Abstract: In a method of producing an identification card, an identification card having identification (ID) information is scanned to thereby generate ID data that represents the ID information. Next, the ID information is retrieved from the ID data. Finally, an identification card print job defining an image that includes the retrieved ID information arranged in accordance with a template is formed.

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 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: A card cleaner roller assembly for use in an identification card printer includes first and second cleaner pinch rollers, first and second tape rollers, first and second brackets, and a biasing mechanism. The first and second cleaner controllers are adapted to receive a transported card therebetween. The first and second tape rollers support a cleaning tape loop that is sandwiched between the second cleaner roller and the first tape roller. The cleaning tape loop includes a debris-collecting exterior surface that engages the second cleaner roller. The first bracket supports the first and second cleaner rollers and the first tape roller. The second bracket supports the second tape roller. The first and second brackets are assembled in sliding arrangement with each other and include a roller release position and an operating position. The biasing mechanism is configured to bias the first and second brackets in the operating position.

Abstract: A trace interconnect assembly designed for transmitting electrical signals to and from a head assembly in a hard disk drive is disclosed. The interconnect assembly includes one or more single-layer thin, elongated, and generally flat substrate-free trace interconnects. The trace interconnects are new conductors etched out of a planar length of preferably a high tensile and high yield strength metal such as beryllium copper. They are shaped to match the surface topology of the suspension assembly. Trace interconnects have a rigid region and flexible regions that match a rigid region and flexible regions in the suspension assembly. Different additional elements include support braces, standoffs, trace tangs, bond pads, and stacked interconnects. Coupling a head assembly to the interconnect assembly creates a head interconnect harness. Methods of manufacture for the trace interconnect assembly, a multi-conductor stacked version, a head suspension assembly, and the head interconnect harness are disclosed.

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.

Abstract: A card printing and encoder apparatus for printing information on a card to provide identification of a person, and includes two encoding stations, one to encode a smart card chip embedded in the card, and the other station to encode a magnetic strip on the card. Card support and drive rollers support the card, and the card is bent out of its plane to contact the smart card encoding station contacts. A magnetic head for encoding a magnetic strip is held under a resilient force against an opposite side of the card from the smart card encoding station. The loading of the print head against a rotatable print platen is controlled in synchronism with card drive and support rollers so that the card drive and support rollers release and the card is driven only by the rotatable print platen during the printing operation.

Abstract: A card hopper includes a control gate that reliably allows cards of varying thicknesses to be fed individually through an outlet opening without adjustment. The hopper is configured to hold a stack of plastic cards or similar, fairly rigid, substrates. The control gate is positioned at the outlet opening and includes a flexible blade that reduces a height of the outlet opening to less than a thickness of an end card of the stack, whereby the flexible blade flexes in response to the end card when driven through the outlet opening. Also disclosed is a card feeder assembly that includes the above-described hopper.

Abstract: A card feed drive roller is provided with a drive section that is a soft elastomeric-material which has a coefficient of friction adequate to break away lower cards in a substantial stack of cards and has at least one support section that is of harder material that will limit the amount of compression of the drive section under weight of the card stack. The limitation of the compression of the drive section insures that when an outlet opening is adjusted it will be high enough so one card will always fit through the outlet opening, and multiple cards will not be fed through the opening.

Abstract: A card hopper includes a control gate that reliably allows cards of varying thicknesses to be fed individually through an outlet opening without adjustment. The hopper is configured to hold a stack of plastic cards or similar, fairly rigid, substrates. The control gate is positioned at the outlet opening and includes a flexible blade that reduces a height of the outlet opening to less than a thickness of an end card of the stack, whereby the flexible blade flexes in response to the end card when driven through the outlet opening. Also disclosed is a card feeder assembly that includes the above-described hopper.

Abstract: A mounting slider bracket for a card printer thermal printhead is supported between a spring and the printhead, and can be adjusted laterally relative to the printhead to shift the center of force that loads the printhead against the ribbon and a card that is being printed. The ability to change the location of the application of force on the printhead permits centering the force when a card of different width is fed from a supply through the printhead. Uniform printing will occur on cards regardless of the width, when properly adjusted by the operator.

Abstract: A method for improving print quality of an identification card printing system is provided. In the method, heat is applied to a primary image portion of a thermal print ribbon corresponding to a primary image. Heat is also applied to a remainder portion of the thermal print ribbon defined as a portion of the thermal print ribbon that extends beyond the primary image portion to at least one lengthwise edge of the thermal print ribbon. In this manner, the thermal print ribbon is substantially uniformly heated across its width thereby reducing uneven stretching of the thermal print ribbon and improving the quality of the primary image that is ultimately transferred to a substrate. Also provided is an identification card printing system that is adapted to implement the above-described method.

Abstract: A card feeder for a card printer provides a stack of cards at an input end of the printer. The cards are supported on a pair of rollers that are driven at differential speeds and through one-way clutches so that a card being fed from the stack will pass through an outlet opening and can be accelerated by further drives. The outlet opening is controlled as to size by a slidable gate that permits changing the thickness of the opening to permit use of different thickness cards in the hopper. The feeder includes cleaning rollers that are formed as a module that can be inserted and replaced, and also an encoding station where the card can be encoded such as for a magnetic strip, or for non contact radio frequency or other smart card chips contained on the card being processed prior to the printing operation.

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.

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: A printer for printing information on images on a substrate such as an identification card in multiple colors has an intermediate transfer film or web on which a reverse image is printed. The printer has a lamination station where the image is transferred to a substrate, such as an identification card. The intermediate transfer film or web is moved back and forth, the intermediate transfer film or web has slack occurring in it between the printing station and the lamination station. The slack is taken up with spring loaded rollers to permit operation of the printer head and the lamination station at the same time. Additionally, the printer is made into modules that are movable for easy access to interior components and to expose film or web paths that permits installing both the print film or web and the intermediate transfer film or web without threading it through enclosed openings.

Abstract: An output card hopper for use in connection with an identification card printer as a hopper that receives the cards and permits the cards to be supported on movable lift rails. The rails can be moved up and down, and the hopper has a pair of pawls that extend into the hopper from the sides and which are retracted as the card is lifted up by the lift rails, and then permitted to move back inwardly so that as the card support is lowered, the card that had been carried up by the rails is supported on the pawls in a stack above the pawls. The hopper includes one adjustable side wall to permit adjusting the width of the hopper. The card lift rails are raised and lowered by operating a cam, with a spring return on the card lift rails to urge the lift rails toward a home or lowered position.