Patent Description:
The present document relates to printing and more particularly, to techniques for reducing or handling ink overspray of an ink jet printer.

Card products include, for example, credit cards, identification cards, driver's licenses, passports, and other card products. Such card products generally include printed information, such as a photo, account numbers, identification numbers, and other personal information. Credentials can also include data that is encoded in a smartcard chip, a magnetic stripe, or a barcode, for example.

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.

Ink overspray can occur when the ink jet print head prints near a edge of the print media or substrate. If unprotected, the ink overspray can land and accumulate on components of the ink jet card printer and can negatively affect printer performance as well as print quality of not removed from the components. Conventional printers have employed ink overspray collectors because cleaning ink from intricate components can be a time consuming and cumbersome task. Some ink overspray collectors are disposable and add additional waste to ink jet card printer processes. Non-disposable ink overspray collectors can be time consuming to remove, time consuming to clean, and time consuming to replace. Additionally, non-disposable ink overspray collectors can easily be damaged which can further complicate removal and replacement.

<CIT> describes an ink jet card printer having a pivotable card feeder.

<CIT> describes a paint overspray exhaust filter. <CIT> describes an ink jet printing system. <CIT> describes as tacky netting for collecting dirt and paint overspray.

Techniques for handling and reducing ink overspray of an ink jet printer are provided. In an example, an ink overspray collector for an ink jet printer can include a first opening defining a first print area of the ink jet printer, and a frame about the first opening. The frame is configured to receive overspray from operation of the ink jet printer and can be formed of a woven material.

Examples of the present disclosure are generally directed to reducing and handling overspray of an ink jet card printer. In certain examples, the ink jet card printer can include an ink overspray collector that can be easily removed, cleaned and re-installed. In some examples, a controller of the ink jet card printer can execute commands that cause the ink jet card printer to reduce the amount of ink deposited at the edges of the card from the amount that would normally be deposited for a given image so that overspray of the ink is reduced. In some examples, a combination of techniques can be used to reduce overspray and reduce waste generated by operation of ink jet card printer.

<FIG> and <FIG> are simplified side and top views of an ink jet card printer <NUM>, or portions thereof, in accordance with the present subject matter. In some examples, the ink jet card 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 examples, the ink jet card printer <NUM> includes a controller <NUM>, which represents one or more distinct controllers of the ink jet card 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 ink jet card 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 ink jet card printer <NUM> to perform functions and method steps described herein.

In certain examples, the ink jet 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 ink jet card printer <NUM> may also include one or more card flippers <NUM>, such as flippers 122A and 122B, that are configured to invert the cards <NUM>. A card supply <NUM>, such as a card cartridge containing a stack of cards, may be provided to supply cards <NUM> for processing by the ink jet card 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> 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> can move the print head <NUM> along a first scan axis <NUM> that is substantially parallel to the processing axis <NUM>, and a second scan axis <NUM> that is substantially perpendicular to the processing axis <NUM>, as shown in <FIG>, during printing operations. As used herein, the term "first 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 "second scan axis" refers to the axis along which the print head <NUM> can be 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 certain examples, 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> may generally extend from the processing axis <NUM>, or immediately above the processing axis <NUM>, into at least a portion of 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 certain examples, the card feeders <NUM> each include a lift mechanism <NUM> to move the card feeders <NUM> to a lowered position, 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> is an isometric view of a card transport <NUM> and card feeders <NUM> in their lowered positions <NUM>.

The lift mechanisms <NUM> may also move the card feeders <NUM> to a raised position, 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>. Thus, the card feeders <NUM> may be moved to their raised positions 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, in which at least a portion of the card feeders <NUM> would obstruct a printing operation, to their lowered positions, 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 certain examples, 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 can 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 certain examples, 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. 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>.

For example, referring to <FIG>, with the card feeders <NUM> in their lowered positions, 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, the gantry <NUM> may move the print head <NUM> along the first 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 second scan axis <NUM>, as indicated by arrow <NUM>. The gantry <NUM> then moves the print head <NUM> back along the first 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 second scan axis <NUM> (arrow <NUM>), and the print head <NUM> prints image lines as the gantry <NUM> moves the print head <NUM> along the first scan axis <NUM> (arrow <NUM>). These steps of printing image lines while moving the print head <NUM> along the first scan axis <NUM> and shifting the position of the print head <NUM> along the second 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 certain examples, 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 certain examples, the card feeders <NUM> each include at least one pinch roller pair <NUM>, such as pinch roller pairs 190A and 190B. In certain examples, 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 a raised position. 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> 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 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 certain examples, 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. 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, the card feed axis <NUM> is at an oblique angle (e.g., <NUM>-<NUM> degrees) to the processing axis <NUM> in the vertical plane. 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, 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 certain examples, 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 example, 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>.

During an exemplary lift operation, in which the card feeder <NUM> is moved from the lowered position to the raised position, the controller <NUM> activates the motor <NUM> of the lift mechanism <NUM> to drive rotation of a cam (not shown) about the axis <NUM> in the direction indicated by arrow <NUM> in <FIG>. As the cam rotates, it drives the card feeder frame <NUM> to pivot about the pivot axis <NUM> until the card feeder <NUM> reaches the raised position. The operation is reversed to move the card feeder <NUM> back to its lowered position.

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>.

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 example, 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>. In certain examples, the card sensors <NUM> are positioned between the pinch roller pair 190A and the adjacent belt <NUM>. In certain examples, the card sensors <NUM> are supported by the card feeder frame <NUM>.

During reception of a card <NUM> by a card feeder <NUM> in its lowered position, 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 to the raised position. After the card feeder <NUM> is moved to the raised position, 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> driven by one or more motors <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.

Some examples 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 example 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. The card feeder 120A is moved to its raised position 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 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>.

In certain examples, the ink jet card printer <NUM> can include a cure light <NUM> to assist in hardening recently ejected ink. Such a cure light <NUM> can project ultraviolet (UV) light for curing UV-curable inks. In some examples, the cure light <NUM> can be attached to the ink jet print head <NUM> and can move with the ink jet print head <NUM>. In some examples, the cure light <NUM> is attached to an axis separate from the ink jet print head axis and can move independent of the ink jet print head <NUM>. In operation, after an image is printed, conventional systems pass an illuminated cure light across the entire width or length of the printed media to cure, or harden, the printed ink. For an ink jet printer according to the present subject matter, after printing of an image onto print media using curable ink, the cure light <NUM> can be passed over the image at a cure speed and can be moved over unprinted portions of the print media, or retracted over cured portions if the image, at a speed higher than the cure speed.

In certain examples, 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 certain examples, the surface of the ink overspray collector <NUM> configured to receive the overspray ink is positioned below or offset some distance, x, from the bottom surface of the card <NUM> to be printed to allow for ink buildup. The offset can allow a finished card to pass over ink buildup on the ink overspray collector <NUM> without the overspray ink transferring to the underside of the finished card or to the underside of a new card entering the print area. In certain examples, 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 certain examples, 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.

In certain examples, the ink overspray collector <NUM> is a reusable component that can be easily cleaned and reused to reduce waste production of the ink jet printer. In certain examples, the ink overspray collector <NUM> can include a coated material that allows the overspray ink to be removed relatively quickly and/or easily (e.g., in seconds). In some examples, the reusable component is stiff enough to maintain its shape when installed and laden with overspray ink, but also flexible enough to allow easy removal from the machine, easy removal of ink from the surface of the component, and easy installation back onto the machine. In some examples, the material of the ink overspray collector <NUM> is a woven material with a coating that has low adhesion with the ink such that the overspray ink can adhere to the ink overspray collector during operation, but the ink can easily be separated from the surface of the ink overspray collector during a short break in the operation of the ink jet printer. In some examples, the woven material can include fiberglass. In some examples, the coating can include polytetrafluoroethylene (PTFE).

<FIG> illustrates generally an example ink overspray collector. The ink overspray collector <NUM> can include openings 184A, 184B for the corresponding exposed belt surfaces <NUM> of the corresponding belt 140A, 140B. In certain examples, the openings 184A, 184B closely extend with the shape of the print media, such that as the print media is being printed, the corresponding belt 140A, 140B is not exposed to receiving ink overspray. The ink overspray collector <NUM> can have a pair of long sides 181A, 181B and a pair of short sides 183A, 183B arranged generally in a rectangular form or footprint. Each long side 183A, 183B can include an optional inward notch 185A, 185B. Each short side can include an optional outward notch 187A, 187B. In certain examples, upon installation in an ink jet card printer, one or more of the inward notches 185A, 185B or outward notches 187A, 187B can be captured or used to secure the ink overspray collector <NUM> in a proper position.

In certain examples, the ink overspray collector <NUM> can be symmetrical about a centerline running parallel with the long sides 181A, 181B. In some examples, the ink overspray collector <NUM> can be symmetrical about a centerline running parallel with the short sides 183A, 183B. Symmetry of the ink overspray collector can allow for proper installation to the ink jet card printer in more than one orientation which can save time.

It is understood that examples of an ink overspray collector can include more opening or less openings than the example of <FIG> without departing from the scope of the present subject matter. The rectangular shaped footprint of the illustrated ink overspray collector <NUM> works well to cover mechanisms of the ink jet card printer and protect those mechanisms from ink overspray. It is understood that mechanisms of other ink jet card printers may be better protected from ink overspray from and ink overspray collector with a footprint that is in a shape other than the illustrated rectangular shape and such ink overspray collectors do not depart from the scope of the present subject matter. It is further understood that an ink overspray collector can have additional or other tabs for securing the ink overspray collector without departing from the scope of the present subject matter.

In some examples, the controller of an example ink jet card printer can also assist in handling ink overspray, for example, by reducing the amount of overspray. In certain examples, generally, as the position of the ink jet print head approaches the edge of the print area, the controller can provide overspray modulation. Overspray modulation of the ink can include reducing the amount of ink dispensed near the edge of the print media or print area of the printer compared to an amount of ink that would otherwise be dispensed without overspray modulation. Using less ink than would otherwise be dispensed without overspray modulation can reduce the amount of ink overspray.

In some examples, overspray modulation of the dispensing of the ink from the printhead can include reducing the number of ink droplets compared to the number requested to provide the full image being printed. In some examples, overspray modulation of the dispensing of the ink from the printhead can include reducing the size of ink droplets compared to the size requested to provide the full image being printed. In some examples, modulation of the dispensing of the ink from the printhead can include reducing the number of ink droplets of certain colors such that the edge of the image fades into the background color provided by the surface of the print media. In some examples, overspray modulation can include one or more of the above techniques in combination with each other. In certain examples, the overspray techniques are applied to nozzles of the print head that dispense ink within a certain distance of the edge of the print media while printing a given image. In various examples, the certain distance is less than <NUM> millimeters (mm), less than <NUM>, less than <NUM>, or less than <NUM> from the edge of the print media or from the edge of the print area.

<FIG> illustrates generally an example method of reducing ink overspray. At <NUM>, an ink jet print head can pass over a card. At <NUM>, in response to the ink jet print head passing over the card, ink can be ejected toward the card to print at least a portion of an image.

The image can extend to a first edge of the card that is perpendicular to the direction of travel of the ink jet print head. At <NUM>, the ink jet print head can approach the first edge of the card. At <NUM>, ejection of ink is reduced, or begins to be reduced, at a certain distance from the first edge from a requested amount of ink to reduce ink overspray at the first edge. In certain examples, the certain distance can be less than <NUM> millimeters (mm), less than <NUM>, less than <NUM>, or less than <NUM> from the edge of the print media or from the edge of the print area. As used herein, the requested amount of ink is the amount of ink that would be dispensed if an overspray reduction method were not employed. In certain examples, the reduction of ink from the requested amount of ink can take the form of reducing the number of ink droplets from the requested number of ink droplets to form the image, reducing the size of ink droplets from the size of ink droplets requested to form the image, reducing the number of certain color ink droplets to fade the image to the color of the surface of the card, or combinations thereof. <FIG> illustrates a generally an example location and relative direction of travel of an ink jet print head 111A when the controller may invoke the ink reduction method of <FIG>.

<FIG> illustrates generally an example method of reducing ink overspray. At <NUM>, an ink jet print head can initiate a pass over a card to print an image on the card from an initial position not over the card. At <NUM>, the ink jet print head can approach a first edge of the card perpendicular to the direction of travel of the ink jet print head. The image can extend from the first edge of the card. At <NUM>, ejection of ink is reduced near the first edge from a requested amount of ink to form the image to reduce ink overspray at the first edge. At <NUM>, ink can be ejected toward the card according to the requested amount of ink to print at least a portion of the image as the print head passes over the card and away from the first edge by a certain distance. In certain examples, the certain distance can be more than <NUM> millimeters (mm), more than <NUM>, more than <NUM>, or more than <NUM> from the edge of the print media or from the edge of the print area. In certain examples, the reduction of ink from the requested amount of ink can take the form of reducing the number of ink droplets from the requested number of ink droplets to form the image, reducing the size of ink droplets from the size of ink droplets requested to form the image, reducing the number of certain color ink droplets to fade the image to the color of the surface of the card, or combinations thereof. As the print head passes over the card and toward the center of the card near the first edge, the amount of reduction of the ink can be decreased to the requested amount when the probability of significant ink overspray at the first edge is eliminated. <FIG> illustrates a generally an example location and relative direction of travel of an ink jet print head 111B when the controller may invoke the ink reduction method of <FIG>.

Claim 1:
An apparatus (<NUM>) for an ink jet printer (<NUM>), the apparatus comprising:
a first opening (184A) defining a first print area of the ink jet printer; and
a frame about the first opening configured to receive overspray from operation of the ink jet printer; characterized in that
the frame is formed of a woven material having a coating with low adhesion with ink.