card 106A may be fed by the belt 140A to the belt 140B, during which the card 106A is simultaneously supported by both belts 140A and 140B, as shown in <FIG>. The card 106A may then be moved by the belt 140B to the print position <NUM>, as shown in <FIG>. The second card 106B is fed to the belt 140A using the pinch roller pair 190A of the card feeder 120A, as indicated in <FIG>, and the second card 106B is moved along the processing axis <NUM> by the belt 140A to its print position <NUM>, as shown in <FIG>. The card feeder 120A is then moved to its lowered position <NUM>.

With the cards 106A and 106B supported in their print positions <NUM> on the belts 140B and 140A, and the card feeders 120A and 120B in their lowered positions <NUM> (<FIG>), a printing operation is simultaneously performed on the first and second cards 106A and 106B using the print unit <NUM>, as discussed above with reference to <FIG>. This printing operation involves moving the ink jet print head <NUM> in the fast scan direction <NUM> across the cards <NUM> and moving the ink jet print head <NUM> in a slow scan direction <NUM> that is perpendicular to the fast scan direction <NUM> through the print zone <NUM> using the gantry <NUM>. The cards <NUM> are imaged by the ink jet print head (i.e., active printing phase) while the print head <NUM> is moved in the fast scan direction <NUM> by the gantry <NUM>.

After the images have been printed to the cards 106A and 106B, the card feeders 120A and 120B are returned to their raised positions <NUM> by the lift mechanisms <NUM>, and the cards 106A and 106B are delivered to the adjacent card feeders 120A and 120B using the belts 140A and 140B, as indicated in <FIG>. After receiving the cards 106A and 106B, the card feeders 120A and 120B are moved to their lowered positions <NUM> by the lift mechanisms <NUM>, and the cards 106A and 106B are fed to the corresponding flippers 122A and 122B, such as generally shown in <FIG>. The flippers 122A and 122B invert the cards 106A and 106B and feed the inverted cards back to the card feeders 120A and 120B, which are then returned to their raised positions <NUM>. The cards 106A and 106B are then fed back to the adjacent belts 140A and 140B by the card feeders 120A and 120B, as indicated in <FIG>. The belts 140A and 140B then move the cards 106B and 106A to the print positions <NUM> (<FIG>) and the card feeders 120A and 120B are again moved to their lowered positions <NUM>. The print head <NUM> then prints images to the non-imaged surfaces <NUM> of the cards 106A and 106B as discussed above with reference to <FIG>.

With images printed to both sides of the cards 106A and 106B, the cards may be discharged to the collector <NUM> using the card feeder 120B. The card feeder 120B is first moved to the raised position <NUM>, and the belt 140B feeds the card 106A to the card feeder 120B. The card feeder 120B is then moved to its lowered position <NUM>, and the card 106A is fed to the collector <NUM> through the flipper 122B (<FIG>). The card 106B is fed from the belt 140A to the belt 140B and the card feeder 120B is returned to the raised position <NUM>. The card feeder 120B then receives the card 106B from the belt 140B, and is moved to its lowered position <NUM> by the corresponding lift mechanism <NUM>. The card 106B can then be discharged from the card feeder 120B to the collector <NUM> through the flipper 122B.

Claim 1:
An ink jet card printer (<NUM>) comprising:
a card transport (<NUM>) comprising:
a first belt (140A);
a first motor (154A) configured to drive the first belt (140A) to feed a card (<NUM>) along a processing axis (<NUM>);
a second belt (140B); and
a second motor (154B) configured to drive the second belt (140B) to feed a card (<NUM>) along the processing axis (<NUM>); and
a print unit (<NUM>) comprising:
an ink jet print head (<NUM>) configured to print images on a card (<NUM>) supported in a print position (<NUM>) on the first belt (140A) and on a card (<NUM>) supported in a print position (<NUM>) on the second belt (140B) in a single print operation; and
a gantry (<NUM>) configured to move the ink jet print head (<NUM>) along a fast scan axis (<NUM>) that is parallel to the processing axis (<NUM>) and a slow scan axis (<NUM>) that is perpendicular to the processing axis (<NUM>).