Patent Application
20080079799
There will be below described several embodiments of the present invention with reference to
In this embodiment, using an ink film having ink layers (e.g. sublimation inks) formed in sequence, the ink is directly printed on a card base to be printed, forming a card. This printing operation is referred to as “direct printing process”.
This card manufacturing apparatus 50 comprises a card feeder (feeding unit) KH having a motor M1 as a feeder driving source for the card base 1 and a pair of pinch rollers 2, 2 connected to a motor M1 to feed the card base 1 while pinching it therebetween, a sensor (detecting unit) 7B for detecting a feeding position of the card base 1, an ink-film feeder (feeding unit) IFH having a pair of reels 4 for winding and rewinding a later-mentioned ink film 3 and motors M2, M3 for rotating the reels 4, 4 respectively, a sensor (detecting unit) 7A for detecting later-mentioned position marks PM1 to PM7, which are marked on the ink film 3 in order to specify the positions of respective ink layers, in non-contact manner, a thermal head 5 for heating up the ink film 3 to sublimate the sublimation inks, a head actuator (transfer mechanism) HA for moving the thermal head 5 vertically (in
In the embodiment, the card base I is provided, on one surface thereof, with a receptor layer 1a for receiving the sublimation inks.
As shown in
Hereinafter, these layers of the ink film 3 might be referred to as “sublimation-ink areas”, “fusible-ink area”, “first protecting-ink area” “sublimation ultraviolet-emitting-ink (invisible-ink) area” and “second protecting-ink area”, respectively.
In detail, a plurality of groups of layers (KM) are formed in the longitudinal direction of the ink film 3 successively. Each group of layers (KM) comprises respective sublimation-ink layers Y, M, C in yellow (Y), magenta (M) and cyan (C), a fusible-ink layer K in black, a first protecting-ink layer OC1, a sublimation ultraviolet-emitting-ink layer UVS and a second protecting-ink layer OC2, in sequence in the longitudinal direction of the ink film 3
The first protecting-ink layer OC1 and the second protecting-ink layer OC2 may be made of acrylate resin, polyester resin, polyurethane resin or the like. Further, as ultraviolet absorbents for the protecting-ink layers, there may be added organic absorbent, for example, benzophenone compound, benzotriazole compound and anilide-oxalate compound, or inorganic absorbent of metal oxide.
For the purpose of allowing the sensor 7A to detect the positions of respective ink layers, the ink film 3 is also provided with a plurality of positioning marks PM1 to PM7 corresponding to the ink layers respectively.
In operation, the controller 6 controls the operation of the card feeder KH to feed the card base 1 so that a print starting position designated on the card base 1 is aligned with the thermal head 5 (cueing of the card base 1).
Based on detection signals from the sensor 7A detecting the positioning marks PM1 to PM7, the controller 6 further controls the operation of the ink-film feeder IFH so that an ink layer corresponding to a certain color to be printed in accordance with a required printing content (e.g. yellow as the first printed color) is aligned with the thermal head 5 (i.e. cueing operation of the ink layer).
Corresponding to the above positioning of the card base 1 and the ink film 3, additionally, the controller 6 drives the head actuator HA to feed the card base 1 and the ink film 3 while allowing the thermal head 5 to pushing the ink film 3 onto the card base 1. Simultaneously, the controller 6 drives the head actuator HA to heat up the thermal head 5 for sublimating or melting respective inks on the ink layers, so that a designated print image is printed on the card base 1.
After that, the cueing operations of the card base 1 and an ink layer of color to be next-printed in the ink film 3 are repeated. In this way, the inks in several colors, the protecting inks and the ultraviolet emitting inks are successively printed on the card base 1, in lamination.
Next, this lamination-printing (referred to as “trapping”) will be described with reference to
First, using the sublimation-ink layers Y, M, C, the printing of respective colors is applied on the card base 1. Consequently, a sublimation-ink image 8 is formed in the receptor layer 1a. This image is suitable for a facial portrait since the image could be printed in full-color printing with high quality.
Next, the printing operation using the fusible-ink layer K in black is performed. Thus, a fusible-ink image 9 is formed on the surface of the receptor layer 1a. This image is suitable for characters and marks since the image could be printed in black remarkably clearly.
Next, the printing operation of the first protecting-ink layer OC1 is carried out against the whole surface of the printing area including the fusible-ink image 9. In this way, the entire printing area including the fusible-ink image 9 is covered with the first protecting-ink layer OC1.
Next, the printing operation using the ultraviolet-emitting-ink layer UVS is carried out. Thus, a designated invisible-ink image (ultraviolet emitting ink image) 10 is printed on the first protecting-ink layer OC1. This image is suitable for personal data (name, birthday, finger print, etc.).
Next, the printing operation of the second protecting-ink layer OC2 is carried out against the whole surface of the printing area including the invisible-ink image (ultraviolet emitting ink image) 10.
In this way, the card 51 is completed through the above-mentioned printing processes.
In the shown embodiment, an invisible-ink layer 10s (as one layer of the invisible-ink image 10) is arranged apart from the card base 1 in comparison with the receptor layer 1a including the sublimation-ink image 8 and additionally, the first protecting-ink layer OC1 as one protecting layer is interposed between the sublimation-ink image 8 and the invisible-ink layer 10s.
Accordingly, as the sublimation-ink image 8 does not abut on the invisible-ink image 10 (image of ultraviolet emitting ink) directly, the light intensity of fluorescence, which is radiated from the invisible-ink image 10 onto the sublimation-ink image 8 in irradiating ultraviolet light in order to make the invisible-ink image 10 visible, is reduced in diffusion by the fluorescence's transmitting through the first protecting-ink layer OC1, so that the color of the sublimation ink is restored to maintain the sublimation-ink image 8 in a good condition for a long period.
It is noted that if the ultraviolet emitting ink (fluorescent ink) makes contact with the sublimation ink, there is a possibility that the color degradation of the sublimation ink is promoted due to the cross-reaction of both inks. However, according to the embodiment, both of the ultraviolet emitting ink and the sublimation ink are separated from each other through the first protecting-ink layer OC1, so that the color degradation of the sublimation ink can be prevented to maintain the sublimation-ink image 8 in a good condition for a long period.
Moreover, if the first protecting-ink layer OC1 is mixed with either known ultraviolet absorbent or known ultraviolet diffusing agent, it is also possible to suppress an influence of ultraviolet rays on the sublimation-ink image 8.
Further, as the invisible-ink image 10 is arranged closer to the surface of the card 51 in comparison with the sublimation-ink image 8 and the fusible-ink image 9, it is possible to make the fluorescence of the invisible-ink image 10 visible more clearly.
We now describe the printing process for the card 51A in detail.
With the use of the sublimation-ink layers Y, M, C, it is firstly performed to print respective colors of Y, M, C on the card base 1. Consequently, a sublimation-ink image 8 is formed in the receptor layer 1a.
Next, the printing operation of the first protecting-ink layer OC1 is applied on the whole surface of the printing area including the sublimation-ink image 8. As a result, the sublimation-ink image 8 is covered with the first protecting-ink layer OC1.
Successively, the printing operation in black is performed with the use of the fusible-ink layer K. Thus, a fusible-ink image 9 is formed on the surface of the first protecting-ink layer OC1.
Next, the printing operation is performed with the use of the ultraviolet-emitting-ink layer UVS. Thus, a designated invisible-ink image (ultraviolet emitting ink image) 10 is printed on the fusible-ink image 9 and the first protecting-ink layer OC1 except its portions having no fusible-ink image.
Next, the printing operation of the second protecting-ink layer OC2 is applied on the whole surface of the printing area including the fusible-ink image 9 covered with no invisible-ink image, the invisible-ink image (ultraviolet-emitting-ink image) 10 and the remaining the first protecting-ink layer OC1.
In this way, the card 51A is completed through the above-mentioned printing processes.
In this modification also, the receptor layer 1a including the sublimation-ink image 8 is arranged close to the card base 1 in comparison with the layer including the invisible-ink image 10 and additionally, the first protecting-ink layer OC1 as one protecting layer is interposed between the receptor layer 1a and the above layer including the invisible-ink image 10.
Accordingly, as the sublimation-ink image 8 does not abut on the invisible-ink image 10 (image of ultraviolet emitting ink) directly, the light intensity of fluorescence, which is radiated from the invisible-ink image 10 onto the sublimation-ink image 8 in irradiating ultraviolet light in order to make the invisible-ink image 10 visible, is reduced in diffusion by the fluorescence's transmitting through the first protecting-ink layer OC1, so that the color of the sublimation ink is restored to maintain the sublimation-ink image 8 in a good condition for a long period.
It is noted that if the ultraviolet emitting ink (fluorescent ink) makes contact with the sublimation ink, there is a possibility that the color degradation of the sublimation ink is promoted due to the cross-reaction of both inks. However, according to the embodiment, both of the ultraviolet emitting ink and the sublimation ink are separated from each other through the first protecting-ink layer OC1, so that the color degradation of the sublimation ink can be prevented to maintain the sublimation-ink image 8 in a good condition for a long period.
Moreover, if the first protecting-ink layer OC1 is mixed with either known ultraviolet absorbent or known ultraviolet diffusing agent, it is also possible to suppress an influence of ultraviolet rays on the sublimation-ink image 8.
Further, as the invisible-ink image is arranged closer to the surface of the card in comparison with the sublimation-ink image 8 and the fusible-ink image 9, it is possible to make the fluorescence of the invisible-ink image 10 visible more clearly.
In this embodiment, using an ink film having ink layers (e.g. sublimation ink) formed in sequence, the ink in the form of an image is transferred to an intermediate transfer film having an ink receptor layer and subsequently, the so-transferred image is further transferred onto a card base to be printed, forming a card. This printing operation is called to as “re-transfer printing process”.
As shown in
Further, the card manufacturing apparatus 60 includes an intermediate-transfer-film feeder TFH (as the second feeding mechanism of the invention) having a pair of reels 12, 12 for winding and rewinding the intermediate transfer film 11 and motors M4, M5 for rotating the reels 12, 12, a sensor 7C (as the second detecting unit of the invention) for detecting positioning marks that are marked on the intermediate transfer film 11 in order to specify its transfer position, in non-contact manner, a thermal head 13 for heating up the intermediate transfer film 11 to sublimate the sublimation ink or melt the fusible ink, a head actuator HA2 (as the second transfer mechanism of the invention) for moving the thermal head 13 vertically (in
As shown in
Hereinafter, these layers on the ink film 33 might be referred to as “fusible-ink areas”, “sublimation ultraviolet-emitting-ink (invisible-ink) area” and “fusible-ink area”, respectively.
In detail, a plurality of groups (KM2) of various layers are formed in the longitudinal direction of the ink film 33 repeatedly. Each of the groups (KM2) comprises respective sublimation-ink layers Y, M, C in yellow (Y), magenta (M) and cyan (C), a sublimation ultraviolet-emitting-ink layer UVS and a fusible-ink layer K in black, all of which successively arranged in the longitudinal direction of the ink film 33, in this order.
For the purpose of allowing the sensor 7A to detect the positions of respective ink layers, the ink film 33 further includes positioning marks PM11 to PM15 corresponding to the ink layers respectively.
While, as shown in
In these laminated layers, both the protecting layer 11c and the ink receptor layer 11d on the front side constitute a transfer layer 11cd of the intermediate transfer film 11. The above release layer 11b is provided to facilitate a peeling of the transfer layer 11cd.
For instance, the protecting layer 11c is made of polyurethane resin, acrylate resin, polyethylene resin or the like.
Based on output signals from the sensors 7A, 7C, the controller 6 carries out the cueing operation of the intermediate transfer film 11 (i.e. cueing of a film's unused area on which an ink is to be transferred) and the cueing operation of the ink film 33, in detail, the cueing of a film's first ink layer (e.g. yellow) of an image to be transferred on the unused area. That is, the controller 6 drives the ink-film feeder IFH and the intermediate-transfer-film feeder TFH so that respective cueing positions of the films 11, 33 are aligned with the thermal head 5.
In association with the positioning of the films 11, 33, the controller 6 drives the head actuator HA to transfer these films 11, 33 while pinching them between the thermal head 5 and the roller 5B. Simultaneously, the controller 6 heats up the thermal head 5 to sublimate inks in order to transfer a designated image on the intermediate transfer film 11.
Then, this transfer operation is completed since the sublimated inks are retained in the ink receptor layer 11d of the intermediate transfer film 11.
On the other hand, respective inks of both the sublimation ultraviolet-emitting-ink layer UVS and the fusible-ink layer K are transferred into a second transcriptional region 22 abutting on the first transcriptional region 21 through a regular interval, in piles.
Thus, as for the sublimation inks, the cueing operation of the first transcriptional region 21 and respective colors in the ink film 33 is repeated, so that respective inks in plural colors Y, M, C are transferred into the ink receptor layer 11d (11d1) of the first transcriptional region 21. As a result, the sublimation-ink image 18 is formed in the ink receptor layer 11d (11d1). (i.e. the sublimation-ink image forming process of the invention) This image is suitable for a facial portrait since the image could be printed in full-color printing with high quality.
At each of the second transcriptional regions 22, the ink in the sublimation ultraviolet-emitting-ink layer UVS is firstly transferred into the ink receptor layer 11d (11d2), forming the invisible-ink image 20 (i.e. the invisible-ink image forming process of the invention). In succession, the ink in the fusible-ink layer K is transferred onto the invisible-ink image 20, so that the fusible-ink image 19 is laminated on the invisible-ink image 20, in piles.
Accordingly, the later-transferred fusible-ink image 19 is formed on the front side of the ink receptor layer 11d in each second transcriptional region 22.
Hereinafter, the ink receptor layer (portion) 11d in the first transcriptional region 21 and the ink receptor layer (portion) 11d in the second transcriptional region 22 are indicated with reference signs 11d1, 11d2, respectively. Similarly, the protecting layer (portion) 11c in the first transcriptional region 21 and the protecting layer (portion) 11c in the second transcriptional region 22 are indicated with signs 11c1, 11c2, respectively.
In this way, respective positions for the first and second transcriptional regions 21, 22 containing the ink images 18˜20 are established in the intermediate transfer film 11 previously. Further, the intermediate transfer film 11 is provided, between each first transcriptional region 21 and each second transcriptional region 22 (and between the second transcriptional region 22 and the first transcriptional region 21), with positioning marks PM16, PM 17 for specifying the transcriptional regions 21, 22. These positioning marks are detected by the sensor 7C, while the controller 6 judges the positions of the marks on the basis of the detection signals from the sensor 7C.
The ink images 18˜20 transferred to the intermediate transfer film 11 in the above way are re-transferred to a card base 1AA.
Based on the positional information of the card base 1AA detected by the sensor 7B, the controller 6 controls the operation of the card feeder KH so as to cue the re-transfer area on the card base 1AA.
This cueing operation is performed so as to align a re-transfer starting position defined on the card base 1AA with the thermal head 13 (see
Based on the detection signal from the sensor 7C, the controller 6 further controls the operation of the intermediate-transfer-film feeder TFH so that, as a film's area to be re-transferred preferentially, the first transcriptional region 21 is selected from the first and second transcriptional regions 21, 22 of the intermediate transfer film 11 and additionally, the re-transfer starting position of the first transcriptional region 21 is aligned with the thermal head 13.
Corresponding to the alignment of the intermediate transfer film 11 with the card base 1AA, the controller 6 drives the head actuator HA2 to transfer both of the intermediate transfer film 11 and the card base 1AA while allowing the thermal head 13 to press the intermediate transfer film 11 on the card base 1AA. Additionally, the controller 6 operates to heat up the thermal head 13 to peel the ink receptor layer 11d1 and the protecting layer 11c1 (i.e. the transfer layer 11cd) in the first transcriptional region 21 from the release layer 11b and successively transfer (re-transfer) these layers 11d1, 11c1 to the card base 1AA (i.e. the first re-transfer process of the invention).
Consequently, the card 52 has the transfer layer 11cd in the first transcriptional region 21 re-transferred on the card base 1AA while positioning the ink receptor layer 11d1 inside the card 52 and the protecting later 11c1 on the front side of the card 52.
Next, it is performed to re-cue the re-transfer area on the card base 1AA and further cue the second transcriptional region 22 of the intermediate transfer film 11. Thereafter, as similar to the re-transferring of the first transcriptional region 21, it is performed to peel the ink receptor layer 11d2 and the protecting layer 11c2 (i.e. the transfer layer 11cd) in the second transcriptional region 22 from the release layer 11b and successively transfer (re-transfer) these layers 11d2, 11c2 onto the transfer layer 11cd in the first transcriptional region 21 previously transferred onto the card base 1AA (i.e. the second re-transfer process of the invention).
Referring to
First, the transfer layer 11cd (containing the sublimation-ink image 18) in the first transcriptional region 21 of the intermediate transfer film 11 is re-transferred to a designated re-transfer area on the card base 1AA. As a result, the ink receptor layer 11d1 and the protecting layer 11c1 both forming the transfer layer 11cd are laminated on the card base 1AA, in this order.
Next, the second transcriptional region 22 having the fusible-ink image 19 and the invisible-ink image 20 is re-transferred so as to overlap a card's portion to which the first transcriptional region 21 has been transferred previously.
The card 52 of the second embodiment is completed by the above-mentioned re-transfer processes.
According to the second embodiment of the present invention, the layer including the sublimation-ink image 18 is arranged close to the card base 1AA in comparison with the layer including the invisible-ink image 20 and additionally, the protecting layer 11c1 is interposed between the former layer and the latter layer.
Accordingly, as the sublimation-ink image 18 does not abut on the invisible-ink image 20 (image of ultraviolet emitting ink) directly, the light intensity of fluorescence, which is radiated from the invisible-ink image 20 onto the sublimation-ink image 18 in irradiating ultraviolet light in order to make the invisible-ink image 20 visible, is reduced in diffusion since the fluorescence is transmitted through the protecting layer 11d1, so that the color of the sublimation ink is restored to maintain the sublimation-ink image 18 in a good condition for a long period.
It is noted that if the ultraviolet emitting ink (fluorescent ink) makes contact with the sublimation ink, there is a possibility that the color degradation of the sublimation ink is accelerated due to the cross-reaction of both inks. However, according to the second embodiment, both of the ultraviolet emitting ink and the sublimation ink are separated from each other through the protecting layer 11c1, so that the color degradation of the sublimation ink can be prevented to maintain the sublimation-ink image 18 in a good condition for a long period.
Moreover, if the protecting layer 11c1 is mixed with either known ultraviolet absorbent or known ultraviolet diffusing agent, it is also possible to suppress an influence of ultraviolet rays on the sublimation-ink image 18.
Further, as the invisible-ink image 20 is arranged closer to the surface of the card 52 in comparison with the sublimation-ink image 18 and the fusible ink image 19, it is possible to make the fluorescence of the invisible-ink image 20 visible more clearly.
We first describe the re-transfer process for the card 52A with reference to
First, respective ink images in the sublimation-ink layers Y, M, C are transferred from the ink film 33 (
Similarly, an ink of the fusible-ink layer K is transferred from the ink film 33 to the first transcriptional region 21 of the intermediate transfer film 11. As a result, the fusible-ink image 19 is formed on the front side of the ink receptor layer 11d in the first transcriptional region 21 of the intermediate transfer film 11.
On the other hand, an ink of the ultraviolet-emitting-ink layer UVS is transferred from the ink film 33 to the ink receptor layer 11d in the second transcriptional region 22 adjoining the first transcriptional region 21 of the intermediate transfer film 11 through a predetermined interval. As a result, the invisible-ink image 20 is formed on the front side of the ink receptor layer 11d in the second transcriptional region 22.
In this case also, respective positions for the first and second transcriptional regions 21, 22 containing the ink images 18˜20 are established in the intermediate transfer film 11 previously. Further, the intermediate transfer film 11 is provided, between the first transcriptional region 21 and the second transcriptional region 22, with either the positioning mark PM16 or the positioning mark PM 17 for specifying the transcriptional regions 21, 22. These positioning marks PM16, PM17 are detected by the sensor 7C, while the controller 6 judges the positions of the marks on the basis of the detection signals from the sensor 7C.
The ink images 18˜20 transferred to the intermediate transfer film 11 in the above way are transferred to the card base 1AA again (i.e. re-transfer operation).
This re-transfer operation will be described with reference to
First, the transfer area 11cd in the first transcriptional region 21 of the intermediate transfer film 11 (containing the sublimation-ink image 18 and the fusible-ink image 19) is transferred to a designated re-transfer area of the card base 1AA, as shown in
Here, it should be noted that the intermediate transfer film 11 had the fusible-ink images 19 positioned on the front side of the ink receptor layer 11d1. Therefore, in the card 52A, the fusible-ink images 19 are positioned on one side of the ink receptor layer 11d1 close to the card base 1AA.
Next, the transfer layer 11cd in the second transcriptional region 22 containing the invisible-ink image 20 is re-transferred from the intermediate transfer film 11 to the card base 1AA so as to overlap the previously-transferred first transcriptional region 21. Consequently, the ink receptor layer 11d2 containing the invisible-ink image 20 is interposed between the protecting layer 11c1 and the protecting layer 11c2 on the front side of the card 52A. In this way, the card 52A in the modification of the second embodiment is completed through the re-transfer process mentioned above.
According to the modification of the second embodiment, the layer including the sublimation-ink image 18 is arranged close to the card base 1AA in comparison with the layer including the invisible-ink image 20 and additionally, the protecting layer 11c1 is interposed between the former layer and the latter layer.
Accordingly, as the sublimation-ink image 18 does not come in direct contact with the invisible-ink image 20 (an image of ultraviolet emitting ink), the light intensity of fluorescence, which is radiated from the invisible-ink image 20 onto the sublimation-ink image 18 in irradiating ultraviolet light in order to make the invisible-ink image 20 visible, is reduced in diffusion since the fluorescence is transmitted through the protecting layer 11c1, so that the color of the sublimation ink is restored to maintain the sublimation-ink image 18 in a good condition for a long period.
It is noted that if the ultraviolet emitting ink (fluorescent ink) makes contact with the sublimation ink, there is a possibility that the color degradation of the sublimation ink is accelerated due to the cross-reaction of both inks. However, according to the second embodiment, both of the ultraviolet emitting ink and the sublimation ink are separated from each other through the protecting layer 11c1, so that the color degradation of the sublimation ink can be prevented to maintain the sublimation-ink image 18 in a good condition for a long period.
Moreover, if the protecting layer 11c (11c1, 11c2) is mixed with either known ultraviolet absorbent or known ultraviolet diffusing agent, it is also possible to suppress an influence of ultraviolet rays on the sublimation-ink image 18. Particularly, if the protecting layer 11c1 is mixed with either known ultraviolet absorbent or known ultraviolet diffusing agent, the above suppression can be effected with high efficiency.
Further, as the invisible-ink image 20 is arranged closer to the surface of the card 52A in comparison with the sublimation-ink image 18 and the fusible ink image 19, it is possible to make the fluorescence of the invisible-ink image 20 visible more clearly.
As for the above-mentioned embodiments and the modifications, we now exhibit materials available for respective inks and films, as follows.
Note: In each case, preferably, the protecting layers OC1, 11c are made of material exhibiting low transmissivity against the wavelength range of fluorescence of the invisible ink.
It will be understood by those skilled in the art that the foregoing descriptions are nothing but two embodiments and their modifications of the disclosed card, its manufacturing method and apparatus and therefore, various changes and modifications may be made within the contents of the present invention.
For instance, the fusible-ink images 9, 19 are not necessarily formed in the cards 51, 51A, 52 and 52A. Even if forming the fusible-ink image, there is no need to arrange the fusible-ink image and the sublimation-ink image (or the invisible-ink image) so as to overlap each other. Thus, the fusible-ink image may be arranged in an area different from the area containing the sublimation-ink image (or the invisible-ink image), out of the superimposition.
Further, as for the ink film 3 of the first embodiment (including the modification), the array of respective ink areas is not limited to the illustrated array only. Irrespective of any array of ink areas, the controller 6 of the card manufacturing apparatus 50 judges the sort of each ink area. Thereupon, the controller 6 controls the entire operation of the apparatus 50 so as to perform, at least in principle, the printing operation using the protecting ink after completing the printing operation using the sublimation inks and subsequently perform the printing operation using the invisible ink.
Similarly to the ink film 33 of the second embodiment (including the modification), the array of respective ink areas is not limited to the illustrated array only. Irrespective of any array of ink areas, the controller 6 of the card manufacturing apparatus 60 judges the sort of each ink area. Thereupon, the controller 6 controls the operation of the apparatus 60 so as to form, at least in principle, the sublimation-ink image 18 by superimposing sublimation inks on a designated area (the first transcriptional region) in the intermediate transfer film 11 and the invisible-ink image 20 in a different area (the second transcriptional region) from the above designated area (the first transcriptional region).
| Number | Date | Country | Kind |
|---|---|---|---|
| P2006-264249 | Sep 2006 | JP | national |
