Patent Description:
Document <CIT> relates to an identification card manufacturing module unification. Document <CIT> relates to an information card producing device. Document <CIT> relates to overcoating plastic cards. Document <CIT> relates to a desktop card processor.

Plastic cards such as financial cards including credit and debit cards, identification cards, driver's licenses, and other personalized plastic cards are typically personalized with personal information of the intended card holder. Examples of personalization include, but not are limited to, names, addresses, photographs, account numbers, employee numbers, or the like. The personal information may be applied to the card in a number of different ways including, but not limited to, printing on a surface of the document, storing the information on a magnetic stripe disposed on the card, and storing the information on an integrated circuit chip or smart chip embedded in the card.

In some cases, the plastic cards are personalized using a desktop card printer that has a relatively small footprint intended to permit the desktop card printer to reside on a desktop and that is designed to personalize cards in relatively small volumes, for example measured in tens or low hundreds per hour. An example of a desktop printer is the CD800 Card Printer available from Entrust Datacard Corporation of Shakopee, Minnesota.

Desktop card printers are typically designed to be relatively small so that the printers can fit onto a desk or table. The desktop card printer may be positioned on a support surface with other office machines and workspace, so that table and desk space is at a premium. Therefore, the amount of desk or table space required for the desktop card printer (i.e., its "footprint") should be minimized.

At the same time, it is desirable that a desktop card printer be able to perform multiple card processing operations, thereby increasing the performance capability of the desktop card printer.

Additionally, desktop card printers should be easy to operate and maintain with only a minimal amount of specialized training. Desktop card printers are often operated by personnel for whom producing cards is only an incidental portion of their job, such as a security guard or a desk clerk, and not by personnel who have special training in such equipment. The operation and maintenance of the card printer should thus be relatively intuitive and straightforward. Furthermore, the cards that are output from the card printer must be of the highest quality, attractive, and durable.

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

In one embodiment, the modular print engine can be removably mounted on top of a lower module that performs one or more card processing operations including, but not limited to, embossing, laminating, or both embossing and laminating. The functionality of the desktop card printer can be selectively altered by installing different ones of the modular print engine components into and/or onto the module print engine. Before or after printing in the modular print engine, a plastic card can be directed from the modular print engine into the lower module to perform the processing operation(s) of the lower module. Thereafter, the plastic card can be output from the lower module or directed back into the modular print engine for further processing and/or output of the personalized card.

The modular print engine can include a card input at a front end of a housing, as well as a card input hopper which is in communication with the card input to input cards into the modular print engine for personalization. A card reorienting mechanism is in the housing adjacent to a rear end thereof, and the card reorienting mechanism is configured to receive a plastic card and rotate the card to redirect the card along a desired card travel path in the housing. A first card travel path extends between the card input and the card reorienting mechanism with cards being transported along the first card travel path by a card transport mechanism. A print engine that is configured to print on a card is disposed along the first card travel path. The print engine can perform any type of printing including, but not limited to, retransfer printing, direct to card printing, ink jet printing, laser marking, laser engraving, and any other type of printing performed on cards.

The modular print engine also includes a second card travel path extending from the card reorienting mechanism. A removable option module is disposed along the second card travel path. The removable option module includes at least one personalization mechanism that is configured to perform a personalization operation on a card. The removable option module can be removed and replaced with a different option module that is configured to have a different functionality. A plurality of different option modules, each having different functionality, can be created. Each option module is configured to be individually and separately removably installed in the housing along the second card travel path, and each option module is configured to perform a different personalization operation on a plastic card received thereby. One option module can be removed and replaced with a different option module to change the functionality of the modular print engine.

The modular print engine includes a first card opening in the bottom of the housing. A third card travel path extends from the card reorienting mechanism to the first card opening to permit a card to be output from the modular print engine and into the lower module. In some embodiments, after processing in the lower module, the plastic card can be input back into the modular print engine through the first card opening for further processing and/or output from the modular print engine.

In one embodiment, a second card opening can be provided in the rear end of the housing, and a fourth card travel path extends from the card reorienting mechanism to the second card opening. In this embodiment, a second option module can be attached to the rear end of the housing for receiving a card from the second card opening. The second option module can include at least one processing mechanism that is configured to perform a processing operation on a card.

In another embodiment, a second card opening can be provided in the top of the housing, and the second card travel path extends from the card reorienting mechanism to the second card opening. An upper expansion module can be attached to the top of the housing and can receive a plastic card from the modular print engine through the second card opening, with the card then being directed to an output of the upper expansion module through which the plastic card can be output from the upper expansion module.

In one embodiment, a modular print engine useable in a desktop card printer that personalizes cards includes a housing having a front end, a rear end, a top and a bottom. A card input is at the front end of the housing, and a card input hopper is disposed at the front end of the housing that is in communication with the card input. A card reorienting mechanism is disposed in the housing adjacent to the rear end, with the card reorienting mechanism being configured to receive a card and rotate the card to redirect the card along a desired card travel path. A first card travel path extends between the card input and the card reorienting mechanism. In addition, a second card travel path extends from the card reorienting mechanism. A print engine that is configured to print on a card is disposed along either the first card travel path or the second card travel path, and a removable option module is disposed along either the first card travel path or the second card travel path. The removable option module includes at least one personalization mechanism that is configured to perform a personalization operation on a card. In addition, a first card opening is formed in the bottom of the housing, and a third card travel path extends from the card reorienting mechanism to the first card opening.

In another embodiment, a desktop card printer system that personalizes cards includes a housing having a front end, a rear end, a top and a bottom. A card input is at the front end of the housing, and a card input hopper is in communication with the card input. A card reorienting mechanism is disposed in the housing adjacent to the rear end, with the card reorienting mechanism being configured to receive a card and rotate the card to redirect the card along a desired card travel path. A first card travel path extends between the card input and the card reorienting mechanism. In addition, a second card travel path extends from the card reorienting mechanism. A print engine that is configured to print on a card is disposed along either the first card travel path or the second card travel path. The system also includes a plurality of option modules, where a single one of the option modules is configured to be removably installed in the housing along either the first card travel path or the second card travel path. Each option module is configured to perform a different personalization operation on a plastic card received thereby. Therefore, by changing the option module that is installed, the functionality of the desktop card printer can be changed.

As used herein, a processing mechanism is intended to encompass a mechanism that performs a processing operation on a card that can involve personalization or not involve personalization. For example, applying a transparent protective laminate, perhaps even including a hologram or other non-personalized security feature, is an example of a card processing operation that does not involve personalization. Applying a name, address, photograph, account number, employee number, signature, or the like to a card are examples of processing operations that involve personalization. A personalization mechanism is intended to encompass a mechanism that performs a processing operation on a card that involves personalization. The term processing operation therefore encompasses both personalization and non-personalization operations performed on a card, while the term personalization operation encompasses personalization operations performed on a card.

As described further below, in some embodiments, a modular print engine <NUM> can include a card reorienting mechanism that is disposed at the intersection of four distinct card travel paths. In one embodiment, the four card travel paths are located at <NUM> degree intervals around the card reorienting mechanism and the card travels paths extend either horizontally or vertically. However, the four card travel paths can be positioned at other spaced intervals about the card reorienting mechanism, and the card travel paths need not extend horizontally or vertically.

In addition, the modular print engine <NUM> described further below can include a card input at a front end thereof and a card opening through a rear end thereof. In some embodiments, there can also be a card opening through a bottom of the modular print engine <NUM>. In other embodiments, there can also be a card opening through a top of the modular print engine. Depending upon the desired card travel path through the desktop card printer, the card openings can be card inputs or both inputs and outputs.

Referring to <FIG>, a first embodiment of a modular print engine <NUM> is illustrated as being detachably and removably mounted on top of a lower module <NUM>. Together, the modular print engine <NUM> and the lower module <NUM> form a desktop card printer that in use is configured to personalize, for example, plastic cards such as financial cards including credit and debit cards, identification cards, driver's licenses, and other personalized plastic cards. The desktop card printer is designed to have a relatively small horizontal (i.e. front to back) footprint intended to permit the desktop card printer to reside on a desktop or table and that is designed to personalize cards in relatively small volumes, for example measured in tens or low hundreds per hour.

The connection between the modular print engine <NUM> and the lower module <NUM> can be any form of non-permanent connection that permits the modular print engine <NUM> to be detachably mounted on top of the lower module <NUM> and that permits the modular print engine <NUM> to be non-destructively detached from the lower module <NUM> without destroying any portion of the modular print engine <NUM> or the lower module <NUM>. An example of a suitable detachable mounting between a print engine and a lower module is the detachable mounting used in the CD800 print engine that interfaces with a lower laminator module or the CE870 print engine that interfaces with a lower embosser module, both of which are available from Entrust Datacard Corporation of Shakopee, Minnesota.

The lower module <NUM> is of conventional construction and operation and as shown in <FIG> generally includes a lower module housing <NUM> illustrated in dashed lines with a front end <NUM>, a rear end <NUM> opposite the front end <NUM>, a top <NUM>, and a bottom <NUM> opposite the top <NUM>. A main card transport path <NUM> is defined in the housing <NUM> along which a plastic card is transported generally in a horizontal direction or generally parallel to the top <NUM> and the bottom <NUM>. A slot <NUM> is defined in the top <NUM> of the housing <NUM> through which a card can be input into the housing <NUM> from the modular print engine <NUM> and, in some embodiments, output from the housing <NUM> back into the modular print engine <NUM>. A secondary card transport path <NUM> leads from the slot <NUM> to a card reorienting mechanism <NUM> that is disposed adjacent to the rear end <NUM> of the housing <NUM>. In one embodiment, the secondary card transport path <NUM> can be generally vertical or perpendicular to the main card transport path <NUM> which can be generally horizontal.

The card reorienting mechanism <NUM> is rotatably disposed in the housing <NUM> for rotation both clockwise and counterclockwise as indicated by the arrow on the card reorienting mechanism <NUM>. When a card is being input into the lower module <NUM> from the modular print engine <NUM>, the card reorienting mechanism <NUM> is configured to receive a card along the secondary card transport path <NUM> and rotate the card so as to direct the card along the main transport path <NUM>. Likewise, when a card is being output from the lower module <NUM> back into the modular print engine <NUM>, the card reorienting mechanism <NUM> can receive a card from the main transport path <NUM>, and rotate the card so as to direct the card along the secondary card transport path <NUM> for transport out of the lower module <NUM>. Examples of suitable card reorienting mechanisms are described in <CIT> and <CIT>.

A card is transported along the main card transport path <NUM> and the secondary card transport path <NUM> by suitable card transport mechanisms, such as rollers <NUM>, <NUM>. In some embodiments, the card transport mechanisms are reversible to allow a card to be transported in forward (i.e. during card input) and reverse (i.e. during card output back through the slot <NUM>) directions along each card transport path <NUM>, <NUM> as shown by the arrows in <FIG>. In other embodiments where the card is to be output directly from the lower module <NUM> after processing in the lower module <NUM>, the card transport mechanisms need not be reversible.

The lower module <NUM> includes at least one card processing mechanism <NUM> disposed along the main card transport path <NUM> that is configured to perform a processing operation on the card. In one embodiment, a single card processing mechanism <NUM> can be provided. In another embodiment, two or more card processing mechanisms <NUM> can be provided one after the other along the main card transport path <NUM>. Examples of card processing mechanisms <NUM> that can be used include, but are not limited to, a card embosser or a card laminator. The lower module <NUM> can also include an output <NUM> at the end of the transport path <NUM> through which a card can be output from the lower module <NUM> after processing by the processing mechanism(s) <NUM>. In some embodiments, the lower module <NUM> may also include a card de-bowing mechanism (not shown) that is used to eliminate a bow that may occur on the card as a result of processing by the processing mechanism(s) <NUM>. An example of a suitable de-bowing mechanism that can be used is described in <CIT>.

A suitable lower module with a card embosser or a card laminator is available from Entrust Datacard Corporation of Shakopee, Minnesota.

In operation of the lower module <NUM>, a card enters the lower module <NUM> from the modular print engine <NUM> through the slot <NUM>. The card is transported along the secondary card transport path <NUM> and into the card reorienting mechanism <NUM> which is then rotated to bring the card in line with the main card transport path <NUM>. The card is then directed along the main card transport path <NUM> to the card processing mechanism(s) <NUM> which performs the one or more processing operations on the card. In one embodiment, the card is then transported along the transport path <NUM> to the output <NUM> and output from the lower module <NUM>, for example into a hopper that can collect multiple cards. In other embodiments, after processing by the card processing mechanism(s) <NUM>, the card can be transported in the reverse direction along the main card transport path <NUM> back to the card reorienting mechanism <NUM> which receives the card and rotates the card to bring the card in line with the secondary card transport path <NUM>. The card is then transported along the secondary card transport path <NUM> and back out of the lower module <NUM> through the slot <NUM> and back into the modular print engine <NUM>.

With continued reference to <FIG>, the modular print engine <NUM> includes a housing <NUM> having a front end <NUM>, a rear end <NUM>, a top <NUM> and a bottom <NUM>. A main card input <NUM> is located at the front end <NUM> of the housing <NUM> through which plastic cards to be processed by the modular print engine <NUM> and/or by the lower module <NUM> (i.e. processed by the desktop card printer) are input. In some embodiments, the card input <NUM> can also form a card output through which processed cards can be output from the modular print engine <NUM>. In other embodiments, a card output that is separate from the card input <NUM>, but also located at the front end <NUM> like the card input <NUM>, can be provided through which processed cards can be output from the modular print engine <NUM>.

A card input hopper <NUM> can be mounted at the front end <NUM> of the housing <NUM> that is in communication with the card input <NUM>. The card input hopper <NUM> is designed to hold a number of plastic cards waiting to be processed which are fed one-by-one into the housing <NUM> by a suitable card feed mechanism <NUM> known in the art. In embodiments where a card output is also located at the front end <NUM>, a card output hopper <NUM> can also be mounted at the front end <NUM> of the housing <NUM> that is in communication with the card output for receiving finished processed cards. The card output hopper <NUM> is designed to hold a number of finished processed cards after they have been processed which are fed out of the housing through a suitable card outlet, which can coincide with or be separate from the card inlet <NUM>, and dropped into the card output hopper <NUM> in a manner known in the art. In one embodiment, the card input hopper <NUM> and the card output hopper <NUM> form an integral, single unit where the input hopper <NUM> and the output hopper <NUM> are combined together into a common structure that is mountable and removable as a single unit from the housing <NUM>. In another embodiment, the input hopper <NUM> (as well as the output hopper <NUM> or both the input hopper <NUM> and the output hopper <NUM>) can be configured with a multihopper configuration where the input hopper <NUM> is configured to simultaneously hold different card stock (for example, Visa® and Mastercard® branded card stock; driver's license card stock from different states; identification card stock having different security levels; etc.) waiting to be personalized. Each type of card stock can be selectively input into the modular print engine from the input hopper <NUM> as selected by the printer controller based on the type of card to be created.

A main or first card travel path <NUM> extends through the housing <NUM> from the input <NUM>. In the illustrated example, the card travel path <NUM> extends substantially horizontally through the housing <NUM> substantially parallel to the bottom <NUM>. Cards are transported along the card travel path <NUM> by a card transport mechanism, such as sets of rollers <NUM>. In some embodiments, the card transport mechanism can be reversible to allow the cards to be transported in forward (for example during card input or during printing) and reverse (for example, if a card is to be output from the modular print engine <NUM> through the front end <NUM> or to transport a card upstream of a printer before, during or after printing) directions along the travel path <NUM> as shown by the arrow in <FIG>.

A card reorienting mechanism <NUM> is disposed in the housing <NUM> along the card travel path <NUM> adjacent to the rear end <NUM>. The card reorienting mechanism <NUM> is rotatably disposed in the housing <NUM> for rotation both clockwise and counterclockwise as indicated by the arrow on the card reorienting mechanism <NUM>. The card reorienting mechanism <NUM> is configured to receive a card along the card travel path <NUM> and rotate the card so as to direct the card in a different direction along a desired card travel path. Examples of suitable card reorienting mechanisms are described in <CIT> and <CIT>.

A print engine <NUM> is disposed along the card travel path <NUM> that is configured to print on a card disposed on the card travel path <NUM>. In one embodiment, the print engine <NUM> can be configured to perform retransfer printing as described further below with respect to <FIG>. However, the print engine <NUM> can be configured to perform direct to card printing, ink jet printing, laser marking, laser engraving, and any other type of printing performed on cards.

With continued reference to <FIG>, a second card travel path <NUM> can extend upwardly from the card reorienting mechanism <NUM>. In one embodiment, the second card travel path <NUM> extends substantially vertically upward from the card reorienting mechanism <NUM>. However, the second card travel path <NUM> is not limited to extending vertically and can instead extend upwardly at an angle to vertical. Cards are transported along the card travel path <NUM> by a card transport mechanism, such as sets of rollers <NUM>. In some embodiments, the card transport mechanism can be reversible to allow the cards to be transported in forward and reverse directions along the travel path <NUM> as shown by the arrow in <FIG>.

A removable option module <NUM> is disposed along the second card travel path <NUM> and above the first card travel path <NUM>. The removable option module <NUM> includes at least one card processing mechanism that is configured to perform a processing operation on a plastic card. As discussed further below with respect to <FIG>, the removable option module <NUM> is one of a plurality of removable option modules <NUM> that can be installed one at a time in the modular print engine <NUM> to permit changes to the functionality of the modular print engine <NUM>. Each option module <NUM> is configured to be individually and separately removably installed in the housing <NUM> along the second card travel path <NUM> and above the first card travel path <NUM>, and each option module <NUM> is configured to perform a different processing operation on a plastic card received thereby. One option module <NUM> can be removed and replaced with a different option module <NUM> to change the functionality of the modular print engine <NUM>.

<FIG> illustrates that in one embodiment, the option module <NUM> can include a magnetic stripe reader and/or writer <NUM> that can read data on a magnetic stripe of a card and/or write data onto the magnetic stripe. Magnetic stripe readers and/or writers are well known in the art. <FIG> illustrates that in another embodiment, the option module <NUM> can include a smart card reader and/or writer <NUM> that can read data stored on an integrated circuit chip (i.e. smart card chip) on the card and/or write data to the chip. The smart card reader and/or writer <NUM> can be configured for contact or contactless reading and/or writing. Smart card readers and/or writers, both contact and contactless, are well known in the art. In another embodiment illustrated in <FIG>, the option module <NUM> can include both the magnetic stripe reader and/or writer <NUM> and the smart card reader and/or writer <NUM> arranged in any order. In another embodiment illustrated in <FIG>, the option module <NUM> can include two smart card readers and/or writers <NUM>. The card processing mechanism(s) in the option modules <NUM> is not limited to a magnetic stripe reader and/or writer <NUM> and a smart card reader and/or writer <NUM>. Other card processing mechanisms can be included in the option modules <NUM> in combination with or separately from the magnetic stripe reader and/or writer <NUM> and the smart card reader and/or writer <NUM>. Examples of other card processing mechanisms that can be included in the option modules <NUM> can include, but are not limited to, a scanner that can read a one dimensional bar code on a card surface, a camera that can be used to read a one or two dimensional bar code on a card surface or capture an image of a card surface, a hole puncher that punches one or more holes in the card, and other card processing mechanisms. In one embodiment, the camera, if used, can be arranged to capture one or more images of a card surface while the card is held by the card reorienting mechanism <NUM>.

Depending upon the desired functionality of the modular print engine <NUM>, one can install the appropriate option module <NUM> in the modular print engine <NUM>. Because each option module <NUM> is modular, each option module <NUM> can be completely tested prior to installation into the modular print engine <NUM> to ensure that the option module <NUM> is working correctly prior to installation. Further, to change functionality of the modular print engine <NUM>, the user can replace one option module <NUM> with another option module <NUM> having the desired functionality.

Returning to <FIG>, a third card travel path <NUM> can extend downwardly from the card reorienting mechanism <NUM>. In one embodiment, the third card travel path <NUM> extends substantially vertically downward from the card reorienting mechanism <NUM> substantially in-line with the card travel path <NUM>. However, the third card travel path <NUM> is not limited to extending vertically and can instead extend downwardly at an angle to vertical. Cards are transported along the card travel path <NUM> by a card transport mechanism, such as rollers <NUM>. In some embodiments, the card transport mechanism can be reversible to allow the cards to be transported in forward and reverse directions along the travel path <NUM> as shown by the arrow in <FIG>.

The third card travel path <NUM> extends to a card opening <NUM> in the bottom <NUM> of the housing <NUM>. When the modular print engine <NUM> is correctly mounted on the lower module <NUM>, the third card travel path <NUM> and the card opening <NUM> are aligned with the card transport path <NUM> and the slot <NUM> of the lower module <NUM> so that a card can be transferred between the modular print engine <NUM> and the lower module <NUM>, i.e. transferred out of the modular print engine <NUM> and into the lower module <NUM>, and in some embodiments, transferred out of the lower module <NUM> and back into the modular print engine <NUM>.

In some embodiments, the modular print engine <NUM> can further include a fourth card travel path <NUM> that can extend rearwardly from the card reorienting mechanism <NUM> as discussed further below with respect to <FIG>. In one embodiment, the fourth card travel path <NUM> can extend substantially horizontally from the card reorienting mechanism <NUM> in-line with the card travel path <NUM>. However, the fourth card travel path <NUM> is not limited to extending horizontally and can instead extend at an angle to horizontal. When the fourth card travel path <NUM> is present, the travel path <NUM> extends to a card opening <NUM> formed in the rear <NUM> of the housing <NUM> to permit cards to exit and enter the card opening <NUM> through the rear <NUM> of the housing <NUM>.

The modular print engine <NUM> can therefore include a card input at the front end <NUM> thereof and the card opening <NUM> through the rear <NUM> thereof. In some embodiments, there can also be the card opening <NUM> through the bottom of the modular print engine <NUM>. In other embodiments, there can also be the card opening <NUM> discussed in <FIG>.

Returning to <FIG>, in some embodiments a card de-bowing mechanism <NUM> can be provided in the travel path <NUM> after the print engine <NUM>. The de-bowing mechanism <NUM> is configured to bend the card after printing to remove a bend in the card that may develop as a result of the printing of the card, especially with retransfer printing. The de-bowing mechanism <NUM> can be any mechanism that is suitable for eliminating a bend that may develop in the card. An example of a suitable de-bowing mechanism <NUM> that can be used is described in <CIT>.

A card reject hopper <NUM> is also located in the modular print engine <NUM>, for example above the travel path <NUM>, above the de-bowing mechanism <NUM>, and adjacent to the card reorienting mechanism <NUM>. The card reject hopper <NUM> is positioned to receive cards that one may wish to store and not output from the modular print engine <NUM>, for example cards that are determined to be defective for some reason. For example, a card may be determined to be defective by failing to read and/or write data using the magnetic stripe reader and/or writer <NUM> or using the smart card reader and/or writer <NUM> of the option module <NUM>. In such a case, the card is transported to the card reorienting mechanism <NUM> which rotates the card so that it is aligned with an input into the card reject hopper <NUM>, and the card reorienting mechanism <NUM> then discharges the defective card into the card reject hopper <NUM> using transport rollers on the card reorienting mechanism <NUM>. Optionally, the card reject hopper <NUM> can be located at any other suitable location in the modular print engine <NUM>, and cards to be stored in the card reject hopper <NUM> can be transported to the card reject hopper <NUM> using a suitable transport mechanism.

In one exemplary operation of the modular print engine <NUM> of <FIG>, a card can be initially input from the input hopper <NUM> through the input <NUM>. In one embodiment, the card is initially transported along the card travel path <NUM> to the card reorienting mechanism <NUM>, which redirects the card onto the second card travel path <NUM> where the card is transported into the option module <NUM>. The option module <NUM> determines whether the magnetic stripe and/or the chip on the card are working correctly, and if they are, data is written onto the magnetic stripe and/or onto the chip. If they are not working correctly, the card can be transported back along the second card travel path <NUM> to the card reorienting mechanism <NUM> which then directs the card into the card reject hopper <NUM>. After the data has been written, the card is transported back along the second card travel path <NUM> to the card reorienting mechanism <NUM> which then directs the card back onto the first card travel path <NUM>. The card is then transported back toward the front end <NUM> upstream of the print engine <NUM> for printing. The card is then printed on by the print engine <NUM>. After printing, if it is anticipated that the printing caused the card to bend, the card is transported to the de-bowing mechanism <NUM> which removes the bend in the card. The card is then transported to the card reorienting mechanism <NUM> which redirects the card to the third card travel path <NUM>. The card is then transported out of the modular print engine <NUM> and into the lower module <NUM> through the aligned card opening <NUM> and the slot <NUM>, and to the card reorienting mechanism <NUM> in the lower module <NUM>. The card reorienting mechanism <NUM> redirects the card onto the card transport path <NUM> where the card is transported to the card processing mechanism(s) <NUM>. After the card is processed in the card processing mechanism(s) <NUM>, the card can then be output from the lower module <NUM> via the output <NUM>.

In other embodiments, after the card is processed in the card processing mechanism(s) <NUM>, the card can then be redirected back to the card reorienting mechanism <NUM> via the card transport path <NUM>, and redirected out of the lower module <NUM> and back into the card reorienting mechanism <NUM> of the modular print engine <NUM>. The card reorienting mechanism <NUM> can reorient the card for transport back along the card travel path <NUM> and into the output hopper <NUM>. Alternatively, if the card opening <NUM> in the rear <NUM> is used, the card can be redirected by the card reorienting mechanism <NUM> to the fourth card travel path <NUM> for discharge out the card opening <NUM>. Alternatively, as discussed further below, the card can be directed upwardly for discharge out of a card opening in the top of the modular print engine <NUM>.

Many other operational sequences of the modular print engine <NUM> of <FIG> are possible including, but not limited to, directing the card first to the lower module <NUM>, and then back into the modular print engine <NUM> for processing by the option module <NUM> and the print engine <NUM>. In addition, the card can be initially printed by the print engine <NUM> prior to the card being directed to the option module <NUM> and/or to the lower module <NUM>. In addition, the card can be initially directed into the option module <NUM>, followed by processing in the lower module, followed by printing by the print engine <NUM>.

As illustrated in <FIG>, the print engine <NUM> is disposed above the card travel path <NUM>. Applicant has discovered that locating the card travel path <NUM> below the print engine <NUM> improves the resulting print process by the print engine <NUM>. For example, card handling is more reliable. For print engines that rely upon heat in the printing process, for example using one or more heated transfer rollers in the case of retransfer printing, the improved card handling is believed to result from heat rising upward in a direction away from the card during printing.

As described above, in one embodiment the print engine <NUM> can be configured to perform retransfer printing. Retransfer printing is well known in the art. <FIG> illustrates an example of the print engine <NUM> configured for retransfer printing. The illustrated retransfer printing configuration includes a print side that includes print ribbon supply <NUM> from which a supply of monochrome or multi-color print ribbon <NUM> is supplied, and a print ribbon take-up <NUM> that takes-up used print ribbon <NUM>. The print ribbon is directed past a print head <NUM>, which in the illustrated example can be stationary, which transfers dye or pigment ink from the print ribbon <NUM> onto a retransfer film <NUM>. After printing, the used print ribbon <NUM> is then wound onto the take-up <NUM>.

The retransfer film <NUM> is supplied from a film supply <NUM> on a retransfer side, and after retransfer the remaining film is wound onto a film take-up <NUM> also on the retransfer side. The retransfer film <NUM> is directed past a platen roller <NUM> positioned opposite the print head <NUM> and which in the illustrated example can be moved toward and away from the print head <NUM> to press the retransfer film <NUM> and the print ribbon <NUM> between the print head <NUM> and the platen roller <NUM> during printing onto the retransfer film <NUM>. The retransfer side can also include a capstan roller <NUM> that is also movable toward and away from the print side.

Once a desired image is printed onto the retransfer film <NUM>, the retransfer film <NUM> with the printed image is advanced to a transfer section <NUM> where the printed image on the retransfer film <NUM> is transferred onto a surface of the card. The transfer section <NUM> includes a heated transfer roller <NUM> that is movable toward and away from a fixed platen <NUM> positioned on the opposite side of the travel path <NUM>. The heated transfer roller <NUM> presses the portion of the retransfer film <NUM> containing the printed image against the surface of the card which is backed by the platen <NUM>, with the retransfer film <NUM> and the card then being transported together past the heated transfer roller <NUM> to transfer the layer of the retransfer film <NUM> containing the printed image onto the card surface. The remainder of the retransfer film <NUM> is then wound onto the film take-up <NUM>.

The specific construction and operation of retransfer printers, including the print ribbon, the retransfer film, printing an image on the retransfer film, and transferring the printed image onto a surface of a card, is well known in the art. One example of retransfer printing is disclosed in <CIT> among many others.

Referring now to <FIG>, another embodiment of a modular print engine <NUM> is illustrated. Elements of the modular print engine <NUM> that are similar in construction and function to corresponding elements in the modular print engine <NUM> of <FIG> are referenced using the same reference numerals. The lower module <NUM> is not illustrated in <FIG>, but the modular print engine <NUM> would be mounted onto a lower module, which can be similar to or different than the lower module <NUM> in <FIG>.

In the embodiment in <FIG>, the second card travel path <NUM> extends from the card reorienting mechanism <NUM> to a card opening <NUM> that is formed in the top <NUM> of the housing <NUM>. An upper expansion module <NUM> is attached to the top <NUM> of the housing <NUM>. The upper expansion module <NUM> can be selectively added to and removed from the modular print engine <NUM> to permit alteration in where cards are output.

The upper expansion module <NUM> includes an input <NUM> that, when the upper expansion module <NUM> is correctly mounted on the housing <NUM>, is aligned with the card opening <NUM> for receiving a card therein. The upper expansion module <NUM> further includes a rotatable card reorienting mechanism <NUM> and an output <NUM> through which a card can be output from the modular print engine in a rearward direction. A card that enters the upper expansion module <NUM> is received in the card reorienting mechanism <NUM>, which redirects the card approximately <NUM> degrees and outputs the card through the output <NUM> aided if necessary by transport rollers <NUM>. The output <NUM>, or a separate output, could be formed at the front of the upper expansion module <NUM> to allow front discharge of cards separately from or in addition to outputting cards to the rear through the output <NUM>. If the upper expansion module <NUM> is not used, cards can still be output at the top <NUM> of the modular print engine <NUM> through the card opening <NUM>, or the card opening <NUM> can be closed to prevent card travel therethrough.

Alternatively, instead of outputting cards from the upper expansion module <NUM>, the cards can be output from the lower module <NUM> or through the card opening <NUM> as discussed above in <FIG>. Or a user may select to output one or more cards from the upper expansion module <NUM>, while selecting to output other cards from other locations of the desktop card printer. In this manner, the upper expansion module <NUM> expands the functionality of the modular print engine <NUM> by allowing a user to configure and select how cards are output from the modular print engine <NUM>.

In the embodiment in <FIG>, the fourth card travel path <NUM> is present that extends substantially horizontally from the card reorienting mechanism <NUM> to the card opening <NUM> formed in the rear <NUM> of the housing <NUM>. A second option, or rear expansion, module <NUM> is removably attached to the rear end <NUM> of the housing <NUM> that permits a user to change the functionality of the modular print engine <NUM>. The second option module <NUM> includes at least one processing mechanism that is configured to perform a processing operation on, for example, a plastic card. The removable second option module <NUM> is one of a plurality of different removable second option modules <NUM>. Each second option module <NUM> is configured to be individually and separately removably installed on the rear <NUM> of the housing <NUM>, and each second option module <NUM> is configured to perform a different processing operation on a plastic card received thereby. One second option module <NUM> can be removed and replaced with a different second option module <NUM> to change the functionality of the modular print engine <NUM>.

In general, each second option module <NUM> includes a card opening <NUM> that, when the second option module <NUM> is correctly mounted on the housing <NUM>, is aligned with the card opening <NUM> for receiving a card therein. In addition, each second option module <NUM> includes a housing <NUM> (seen in <FIG>) that houses at least one processing mechanism that is configured to perform a processing operation, for example a personalization operation, on a plastic card.

<FIG> illustrate different examples of the second option modules <NUM>. Many other examples of second option modules <NUM> are possible including any combinations of the concepts illustrated in <FIG>.

In <FIG>, the second option module <NUM> includes a card travel path <NUM> that extends from the card opening <NUM> substantially in-line with the travel paths <NUM> and <NUM>. The travel path <NUM> can extend to an output <NUM> in the rear of the housing <NUM> through which cards can be selectively output. Cards are transported along the travel path <NUM> by a suitable reversible or non-reversible transport mechanism, such as transport rollers <NUM>. One or more card processing mechanisms <NUM> are provided along the travel path <NUM>, for example above the travel path <NUM>, for performing one or more additional processing operations on the card. The processing mechanism <NUM> can be, for example, a personalization mechanism such as a magnetic stripe reader and/or writer or a smart card reader and/or writer. The processing mechanism <NUM> can be any one or more mechanisms that perform one or more processing operations, such as personalization or non-personalization operations, on a card. After the processing mechanism <NUM> finishes processing the card, the card can be output through the output <NUM> or transported back into the modular print engine <NUM>.

<FIG> illustrates the second option module <NUM> as being similar to the second option module <NUM> of <FIG>, but including a card reorienting mechanism <NUM> that can reorient a card onto a new travel path <NUM> up to the card processing mechanism <NUM>. After processing by the processing mechanism <NUM>, the card can be directed back to the card reorienting mechanism <NUM>, which then directs the card back onto the travel path <NUM> for output through the output <NUM> or transport back into the modular print engine <NUM>.

<FIG> illustrates the second option module <NUM> as including the travel path <NUM> but no output <NUM>. Instead, the travel path <NUM> ends at the processing mechanism <NUM>. In <FIG>, after processing by the processing mechanism <NUM>, the card is transported back into the modular print engine <NUM>.

Referring now to <FIG>, another embodiment of a modular print engine <NUM> is illustrated. Elements of the modular print engine <NUM> that are similar in construction and function to corresponding elements in the modular print engine <NUM> of <FIG> are referenced using the same reference numerals. For sake of simplicity, the lower module <NUM> is not illustrated in <FIG>, but the modular print engine <NUM> would be mounted onto a lower module, which can be similar to or different than the lower module <NUM> in <FIG>. In addition, the transport mechanism, such as the rollers <NUM>, and the card de-bowing mechanism <NUM> are not illustrated in <FIG> for sake of simplicity, although a transport mechanism would be included for transporting a card along the various card travel paths described below, and the card de-bowing mechanism <NUM> can optionally be included.

In the embodiment illustrated in <FIG>, the removable option module <NUM> is physically located below the print engine <NUM>. A card travels along the card travel path <NUM> to the card reorienting mechanism <NUM> which can reorient the card downward along another card travel path <NUM> that extends to the card opening <NUM> in the bottom <NUM> of the housing <NUM> that communicates with the lower module <NUM> (not illustrated in <FIG>). A second card reorienting mechanism <NUM> is located along the card travel path <NUM> that can redirect the card onto a card travel path <NUM> along which the removable option module <NUM> is disposed. The option module <NUM> can be removable and replaceable with another, differently configured option module <NUM> as discussed above for <FIG> and <FIG>. The option module <NUM> in <FIG> can have the same configuration and operation as the option modules <NUM> described above with respect to <FIG> and <FIG>. The card travel path <NUM> is illustrated as being parallel to the card travel path <NUM>, although the card travel path <NUM> can extend at an angle to the card travel path <NUM>.

In addition, the card reject hopper <NUM> can be located in the same position as shown in <FIG>, <FIG>, and <FIG>. Alternatively, as shown in <FIG>, the card reject hopper <NUM> can be located between the second card reorienting mechanism <NUM> and the rear end <NUM> of the housing <NUM>. Cards to be rejected can be directed into the card reject hopper <NUM> by the second card reorienting mechanism <NUM>, by the first card reorienting mechanism <NUM>, or by both of the card reorienting mechanisms <NUM>, <NUM>.

The modular print engine <NUM> can also include a card imaging device <NUM> that is separate from the option module <NUM> and adjacent to the card reorienting mechanism <NUM>. The imaging device <NUM> can be, for example, a scanner that can read a one dimensional bar code on a card surface or a camera that can be used to read a one or two dimensional bar code on a card surface or capture an image of a card surface. In one embodiment, the camera can be arranged to capture one or more images of a card surface while the card is held by the card reorienting mechanism <NUM>.

Although not illustrated in <FIG>, the modular print engine <NUM> can also include the card opening <NUM> in the rear end <NUM> thereof that leads to one of the second option modules <NUM> described above with respect to <FIG> and <FIG> and/or can include the card opening <NUM> in the top <NUM> that leads to the upper expansion module <NUM> described above with respect to <FIG>.

In the embodiment illustrated in <FIG>, the removable option module <NUM> is physically located along the card travel path <NUM> between the input <NUM> and the card reorienting mechanism <NUM>. In addition, the print engine <NUM> is positioned along a card travel path <NUM> that extends downwardly from the card reorienting mechanism <NUM> to the card opening <NUM> in the bottom <NUM> of the housing <NUM> that communicates with the lower module <NUM> (not illustrated in <FIG>). The print engine <NUM> can be oriented in a direction so that printing on the card occurs along the card travel path <NUM>. In the case of the print engine <NUM> being configured for retransfer printing, the heated transfer roller <NUM> would be located adjacent to the card travel path <NUM> as illustrated. A card travels along the card travel path <NUM> to or through the option module <NUM> and then to the card reorienting mechanism <NUM> which can reorient the card and direct the card downward along the card travel path <NUM>. The option module <NUM> can be removable and replaceable with another, differently configured option module <NUM> as discussed above for <FIG> and <FIG>. The card travel path <NUM> is illustrated as being perpendicular to the card travel path <NUM>, although the card travel path <NUM> can extend at an angle to the card travel path <NUM>.

In addition, the card reject hopper <NUM> can be located in the same position as shown in <FIG>, <FIG>, and <FIG>. Alternatively, as shown in <FIG>, the card reject hopper <NUM> can be located adjacent to the card reorienting mechanism <NUM> between the card travel path <NUM> and the rear end <NUM> of the housing <NUM>. Cards to be rejected can be directed into the card reject hopper <NUM> by the card reorienting mechanism <NUM>.

In one embodiment, the modular print engine <NUM> can also include a card imaging device <NUM> that is separate from the option module <NUM> and adjacent to the card reorienting mechanism <NUM>. The imaging device <NUM> can be, for example, a scanner that can read a one dimensional bar code on a card surface or a camera that can be used to read a one or two dimensional bar code on a card surface or capture an image of a card surface. In one embodiment, the camera can be arranged to capture one or more images of a card surface while the card is held by the card reorienting mechanism <NUM>. In another embodiment, the card can be output from the card reorienting mechanism <NUM> onto a platform structure <NUM> that holds the card while being imaged by the imaging device <NUM>.

In another embodiment, the modular print engine <NUM> can also include a smart card reader and/or writer <NUM> that is separate from the option module <NUM> and is located adjacent to the card reorienting mechanism <NUM> so that the card reorienting mechanism <NUM> can reorient and direct a card into the smart card reader and/or writer <NUM> for reading and/or writing on an integrated circuit chip (i.e. smart card chip) on the card. Like the option module <NUM>, the smart card reader and/or writer <NUM> can also be removable and replaceable with a mechanism having different functionality. For example, a contact type smart card reader and/or writer <NUM> can be replaced with a contactless type smart card reader and/or writer <NUM>, or the smart card reader and/or writer <NUM> can be replaced with a magnetic stripe reader and/or writer or other card processing mechanism.

Claim 1:
A modular print engine (<NUM>, <NUM>, <NUM>, <NUM>) useable in a desktop personalized plastic card printer, comprising:
a housing (<NUM>) having a front end (<NUM>), a rear end (<NUM>), a top (<NUM>) and a bottom (<NUM>);
a card input (<NUM>) at the front end of the housing;
a card input hopper (<NUM>) that is in communication with the card input;
a card reorienting mechanism (<NUM>) in the housing adjacent to the rear end, the card reorienting mechanism is configured to receive a card and rotate the card to redirect the card along a desired card travel path;
a first card travel path (<NUM>) in the housing between the card input and the card reorienting mechanism;
a second card travel path (<NUM>, <NUM>, <NUM>, <NUM>) in the housing extending vertically upward from the card reorienting mechanism or extending upwardly from the card reorienting mechanism at a non-vertical angle;
a print engine (<NUM>) in the housing, the print engine is configured to print on a card; and
a removable option module (<NUM>) in the housing and disposed along either the first card travel path or the second card travel path, the removable option module includes at least one processing mechanism (<NUM>, <NUM>) that is configured to perform a processing operation on a card, characterized in that
the print engine (<NUM>) is disposed along the first card travel path (<NUM>) and includes a print ribbon (<NUM>), and the first card travel path (<NUM>) is below the print engine (<NUM>).