Abstract: A card hopper for holding a stack of identification cards that are to be printed or in other ways processed has an outlet opening on one end through which the cards are fed. The outlet opening is adjustable in size to accommodate cards of different thicknesses by using a control gate that is slidably mounted relative to the hopper and can be adjusted through the use of a cam actuator to change the opening size of the outlet opening. Manual operation is shown using both rotating and sliding cams.

Abstract: A ribbon cartridge includes a cartridge housing, a supply spool, a take-up spool, and a supply of ribbon. The cartridge housing includes a supply spool enclosure, a take-up spool enclosure, a pair of ribbon guides, and a gap between the ribbon guides and the supply and take-up spool enclosures. The supply spool is contained in the supply spool enclosure, and the take-up spool is contained in the take-up spool enclosure. The ribbon extends from the supply spool, over the ribbon guides and the gap, and to the take-up spool. Another aspect of the ribbon cartridge includes a cartridge housing and a cleaner roller. The cartridge housing includes front and rear walls. The cleaner roller is rotatably supported between the front and rear walls.

Abstract: The present invention is directed to a carrier for use with a printer that can support irregularly shaped substrates having a top surface. The carrier includes first and second planar members. The first planar member has top and bottom surfaces, a thickness, and an inner edge that conforms to an irregularly shaped outer edge of a substrate. The second planar member has a top surface that is coupled to the bottom surface of the first planar member. A recess, defined by the inner edge of the first planar member and the top surface of the second planar member, is adapted to receive the substrate such that top surfaces of the substrate and the first planar member are coplanar.

Abstract: An identification card printer includes a card input, a card transport, a printhead, and a card output. The card transport is configured to feed a card from the card input along a print path. The printhead is positioned below the print path and is configured to print an image on a surface of the card. The card can then be discharged through the card output.

Abstract: In a method of forming an ink-receptive card substrate, an ink-receptive material is provided. The ink-receptive material includes a backing layer and an ink-receptive coating on a surface of the backing layer. Next, a card member is provided. Finally, the ink-receptive material is laminated to a surface of the card member with the ink-receptive coating facing the surface of the card member. This results in the bonding of the ink-receptive coating to the surface of the card member. Additional embodiments of the present invention are directed to devices that are configured to perform the above-identified method.

Abstract: A laminate of transparent flexible material is formed to the precise size of a substrate and is made so that it will be laminated in place on the substrate. The laminate is in an elongated web that is separated into individual laminate sections by transverse lines of reduced tear strength so that the laminate sections can be removed from the web sequentially.

Abstract: An identification card printer for printing an identification card includes a print mechanism configured to print onto the identification card. A process signal input is configured to receive a process signal related to operation of the identification card printer. A memory contains a nominal process signal statistical parameter and a rule. A microprocessor is coupled to the memory and configured to receive the process signal from the process signal input and calculates a statistical parameter of the process signal. The microprocessor compares the calculated statistical parameter to the nominal statistical parameter based upon the rule and responsively provides an event output as a function of the comparison. The event output is related to an occurrence of an event during operation of the identification card printer.

Abstract: In a method of forming an identification card printer a sheet feed printer is provided having a printhead and a sheet feed mechanism that is driven by a sheet feed drive to feed paper sheets to the printhead for printing. Next, the sheet feed mechanism is replaced with a card transport mechanism that is used to feed cards from a card supply to the printhead for printing. The card transport mechanism is then linked to the sheet feed drive through a feed drive link. Finally, a master controller for controlling the operation of the card transport mechanism is installed. Additional aspects of the present invention relate to an identification card printer formed in accordance with the above-described method.

Abstract: A roller support includes a body member, a bushing member, and a step member. The body member includes a first guide roller receiver that is adapted to receive an end of a first guide roller. The bushing member extends from a surface of the body member and has a central bore that extends through the body member. The step member is positioned adjacent the bushing member and extends from the surface of the body member in the direction of the bushing member.

Abstract: The present invention is directed to a carrier for use with a printer that can support irregularly shaped substrates having a top surface. The carrier includes first and second planar members. The first planar member has top and bottom surfaces, a thickness, and an inner edge that conforms to an irregularly shaped outer edge of a substrate. The second planar member has a top surface that is coupled to the bottom surface of the first planar member. A recess, defined by the inner edge of the first planar member and the top surface of the second planar member, is adapted to receive the substrate such that top surfaces of the substrate and the first planar member are coplanar.

Abstract: A card supply for use with an identification card printing system includes a card hopper and a supply circuit. The card hopper contains a stack of cards. The supply circuit is mounted to the card hopper that includes a memory containing supply information relating to parameters of the card supply.

Abstract: An ink jet card printer is disclosed that includes an ink jet printhead and a transport mechanism. The ink jet printhead is adapted to print on portions of a surface of a card that are presented in a print position along a print path. The transport mechanism includes at least one cantilevering mechanism that is positioned to a side of the print position along the print path. The cantilevering mechanism is adapted to unobstructively present the surface of the card to the printhead in the print position.

Abstract: A swing arm assembly includes a swing frame, a laminating roller, and a motor. The swing frame is rotatably mountable to a frame of a card laminator for pivotal movement relative to the frame between open and closed positions. The laminating roller is movably mounted to the swing frame. The motor is mounted to the swing frame and is configured to drive a roller actuator to move the laminating roller relative to the swing frame between a laminating position and a recessed position.

Abstract: An identification card manufacturing system that includes first and second identification card manufacturing device modules and a unification mounting. The first identification card manufacturing device module includes a first card transport mechanism and an output, through which the card transport mechanism is configured to discharge individual cards. The second identification card manufacturing device module includes a second card transport mechanism and an input, at which the second card transport mechanism is configured to receive cards. The unification mounting positions the output of the first device module in card handoff alignment with the input of the second device module.

Abstract: A heat shield for use in a laminator having a laminating roller includes a movable shield member. The heat shield has a retracted position in which a laminating side of the laminating roller is exposed. Additionally, the heat shield has a shielding position in which the shield member covers the laminating side of the laminating roller.

Abstract: Identification card manufacturing security restricts use of an identification card manufacturing system with only authorized supplies. In accordance with one aspect of the invention, a supply-specific security code (SSSC) and supply-specific data are stored in memory of the supply. The SSSC is translated using the supply-specific data. Finally, the supply is authorized for use with the identification card manufacturing system only when the translated SSSC is found to be valid. In accordance with another aspect of the invention, an identification card manufacturing system is configured to operate only with supplies having corresponding customer-specific security codes (CSSC). A supply CSSC and supply-specific data are retrieved from memory of the supply. Additionally, a system CSSC and system-specific data are retrieved from memory of the identification card manufacturing system. The supply CSSC and the system CSSC are translated using the supply-specific data and the system-specific data, respectively.

Abstract: A printer is provided with a smart card encoding device that is externally accessible. The smart card is a key with an integrated circuit including a memory that will retain a discrete password and other digital information. The password on the smart card key must be compared to a password stored in the printer memory before printing operations will be permitted. The digital information in the smart card key memory can include marks or graphics that would indicate that the cards being printed by the printer are secured cards and authorized cards. The information will be printed from the smart card key memory only when the passwords match so that the discrete information on the smart card key can be used for driving the printer for printing this information. The printer is made into a high security printer by permitting the overriding of the password only upon the generating of identical numbers from separated algorithms, one in the printer memory and one at a secure location.

Abstract: A card printer is provided with a cleaning roller that will pick up debris on the surface of a card on which printing is to take place. The cleaning roller has a sticky surface, that is engagement with a band of adhesive tape that moves to contact the surface of the cleaning roller and remove debris that is on the cleaning roller surface. The tape is preferably formed in an endless band mounted on a pair of rollers that are in a common housing with the cleaning roller. The housing is removably mounted in the printer, and can be opened for replacement of the band of tape.

Abstract: A reverse image printer that has a backing web carrying a laminate layer upon which a reverse image is printed. The laminate layer is laminated onto a card. The backing web carrying the transfer layer is separated from the laminate layer after the laminate layer and card have been laminated together using a peel-off assembly that guides the backing web at a selected desired separation angle relative to the plane of movement of the card and the laminate layer after lamination. The peel-off assembly uses two guide members to maintain the desired separation angle regardless of changes in diameter of a take-up roller used for the backing web.

Abstract: An intermediate transfer film on which an image is printed is carried on a backing web and after is laminated to a substrate, such as an identification card. A lamination station uses heater rollers for the lamination process, and subsequent to the lamination station the backing web is guided to a take-up roller around a peel-off roller. The peel-off roller is supported in a heat insulating frame to minimize storing heat that increases the likelihood of flakes of the laminate material remaining with the backing web.