Patent Description:
When printing on the surface of a plastic card, it is often desirable that a surface of the card be printed edge-to-edge so that the applied ink extends all the way up to each edge of the card or up to select edges of the card, for example up to the leading edge and/or the trailing edge and/or each one of the side edges. Edge-to-edge printing eliminates a white border that can appear where the applied ink stops short of an edge.

In DOD printing on a plastic card, ink is ejected from one or more print heads onto the card surface. During edge-to-edge printing, as the printing approaches an edge of the card, the ejected ink may "overspray" the edge and fall onto a structure, for example a vacuum belt, of the identification document printer underneath the edge. Over time, the oversprayed ink accumulates on the structure, requiring the structure to be periodically replaced or periodically cleaned. To prevent such overspray, the printing can be stopped a predetermined distance from the edge. However, this does not result in edge-to-edge printing and results in a white border at the edge. <CIT> and <CIT> disclose known inkjet printers for a card.

A DOD card printer (also referred to as an inkjet card printer) according to the invention as defined in claim <NUM> is described that includes a tray disposed underneath the card during DOD printing to catch any overspray that may occur during printing on the card. In an embodiment not claimed, the tray may be disposable so that the tray is intended to be removed and disposed of. In an embodiment, an ink absorbent pad can be disposed in the tray to absorb the oversprayed ink. The ink absorbent pad can be disposed of along with the tray.

The techniques described herein facilitate edge-to-edge printing on a plastic card, or printing near at least one edge of a plastic card where overspray may occur. So the techniques described herein are not limited to printing near all of the edges of the plastic cards. In some embodiments, the print job may require that ink be applied to a surface of the plastic card only near one or more edges but not near one or more other edges. As used herein, the term "edge-to-edge printing" on a plastic card is intended to encompass printing near all of the edges of the plastic card, or near at least one edge of the plastic card.

The tray is mounted on a card transport that transports the card to and from a drop-on-demand print station that includes at least one drop-on-demand print head. In one embodiment, the tray can be configured so as to be removably mounted on the card transport in a manner that allows an operator of the DOD card printer to manually remove and install the tray using their fingers/hand without requiring the operator to loosen or tighten any mechanical fasteners. In one non-limiting example, the tray can include one or more magnets that magnetically interact with one or more corresponding magnets on the card transport to magnetically removably secure the tray to the card transport.

In another embodiment, a means can be provided that allows the DOD card printer to sense whether the tray is present. If the tray is sensed, edge-to-edge printing on the card can be permitted. If the tray is not sensed, edge-to-edge printing can be prevented. In one non-limiting example, the means for sensing the presence of the tray can include a radio frequency identification (RFID) tag that is fixed to the tray. Alternatively, one or more of the magnets used to removably secure the tray to the card transport could be sensed. Other means for sensing the tray, such as a proximity sensor or a photocell, could also be used. If the RFID tag is used, the RFID tag can store various data thereon, as well as permit data to be read from and/or permit data to be written to the RFID tag. Examples of data that can be stored on the RFID tag include, but are not limited to, the number of plastic cards edge-to-edge printed with the tray in position, an estimated volume of ink absorbed by the ink absorbent pad of the tray, and a date of installation of the tray.

The card printer includes a drop-on-demand print station that includes at least one drop-on-demand print head and a card transport that is configured to support a card during printing and that is configured to transport the card to a printing position underneath the at least one drop-on-demand print head. A tray is mounted on the card transport so that the tray is positioned under the card and the tray projects beyond at least one edge of the card. With this configuration, the tray is able to collect any ink that oversprays the at least one edge.

In another embodiment not claimed, a plastic card printer is provided for edge-to-edge printing on a plastic card having a perimeter edge. The plastic card printer can include a drop-on-demand print station that includes at least one drop-on-demand print head that prints using ink, and a card transport that is configured to support the plastic card during printing and that is configured to transport the plastic card to a printing position underneath the at least one drop-on-demand print head for edge-to-edge printing on the plastic card. A disposable tray is removably mounted on the card transport so that the disposable tray is positioned under the plastic card and the disposable tray projects beyond the perimeter edge of the plastic card to collect ink that oversprays the perimeter edge. The disposable tray can include an ink collection channel, and an ink absorbent pad can be disposed in the ink collection channel to absorb the oversprayed ink.

In some embodiments, the card printers described herein can be part of a card processing system that includes a card input that holds a plurality of cards to be printed, and a card output that holds a plurality of printed cards.

A method of drop-on-demand printing on a card is as defined in claim <NUM>. The card is then printed on using the at least one drop-on-demand print head while the tray is positioned under the card.

Various embodiments of the method are as defined in claims <NUM> to <NUM>.

In another embodiment not claimed, a method of edge-to-edge printing in a plastic card printer is provided. The printing occurs on a plastic card having a perimeter edge. The method includes transporting the plastic card to a printing position in a drop-on-demand print station that includes at least one drop-on-demand print head that prints using ink, where the plastic card is transported by a card transport. The plastic card printer senses whether a disposable tray is mounted on the card transport. The tray is configured to be positioned under the plastic card and the tray projects beyond the perimeter edge of the plastic card to collect ink that may overspray the perimeter edge during drop-on-demand edge-to-edge printing on the plastic card. If the disposable tray is sensed, drop-on-demand edge-to-edge printing on the plastic card is performed. If the disposable tray is not sensed, drop-on-demand edge-to-edge printing on the plastic card is prevented.

The concepts described herein can be applied to edge-to-edge printing on substrates other than cards including, but not limited to, passport pages, and non-personalized substrates such as paper, labels, or the like.

Referring to <FIG>, an example of a plastic card <NUM> which can be DOD printed using a DOD card printer described herein is illustrated. The plastic card <NUM> can include, but is not limited to, a financial (e.g., credit, debit, or the like) card, a driver's license, a national identification card, a business identification card, a gift card, and other plastic cards. The plastic card <NUM> is formed partially or entirely of a plastic material as is well known in the art of plastic card printing. In some embodiments, the concepts described herein can be applied to edge-to-edge printing on substrates other than cards including, but not limited to, passport pages, and non-personalized substrates such as paper, labels, or the like.

The plastic card <NUM> includes a first surface <NUM> and a second surface <NUM> (visible in <FIG>) opposite the first surface <NUM>. The first surface <NUM> may be considered the top surface of the plastic card <NUM> or the bottom surface of the plastic card <NUM>. Likewise, the second surface <NUM> may be considered the bottom surface of the plastic card <NUM> or the top surface of the plastic card <NUM>. To simplify the description, the first surface <NUM> will be considered the top surface, while the second surface <NUM> will be considered the bottom surface.

In the top view of <FIG>, the plastic card <NUM> has a perimeter edge that includes a first end edge <NUM>, a second end edge <NUM>, a first longitudinal side edge <NUM>, and a second longitudinal side edge <NUM>. A length L is defined between the first end edge <NUM> and the second end edge <NUM>, and a width W is defined between the first longitudinal side edge <NUM> and the second longitudinal side edge <NUM>. In one embodiment, the plastic card <NUM> can have a length L of about <NUM> and a width W of about <NUM>. However, other card lengths L and widths W are possible.

The first surface <NUM> can be printed with background graphics (not shown) as well as a logo and the name of the card issuer (not shown). In some embodiments, the first surface <NUM> may also be printed with various data (not shown) relating to the intended cardholder such as, but not limited to, an image of the intended cardholder, the name of the intended cardholder, an account number, a card expiration date, and other printed data known in the art of plastic cards. At least some of the printing on the first surface <NUM> is created by DOD inkjet printing using an ink that is suitable for application to plastic cards. In one non-limiting embodiment, the ink applied by the DOD inkjet printing is radiation curable ink, such as ultraviolet (UV) radiation curable ink. In addition to DOD inkjet printing, other printing techniques can be used to apply printing to the first surface <NUM>, such as retransfer printing, laser marking, thermal transfer, and other printing known in the art.

The second surface <NUM> can also be printed with background graphics (not shown); various data (not shown) relating to the intended cardholder such as, but not limited to, the name of the intended cardholder, an account number, a card verification value number, a card expiration date, and other printed data known in the art of plastic cards; card issuer contact information; and other data. At least some of the printing on the second surface <NUM> may be created by DOD inkjet printing using the same type of ink or a different type of ink that is applied to the first surface <NUM>. In addition to DOD inkjet printing, other printing techniques can be used to apply printing to the second surface <NUM>, such as retransfer printing, laser marking, thermal transfer, and other printing known in the art.

Some of the printing that takes place on the first surface <NUM> or on the second surface <NUM> may occur by DOD inkjet printing using an ink such as UV curable ink. To facilitate the description, it will be assumed that the first surface <NUM> is the printed surface to which the ink is to be applied. However, the second surface <NUM> could be the printed surface, or after the first surface <NUM> is printed, the second surface <NUM> could later be subject to DOD inkjet printing and become the printed surface.

The card <NUM> may also be provided with various other features. For example, as shown in <FIG>, the card <NUM> may be provided with an integrated circuit chip <NUM> that is accessible via the first surface <NUM> (or alternatively via the second surface <NUM>), or the chip <NUM> may be completely embedded in the card <NUM>. The card <NUM> can also include a magnetic stripe <NUM> (shown in dashed lines) on the second surface <NUM>. The integrated circuit chip <NUM>, which can be a contact chip or a contactless chip, can be electronically programmed with data and/or data can be electronically read therefrom using an integrated circuit chip programming device known in the art. The magnetic stripe <NUM> (if present) can have data magnetically written to and/or data read therefrom using a suitable magnetic stripe read/write device known in the art.

Assuming the first surface <NUM> is the printed surface, some of the DOD inkjet printing may take place near one or more of the edges <NUM>, <NUM>, <NUM>, <NUM>, or in the case of true edge-to-edge printing, the inkjet printing may take place near all of the edges <NUM>, <NUM>, <NUM>, <NUM>. However, when inkjet printing near one of the edges <NUM>, <NUM>, <NUM>, <NUM>, some of the ink delivered from the DOD print head may overspray the edge. The term "overspray" and the like as used herein refers to ink that is ejected from the DOD print head that does not fall onto the card surface. As discussed in further detail below, a tray <NUM> is positioned under some or all of the edges of the card <NUM> to catch any oversprayed ink and prevent the oversprayed ink from contaminating undesired structures of the DOD card printer, such as the card transport used to transport the card <NUM>.

<FIG> illustrates a portion of a DOD card printer <NUM> described herein. The card printer <NUM> is configured to perform DOD inkjet printing at a drop-on-demand print station <NUM> that includes at least one drop-on-demand print head. The printing performed by the card printer <NUM> can be monochromatic or multi-color. <FIG> illustrates the print station <NUM> as including five drop-on-demand print heads 36a-e each of which prints a different color ink or other material to be applied to the card surface <NUM>, <NUM>. The print heads 36a-e are arranged side-by-side to sequentially print onto the surface <NUM>, <NUM> of the card <NUM> as the card <NUM> is transported past the print heads 36a-e, for example underneath the print heads 36a-e. However, a smaller or larger number of print heads, including one of the print heads, can be utilized. Each print head 36a-e is supplied with its respective ink from a corresponding ink or material supply 38a-e.

The print heads 36a-e can print using any suitable ink or coating used in drop-on-demand printing and that is suitable for use on the types of cards described herein. For example, the ink can be a UV curable ink, a heat curable ink that can be cured by applying heat to the heat curable ink, or other ink or materials that can be deposited by print heads 36a-e. In the case of the five print heads 36a-e in <FIG>, each print head can print a specific color ink. For example, the print head 36a can print cyan colored ink, the print head 36b can print magenta colored ink, the print head 36c can print yellow colored ink, the print head 36d can print black ink, and the print head 36e can print white ink. An example of a drop-on-demand printer that prints using UV curable ink in a card printing system is the Persomaster card personalization system available from Atlantic Zeiser GmbH of Emmingen, Germany. If printing on both surfaces <NUM>, <NUM> of the card <NUM> is required, a card flipper or card reorienting mechanism (not shown) can be included to flip or rotate the card <NUM><NUM> degrees so that the surface <NUM> now faces upward and the surface <NUM> faces downward, and the card <NUM> is then transported back upstream of the print heads 36a-e to print on the surface <NUM>. Examples of card flippers are disclosed in <CIT> and <CIT>. In other embodiments, a card flipper followed by a second DOD plastic card printer, which can be identical to the card printer <NUM>, could be provided in order to print on both sides of the card. This would eliminate the need to transport the card <NUM> back upstream of the print heads 36a-e of the single card printer.

The specific construction and operation of the print heads 36a-e is well known and can be identical to the construction and operation of DOD print heads known in the art. The print heads 36a-e each includes a bottom surface that faces downward toward the card to be printed on, and a nozzle plate, through which ink is ejected, is provided on the bottom surface.

With continued reference to <FIG>, the card printer <NUM> further includes an input end <NUM> through which the card <NUM> can enter the card printer <NUM> for printing on the card <NUM>, and a card output end <NUM> through which the card <NUM> can exit the card printer <NUM> after printing (or exit if no printing takes place). The input end <NUM> and the output end <NUM> can take any form suitable for allowing cards to enter and exit the card printer <NUM>, for example input and output slots. The card printer <NUM> further includes a card transport mechanism that transports cards <NUM> from the input end <NUM>, through the print station <NUM>, and then to the output end <NUM>. In some embodiments, the card transport mechanism may also transport cards <NUM> back toward the input end <NUM>. In the illustrated embodiment, the card transport mechanism has at least first and second separate card transports 44a, 44b (or first and second card transport means 44a, 44b) each of which can receive a card <NUM> from the input end <NUM>, support the card <NUM> as the card <NUM> is transported in the card printer <NUM> and during printing in the print station <NUM>, and ultimately deliver the card <NUM> to the output end <NUM>. Although the card transport mechanism is illustrated as having the two card transports 44a, 44b, additional card transports or only a single one of the card transports 44a, 44b can be provided as well.

Each card transport 44a, 44b can include a vacuum platen 46a, 46b (best seen in <FIG>). Each vacuum platen 46a, 46b is configured to apply a vacuum to a card <NUM> disposed thereon, much like a conventional vacuum belt, to retain the card <NUM> in position on the platen 46a, 46b during transport and during printing in the card printer <NUM>. A pair of rails 48a, 48b (illustrated schematically in dashed lines in <FIG>) are provided, and the vacuum platen 46a is movably supported on the rail 48a while the vacuum platen 46b is movably supported on the rail 48b. Each card transport 44a, 44b forms a two axis or an X-Y axis transport system where each of the vacuum platens <NUM> is actuatable along the X and Y axes as indicated by the double-headed arrows in <FIG>.

A common card pick-up position is defined near or adjacent to the input end <NUM>, while a common card discharge position is defined near or adjacent to the output end <NUM>. The common card pick-up position and the common card discharge position are locations in the card printer <NUM> that permit each of the vacuum platens 46a, 46b to be separately positioned at separate times at the same location in the card printer <NUM> to pick-up cards that are input via the input end <NUM> and to deliver the cards to the output end <NUM> for discharge of the cards. So the word "common" in the common card pick-up position and the common card discharge position refers to the situation where the vacuum platens 46a, 46b can each occupy the same space in the card printer <NUM>, but at different times, and the card transports 44a, 44b are suitably designed to actuate the vacuum platens 46a, 46b between the common card pick-up position and the common card discharge position without the vacuum platens 46a, 46b interfering with one another. Further information on the construction and operation of the card transports 44a, 44b are disclosed in <CIT> titled Dual Card Transport in a Card Processing System.

<FIG> illustrates the card transport 44b and the vacuum platen 46b thereof positioned underneath the print heads 36a-e with a card (not shown) held by the vacuum platen for printing on the card. After printing is complete, the card transport 44b will be actuated to the output end <NUM> to output the printed card. The card transport 44b will then be actuated to return to the input end <NUM> to pick up a new card to be printed. As this is occurring, the card transport 44a and the vacuum platen thereof, with a card <NUM> supported thereon to be printed, will be actuated to a position underneath the print heads 36a-e for printing on the card <NUM>.

With reference to <FIG>, the tray <NUM> is designed to be removably mounted on the card transport 44a, 44b so as to move with the card transport 44a, 44b. The tray <NUM> can be made of plastic or other lightweight material to minimize the weight of the tray <NUM>. In some embodiments not claimed, the tray <NUM> can also be disposable whereby the tray <NUM> is intended to be discarded at the end of its intended life. The term "removably mounted" or similar as used herein and in the claims means that the tray <NUM> is secured to the card transport 44a, 44b in a manner that allows an operator of the DOD card printer to manually remove and install the tray <NUM> using their fingers/hand without requiring the operator to loosen or tighten any mechanical fasteners.

In the embodiment illustrated in <FIG>, the tray <NUM> has a main body <NUM> with a tab <NUM> projecting from one end of the main body <NUM>. The tab <NUM> is intended to provide a means for a user to grip and hold the tray <NUM> during removal and installation of the tray <NUM>. The tray <NUM> includes an ink collection channel <NUM> that is intended to collect oversprayed ink. The channel <NUM> is defined by an outer wall <NUM>, an interior wall <NUM> spaced from the outer wall <NUM>, and a bottom wall <NUM> that interconnects the outer wall <NUM> and the interior wall <NUM>. In some embodiments, an ink absorbent pad <NUM> can be disposed in the channel <NUM>, with the pad <NUM> intended to absorb oversprayed ink rather than the ink sitting loosely in the channel <NUM>. The pad <NUM> may be disposed of along with the tray <NUM>. Instead of the tray <NUM> being disposable, in some embodiments not claimed the pad <NUM> can be disposable and replaced with a new pad <NUM> that is inserted into the same tray <NUM>, whereby the tray <NUM> is re-used at least once instead of being disposable along with the pad <NUM>.

The tray <NUM> includes a central opening <NUM> defined by the interior wall <NUM>. The central opening <NUM> allows passage of the vacuum platen 46a, 46b through the tray <NUM> in order to engage with the card <NUM>. As shown in <FIG>, when the tray <NUM> is properly mounted on the card transport 44a, 44b, an upper end of the vacuum platen 46a, 46b projects above the top edge of the interior wall <NUM> of the tray <NUM> so that the card <NUM> is supported on the vacuum platen 46a, 46b at a distance above the upper edge of the interior wall <NUM> whereby the card <NUM> is not in direct physical contact with the tray <NUM>.

The tray <NUM> can have any configuration that allows the tray <NUM> to be removably mounted on the card transport 44a, 44b, that allows the vacuum platen 46a, 46b to engage with the card <NUM>, and that allows the tray <NUM> to catch oversprayed ink. In the embodiment illustrated in <FIG>, the main body <NUM> is generally rectangular, the ink collection channel <NUM> is generally rectangular, and the central opening <NUM> is generally rectangular. However, other shapes such as square, circular, triangular, and the like could be used.

The tray <NUM> further includes means for removably securing the tray <NUM> to the card transport 44a, 44b in a manner that permits a user to remove and install the tray <NUM> by gripping the tab <NUM>. In the illustrated example in <FIG>, the means for removably securing comprises a plurality of bosses <NUM> on the main body <NUM> that are positioned and configured to engage with corresponding receptacles <NUM> on the card transport 44a, 44b (only one receptacle <NUM> is visible in <FIG>). The bosses <NUM> can be located anywhere on the main body <NUM> to achieve the removable securing function. For example, the bosses <NUM> can project downwardly from the bottom wall <NUM>.

If additional securement of the tray <NUM> to the card transport 44a, 44b is desired, each boss <NUM> can be provided with a magnet <NUM> at the base thereof that magnetically interface with corresponding magnets (not shown) in the receptacles <NUM> to magnetically secure the tray <NUM> to the card transport 44a, 44b.

With continued reference to <FIG>, a radio frequency identification (RFID) tag <NUM> can be fixed to the tray <NUM>, for example to the bottom side of the tab <NUM>. The RFID tag <NUM> permits storage of various data thereon, as well as functions as a means for sensing the presence of the tray <NUM> by a suitable RFID tag reader/writer (not shown) to determine whether the tray <NUM> is installed on the card transport 44a, 44b prior to beginning a printing operation where overspray of the ink may occur. One or more of the magnets <NUM> (if used) may also be sensed by a suitable detection device to detect the presence of the tray <NUM> prior to beginning a printing operation where overspray of the ink may occur. Other means for sensing the tray, such as a proximity sensor or a photocell, could also be used.

The RFID tag <NUM> can store data thereon, as well as permit data to be read from and/or permit data to be written to the RFID tag <NUM>. Examples of data that can be stored on the RFID tag <NUM> include, but are not limited to, the number of plastic cards edge-to-edge printed with the tray <NUM> in position, an estimated volume of ink absorbed by the ink absorbent pad <NUM> of the tray <NUM>, and a date of installation of the tray <NUM> onto the card transport 44a, 44b. The volume of ink absorbed by the pad <NUM> can be estimated by estimating an amount of oversprayed ink that will occur with each edge-to-edge print job on each plastic card <NUM>. In some embodiments, if the RFID tag <NUM> is not detected by the RFID tag reader/writer, the system can prevent edge-to-edge printing by the card printer <NUM> although the system can permit non-edge-to-edge printing where overspray of the ink will not occur.

<FIG> illustrates the relative positioning of the card <NUM> and the tray <NUM> when the card <NUM> is in position on the card transport. The vacuum platen 46a, 46b is shown in dashed lines. The card <NUM> is positioned so that the edges <NUM>, <NUM>, <NUM>, <NUM> are disposed over and above the channel <NUM> of the tray <NUM>. Another way of describing the positioning between the card <NUM> and the tray <NUM> is that the tray <NUM> is positioned under the card <NUM> and the tray <NUM> projects beyond at least one edge of the card, preferably all of the edges <NUM>, <NUM>, <NUM>, <NUM> so that the edges <NUM>, <NUM>, <NUM>, <NUM> are aligned with the channel <NUM>. Accordingly, in the top view of <FIG>, there is a gap X between each edge <NUM>, <NUM>, <NUM>, <NUM> and the outer wall <NUM>. The gap X can be the same for each one of the edges <NUM>, <NUM>, <NUM>, <NUM>, or the gap X could be different for one or more of the edges <NUM>, <NUM>, <NUM>, <NUM>.

As a result of the positioning between the card <NUM> and the tray <NUM>, ink that oversprays any one of the edges <NUM>, <NUM>, <NUM>, <NUM> of the card <NUM> will fall into the channel <NUM> and be absorbed by the pad <NUM>. After a number of cards have been printed, the tray <NUM> can be lifted from the card transport by the user gripping the tab <NUM>. The tray <NUM> can then be disposed of, or cleaned for reuse. If the tray is disposed of, a new tray <NUM> can then be installed on the card transport to continue printing new cards.

The card printer <NUM> can be used as a stand-alone printer, or used with other systems in a plastic card processing system. <FIG> schematically depicts one embodiment of a plastic card processing system <NUM> in which the card printer <NUM> described herein can be implemented. The system <NUM> is configured as a central issuance system with multiple processing stations or modules. An example of a central issuance system is the MX or MPR-lines of central issuance systems available from Entrust Datacard Corporation of Shakopee, Minnesota. Additional examples of central issuance systems are disclosed in <CIT>, <CIT>, <CIT>, and <CIT>.

In another embodiment, the card printer <NUM> can be used in a desktop card processing system. An example of a desktop plastic card processing system is the CD800 Card Printer available from Entrust Datacard Corporation of Shakopee, Minnesota. Additional examples of desktop card processing systems are disclosed in <CIT> and <CIT>.

The system <NUM> illustrated in <FIG> includes the DOD plastic card printer <NUM> and an optional curing station <NUM>, such as a UV curing station if UV curable ink is printed by the printer <NUM>. The system <NUM> can also include a card input <NUM>, one or more optional additional card processing stations <NUM> between the card input <NUM> and the card printer <NUM>, one or more optional additional card processing stations <NUM> between card printer <NUM> and a card output <NUM>. Each plastic card <NUM> progresses through the system <NUM> generally in the direction of the arrow A.

The curing station <NUM> (if present) is configured to cure radiation curable ink applied to the card surface. An example of a curing station that applies UV radiation in a card printing system is the Persomaster card personalization system available from Atlantic Zeiser GmbH of Emmingen, Germany.

The card input <NUM> is configured to hold a plurality of plastic cards waiting to be processed. Cards are fed one-by-one from the card input <NUM> into the rest of the system <NUM> where each card is individually printed and otherwise processed. Processed plastic cards are ultimately transported into the card output <NUM> that is configured to hold a plurality of the printed plastic cards.

The optional additional card processing station(s) <NUM> can be between the card input <NUM> and the card printer <NUM>. The optional additional card processing station(s) <NUM> can be between the card printer <NUM> and the card output <NUM>. The optional additional card processing station(s) <NUM>, <NUM> can be plastic card processing stations known in the art to perform plastic card processing operations that are known in the art. For example, the optional additional card processing stations can include a magnetic stripe read/write system that is configured to read data from and/or write data to the magnetic stripe <NUM>, and/or an integrated circuit chip programming system that is configured to program the integrated circuit chip <NUM>. Magnetic stripe read/write systems and integrated circuit chip programming systems are disclosed, for example, in <CIT> and <CIT>, and can be found in the MX family of central issuance systems available from Entrust Datacard Corporation of Shakopee, Minnesota. The optional additional card processing station(s) <NUM>, <NUM> can also be configured to perform one or more of embossing; indenting; laminating; laser marking; apply a topcoat; a quality control station that is configured to check the quality of personalization/processing applied to the cards; a security station that is configured to apply a security feature such as a holographic foil patch to the cards; and other card processing operations.

Other than the card transport mechanism used in the card printer <NUM>, transport of the plastic cards <NUM> in other portions of the system <NUM> can occur using conventional card transport mechanisms that are known in the art. Examples of card transport mechanisms that could be used are known in the art and include, but are not limited to, transport rollers, transport belts (with tabs and/or without tabs), vacuum transport mechanisms, transport carriages, and the like and combinations thereof. Card transport mechanisms are well known in the art including those disclosed in <CIT>, <CIT>, <CIT>, and <CIT> and <CIT>. A person of ordinary skill in the art would readily understand the type(s) of card transport mechanisms that could be used, as well as the construction and operation of such card transport mechanisms.

Claim 1:
A card printer (<NUM>), comprising:
a drop-on-demand print station (<NUM>) that includes at least one drop-on-demand print head (36a-e);
a card transport (44a, 44b) that is configured to transport the card (<NUM>) to a printing position underneath the at least one drop-on-demand print head;
characterized in that the card printer (<NUM>) comprises a tray (<NUM>) mounted on the card transport so that the tray is positioned under the card during printing on the card by the at least one drop-on-demand print head and the tray projects beyond at least one edge of the card, and the tray is able to collect any ink that oversprays the at least one edge;
the card (<NUM>) is mounted on the card transport (44a, 44b) a distance above the tray (<NUM>) whereby the card (<NUM>) is not in direct physical contact with the tray (<NUM>).