Ink jet card printer

#The present invention relates to card printers used to print images on a surface of rigid or semi-rigid planar substrates. More particularly, the present invention relates to an ink jet card printer having full edge-to-edge printing capability on a surface of the substrate.

#Card printers are used to print an image onto a surface of semi-rigid planar substrates. The substrates include, but are not limited to, plastic cards, tokens, and other types of rigid or semi-rigid planar substrates. Hereinafter, the terms “card” and “substrate” are intended to describe these and other rigid and semi-rigid substrates having various shapes and sizes.

#In the past, graphical and textual information was placed on such cards using a labor intensive process in which, for example, an identification card was formed by manually stamping or imprinting an individual's data onto the card. Additionally, in some cases, an instant photograph was taken of the subject and adhered or laminated to the card.

#FIG. 1 is a simplified side view of an ink jet card printer in accordance with various embodiments of the invention.

#FIG. 2 is a simplified perspective view illustrating a print position of an ink jet printhead.

#FIGS. 3A-C are simplified side views illustrating first, second, and third positions, respectively, in which a card is supported by a transport mechanism while moving through a print position in accordance with various embodiments of the invention.

#FIG. 1 is a simplified block diagram of an ink jet card printer 20, in accordance with various embodiments of the invention. Printer 20 generally includes an ink jet printhead 22, a transport mechanism 24, an input portion 26, an output portion 28, and a controller 30. A personal computer (PC) 34 can communicate with controller 30 through input/output (I/O) or data bus 36. Data bus 36 can be any suitable connection, such as a parallel cable, serial cable, or a Universal Serial Bus (USB) cable, through which data is provided to controller 30 contained within printer 20. A user operates PC 34 to configure and format a print job using a software application. Data relating to the print job is then provided to controller 30 over data bus 36, and controller 30 uses the data to process the print job by controlling the various components of ink jet identification card printer 20.

#Ink jet printhead 22 includes an ink cartridge 38 containing a supply of ink. Printhead 22 is generally adapted to move along an axis that is directed into the paper on which FIG. 1 is provided by sliding along rod 40. The movement of printhead 22 is controlled by controller 30 and is actuated using conventional methods. Printhead 22 is generally adapted to print on portions of surface 42 of card 21 that are presented to printhead 22 in a print position 44 along a print path 39, as illustrated in FIG. 2.

#Print position 44 is generally defined by a volume of space in which surface 42 of card 21 must be presented to ink jet printhead 22 to ensure accurate printing of the image onto surface 42. Print path 39 (FIG. 1) runs through the center of print position 44 and indicates a preferred position of surface 42 of card 21. Print path 39 is typically a distance of 0.025-0.050 inches from printhead 22. The volume of print position 44 includes a length L, a width W, and a depth D. The length L is generally limited to the range of motion of printhead 22, indicated by arrows 45, along rod 40. The width W is defined as the distance over which printhead 22 is capable of printing ink in a single pass across the substrate. Typical ink jet printheads 22 have print widths W of approximately 0.4 inches. The depth D of print position 44 defines a distance from print path region within which ink can be properly transferred from printhead 22 to surface 42. The depth D is typically approximately 0.01 inches. Therefore, surface 42 of card 21 is preferably positioned plus or minus 0.005 inches from print path 39. The accuracy of the printing is further affected by changes in the distance separating surface 42 from printhead 22, which can lead to color variance within the printed image, and imprecise control of the movement of card 21 through the print position, which can lead to banding. Consequently, printhead 22 can accurately apply ink to only those portions of surface 42 of card 21 that are presented to printhead 22 in the print position 44 and at a substantially constant distance from printhead 22 as card 21 is precisely moved by transport mechanism 24 along print path 39.