Abstract: A card encoding system comprises a belt to receive an encodable card on a first surface of the belt; a contactless encoding module including an encoding antenna, wherein the encoding antenna is positioned opposite a second surface of the belt; and a belt drive controller configured to rotate a drive roller to move the belt to position the encodable card for encoding using the encoding antenna.

Abstract: A card encoding system comprises a belt to receive an encodable card on a first surface of the belt; a contactless encoding module including an encoding antenna, wherein the encoding antenna is positioned opposite a second surface of the belt; and a belt drive controller configured to rotate a drive roller to move the belt to position the encodable card for encoding using the encoding antenna.

Abstract: An asymmetric thermal print head includes a print head body and a plurality of print elements supported on the print head body. The print elements are aligned along a first axis. Each print element includes a heater portion having a burn width measured along the first axis corresponding to a first print resolution, and a burn length measured along a second axis, which is perpendicular to the first axis, corresponding to a second print resolution. The second print resolution is higher than the first print resolution. One or more control circuits are configured to individually activate the print elements.

Abstract: In a method of operating an ink jet card printer, which includes a transport belt, a print unit including an ink jet print head, a sensor and a gantry, a card is loaded onto the transport belt along a processing axis using an exposed surface of the transport belt. The sensor and the ink jet print head are moved relative to the card using the gantry. A current position of the card is detected using the sensor. An image is printed to the card using the ink jet print head when the detected current position of the card indicates that the card is supported on the transport belt in a print position. Printing is interrupted when the detected current position of the card indicates that the card is not in the print position.

Abstract: In a method of operating an ink jet card printer, which includes a transport belt, a print unit including an ink jet print head, a sensor and a gantry, a card is loaded onto the transport belt along a processing axis using an exposed surface of the transport belt. The sensor and the ink jet print head are moved relative to the card using the gantry. A current position of the card is detected using the sensor. An image is printed to the card using the ink jet print head when the detected current position of the card indicates that the card is supported on the transport belt in a print position. Printing is interrupted when the detected current position of the card indicates that the card is not in the print position.

Abstract: An asymmetric thermal print head includes a print head body and a plurality of print elements supported on the print head body. The print elements are aligned along a first axis. Each print element includes a heater portion having a burn width measured along the first axis corresponding to a first print resolution, and a burn length measured along a second axis, which is perpendicular to the first axis, corresponding to a second print resolution. The second print resolution is higher than the first print resolution. One or more control circuits are configured to individually activate the print elements.

Abstract: Card substrate printers, such as credential production devices, are generally configured to print images to plastic substrates to form identification cards, driver's licenses, credit cards, and other items. The image printing process that is performed by the printer may be a direct-to-card printing operation, in which a print unit prints an image directly to a surface of the substrate. Alternatively, the image printing process may involve a reverse-image printing process, during which a print unit prints an image to an intermediate substrate, such as a transfer film, and the printed image is transferred from the intermediate substrate to a surface of the card substrate to complete the printing process.

Abstract: In a method of laminating a transfer layer to a substrate, a transfer layer is provided on a carrier layer. Portions of the transfer layer are selectively removed from the carrier layer using an adhesive panel by heating portions of the adhesive panel corresponding to the portions of the transfer layer, and transferring the portions of the transfer layer from the carrier layer to the adhesive panel. A transfer section of the transfer layer is then transferred from the carrier layer to a surface of the substrate by fracturing the transfer layer along an edge of the transfer section.

Abstract: In a method of laminating a transfer layer to a substrate, a transfer layer is provided on a carrier layer. Portions of the transfer layer are selectively removed from the carrier layer using an adhesive panel by heating portions of the adhesive panel corresponding to the portions of the transfer layer, and transferring the portions of the transfer layer from the carrier layer to the adhesive panel. A transfer section of the transfer layer is then transferred from the carrier layer to a surface of the substrate by fracturing the transfer layer along an edge of the transfer section.

Abstract: A printer includes a print ribbon, a transfer ribbon, a printhead, and a first sensor. The transfer ribbon includes a series of panels each separated from adjacent panels by a transition portion. A section of the transfer ribbon is supported between a supply roll and a take-up roll and has a feeding direction that is toward the take-up roll. The printhead is configured to transfer print material from the print ribbon to the section of transfer ribbon. The first sensor is positioned downstream of the printhead relative to the feeding direction of the section of transfer ribbon and includes an output signal that is indicative of a position of one of the transition portions relative to the printhead.

Abstract: A card manufacturing device includes a web of laminate material, a first set of feed rollers, and a aligning roller. The first set of feed rollers is configured to feed the web along a laminate feed path. The feed rollers each include an axis of rotation that is perpendicular to the laminate feed path. The aligning roller is configured to receive the web from the first set of feed rollers. The aligning roller includes a shaft having a skewed axis of rotation that is non-parallel to the axes of rotation of the first set of feed rollers, and a main roller that is supported on the shaft for rotation about the skewed axis. In accordance with one embodiment of the invention, the aligning roller includes a plurality of lugs that extend from the surface of the main roller to thereby form a paddlewheel.

Abstract: Methods of the present invention relating to an identification card printer include a method of calibrating a ribbon sensor for detecting transition portions between adjoining panels of a ribbon and a method of calibrating tension in a ribbon. Identification card printers in accordance with embodiments of the invention include a sensor positioned downstream of a printhead relative to a feeding direction of a ribbon; support for a printhead that is moveable between print and withdrawn positions; a swing frame supporting a first roll of a ribbon for rotation about an axis about which the swing frame pivots; an adjustable card guide in line with a print path; and a card bender including a pinch roller assembly having first and second rollers, axes of rotation of which are aligned in a plane that is non-perpendicular to a card path.

Abstract: A magnetic head suspension for attachment to a rigid arm comprises a spring load beam element and a flexure means joined to the distal end of the load beam element for supporting a read/write head. The spring load beam element portion is formed from material generally having a first thickness. The load beam has a central region in the spring region which has a second thickness, generally thinner than the first thickness. The second thickness may be formed by the partial or complete removal of load beam material in the central region. First thickness legs bounding the central region may be formed to be of widest width at the location proximal to the rigid section of the load beam, of medium width at the location distal to the rigid section of the load beam, and of narrowest width between the two ends of each leg, thus providing a load beam of good lateral stiffness and spring rate characteristics.

Abstract: An improved magnetic head suspension having a unitary load beam and flexure structure with a gimballed slider baseplate etched into the slider.