Patent Application
20090282994
This invention relates to flexographic printing, and more particularly, this invention relates to producing debit cards.
Commonly assigned U.S. Pat. No. 6,729,656, the disclosure which is hereby incorporated by reference in its entirety, discloses a system and method of forming a debit card having a personal identification number (PIN) radiation cured, opaque scratch-off coating applied over the PIN. A card supply feeds cards that are advanced along a predetermined path of travel on a conveyor into various print stations where the personal identification number (PIN) is printed onto the surface of the card, such as by inkjet printing, followed by advancement into successive print stations for further processing. A first print station prints a release coating over the PIN. A second print station prints a scratch-off coating. A third print station applies a second or subsequent ink layer or other coating over the opaque scratch-off coating.
The print stations include an Anilox metering roll and a plate cylinder having impression plates as print pads as commonly used in flexographic printing stations that print a “stripe,” i.e., a strip of material such as an ink, for example, in the form of a release coating or scratch-off coating, of predetermined thickness and predetermined length as defined by the type of plate cylinder and impression plate on the print pad. This particular “stripe” or strip of release coating or scratch-off coating is of a predetermined length, width, and position on the card resulting from the configuration of the print cylinder and its print pad positioned on the print cylinder's periphery and timing relationship relative to the advancing card. In this type of system, however, there is no variation in the length or number of stripes that can be printed on the card. There are many applications, however, where a vendor desires to vary the number and length of the stripes depending on individual cards or end use customer requirements.
A system forms a debit card and includes a conveying mechanism for sequentially advancing planar card members along a predetermined path of travel. Each card has a PIN on one of the surfaces. A flexographic printing station is positioned along the predetermined path of travel for printing at least one print stripe of opaque scratch-off coating onto the surface of the card having the PIN as a card member is advanced into the printing station such that the PIN is covered by at least one print stripe of scratch-off coating. The flexographic printing station includes an Anilox metering roll that receives a scratch-off coating and a print cylinder having a circumferential printing surface that engages the Anilox metering roll and receives the scratch-off coating therefrom and transfers the scratch-off coating from the printing surface onto the surface of the debit card. A drive mechanism continuously rotates the print cylinder with respect to the Anilox metering roll. A mounting mechanism supports the print cylinder for vertical movement with respect to the advancing mechanism and drives the print cylinder into and out of engagement with the surface of the debit card advanced into the flexographic printing station while maintaining sufficient contact with the Anilox metering roll. A controller is operative with the mounting mechanism for controlling movement of the print cylinder into and out of engagement with the surface of the debit card at a predetermined location and for a predetermined length of time to apply at least one print stripe of predetermined length onto the surface of the debit card based on the length of time the printing surface engages the surface of the debit card.
In one aspect, the mounting mechanism is operative such that the setting between the Anilox metering roll and print cylinder is not sufficiently changed to impede adequate transfer of scratch-off coating between the Anilox metering roll and printing surface. The mounting mechanism can be formed as a pivot mount member that supports the print cylinder for pivoting motion about a pivot point at a location such that the print cylinder upon pivoting is raised and lowered with respect to the advancing mechanism. A piston actuator having a piston is connected to the print cylinder and operative from the controller for actuating piston movement and driving the print cylinder into and out of engagement with the debit card.
In yet another aspect, a plurality of parallel print pads form the printing surface for printing parallel print stripes onto the surface of the debit card. In another aspect, the controller is operative with the mounting mechanism for lowering the print cylinder into engagement with a surface of a debit card a number of times for varying the number and length of print stripes printed on the surface of the debit card. An adjustable stop member can limit downward movement of the print cylinder relative to the advancing mechanism for changing the clearance from the print cylinder and conveying mechanism and adjusting to a different debit card thickness for developing a predetermined pressure to be exerted onto the surface of the debit card. The adjustable stop member can limit upward movement of the print cylinder relative to the advancing mechanism for ensuring that the print cylinder is sufficiently clear of the advancing mechanism for advancing debit cards.
In yet another aspect, a radiation curing station is located along the path of travel for radiation curing the scratch-off coating. This radiation curing station can be formed as an ultraviolet radiation curing station. The printing station can also print a security indicia on the opaque scratch-off coating. A flexographic printing station can be positioned along the predetermined path of travel for printing a release coating onto the surface of the PIN before printing the opaque scratch-off coating.
A method aspect is also set forth. The flexographic printing process as described can be used for any printing of ink on a substrate.
Other objects, features and advantages will become apparent from the detailed description of the preferred embodiments which follows, when considered in light of the accompanying drawings in which:
Different embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments are shown. Many different forms can be set forth and described embodiments should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope to those skilled in the art. Like numbers refer to like elements throughout.
Referring now to
Although different planar card members can be used in the system shown in
As shown in
After the PIN is printed onto the surface of the planar card member by PIN print station 16, the debit card is advanced in a predetermined path of travel by the belt conveyor where, in one aspect of the invention, a release coating is applied over the PIN. The release coating is typically less than about 2 mil thickness and preferably about 0.0002 to about 0.0005 inches thick and could range up to about 0.002 inches. The release coating is preferably transparent, but it does not have to be necessarily clear, but could be color tinted for aesthetic purposes. Typically, the release coating (if used) should be of a thickness and color such that the PIN can be seen through the release coating.
In a preferred aspect, the release coating is applied by printing the release coating using a metering roll 22 and impression plate 26 in a flexographic printing process. Other printing methods that could be used include rotary letter press, offset (lithography), gravure, and rotary screen printing methods. The preferred printing method has been found to be the flexographic printing method, and includes an ink reservoir 30 in the form of an ink bath container. The bath container 30 holds the ink in liquid form, which could be the release material or scratch-off material in this non-limiting example. The ink bath container 30 could be a chambered doctor blade system or other enclosed doctor blade system. Although an open system is illustrated for purposes of description, a chambered doctor blade system would provide cleaner operation.
The Anilox metering roll 22, as known to those skilled in the art, is contained within the ink bath and includes a common knurled or other surface. A doctor blade 32 is operative with the metering roll 22 for engaging close to the metering roll and removing part of the liquid or ink in the form of the release material or scratch-off material from the Anilox metering roll.
The plate cylinder 24 has impression plates 26 in the form of print pads mounted thereon that engage the Anilox metering roll and transfers the release or scratch-off coating material from the plate (pads) onto the surface of the planar card member. The plate cylinder 24 is a generic term describing many types of flexographic design options. A barbell configuration could support two print pads 26. Other designs could support three or four print pads, essentially doubling throughput when four print pads are used. The impression plates (print pads) 26 can be formed of any type of material commonly known to those skilled in the art, including rubber print pads or photopolymer plates 26 and/or other flexible plate or pad material, typically known and used by those skilled in the art.
The release coating can be applied in a printing manner similar to any ink coating applied in printing techniques, including the preferred flexographic techniques. This release coating can, thus, be referred to as a printed ink coating that is applied onto the surface of the card over the PIN and radiation/ultraviolet cured by the preferred ultraviolet curing lamp 28, which uses an ultraviolet bulb 28a in an ultraviolet lamp housing 28b.
The belt conveyor 14 in this illustrated aspect typically includes a servodrive in the form of a servomotor 34 operatively connected onto a support shaft 14a of the belt conveyor. An encoder 36 is operatively connected to the shaft 14a and a controller 38. The laser sensor 18 is operative with the conveyor, as shown in
Naturally, a release coating is not always necessary depending on the type of substrate used for the card member. The amount of surface tension created by the card surface has an impact on the removability of opaque scratch-off layers, typically formed as a silver ink, as known to those skilled in the art, such that the scratch-off layer could be removed without damaging the PIN even without a release coating, in some instances.
At the second print station 22b, the scratch-off coating is applied after the first print station 22a has printed a release coating in this non-limiting example. As is typical, the scratch-off coating can be a silver ink formed of a material known to those skilled in the art, but could be formed of another type of opaque ink. The print station 22b is similar in design to the first print station 22a and includes the basic printing components as described before, including an Anilox metering roll 22 and plate cylinder 24, the appropriate ink well or reservoir 30, doctor blade 32, DC motor drive 40, servodrive mechanism in the form of a precisely controlled servomotor 44, encoder 42, and impression plates or print pads 26 contained on the plate cylinder. A second ultraviolet curing station (lamp) 28 provides for radiation curing of the printed ink in the form of the opaque scratch-off coating. Although ultraviolet curing is the preferred method of curing as described, it is possible in some cases to use other types of radiation curing, including the possible use of electron beam, blue light, laser or other radiation curing methods known to those skilled in the art.
In one aspect, the ultraviolet curing stations 28 are an ultraviolet, modular curing subsystems, such as manufactured and sold by Uvexs of Sunnyville, Calif. Such ultraviolet curing stations include an ultraviolet lamp housing that could use a metal halide, mercury vapor, or other type of ultraviolet lamp known to those skilled in the art with power levels ranging from as low as about 100 watts/inch to as high as about 600 watts/inch. If a release coating is applied, then a mercury vapor lamp could be used. For the opaque scratch-off coating, a metal halide lamp is preferred, but of course, other lamps could be used as suggested by those skilled in the art. The station could have remote operating controls for operator control at a console located a distance from the system, and an adequate power supply for direct ultraviolet exposure (and infrared filter exposure in some cases). The station 28 could also include an internal shutter and a digital exposure timer having a continuous variable power control.
The station 28 could provide surface and in-depth curing for high intensity, full spectrum ultraviolet energy from about 200 to about 400 nanometers. The lamp lengths can vary from as little as 2 to about 80 or more inches and include a single medium pressure mercury vapor, metal halide, or other lamp. Internal cooling fans could be provided with appropriate venting using vent systems. A reflector could be included in the oven for unfiltered and filtered infrared operation. The shutter could allow exposure control and could be provided by an internally mounted knife blade shutter using a pneumatic cylinder to drive the shutter plate at an adjustable open/close rate. Clean dry air or nitrogen could be used for efficient curing operation. The shutter control could include a pneumatic switch and digital timer for open/close functions. A programmable logic control (PLC) can be used as an interface connector using techniques known to those skilled in the art. Variable power control can provide power control over the ultraviolet lamp.
The third print station 20c can be used for personalization and can include a similarly fabricated, flexographic print station as described for the first and second print stations, or could be another type of printing apparatus besides the described flexograph type of printing station. The third print station 20c applies a second coat of ink, scratch-off coating material, or other printed indicia over the first scratch-off coating. Naturally, the print station 20c location would vary if it is used to print a layer over the PIN before application of the scratch-off coating. The third print station could be an ink jet print station and apply a fingerprint pattern or similar pattern that is opaque over (or under depending on position of the print station) the scratch-off coating. Also the ink jet printing could apply a security indicia on the opaque scratch-off coating that could be a control code. Thus, if the scratch-off coating and control code were removed, and a scratch-off label applied in its place, then a user would know that tampering of the card has occurred because there would be no control code. Also, the control code could be used for further security and correspond to other control codes printed on the planar card member. During ink jet printing of the second layer, coating, or indicia after the scratch-off coating has been applied, a typical black ink can be provided, although other ink could be provided as known to those skilled in the art.
The controller 38 could be a personal computer or other controller system as known to those skilled in the art. The ink jet PIN print station 16, laser sensors 18, DC motor drives 40, servodrives (motors) 34, 44, encoders 36, 42, shutter controls for the UV station 28, and any other motors and encoders used for the belt conveyor 14 and other components of the system are all operatively connected to the controller.
In operation with this aspect shown in
In this aspect shown in
The system and method described relative to
Referring now to
In this improved apparatus, the Anilox metering roll 56 can be similarly formed as in the print station 50 shown in
The print cylinder 52 can be rotated slightly about its pivot pin 66 to raise and lower the printing cylinder approximately 0.020 inches in one non-limiting example without materially changing the setting between the Anilox roll 56 and the print cylinder 52. This rotating movement is driven by a hydraulic, pneumatic or other cylinder 84 that has an output shaft 86 connected to a print cylinder pivot support 88. As the shaft 86 piston drives vertically up or down, it pivots the print cylinder 52 about its pivot pin 66 to raise or lower the print cylinder 52 and bring its printing surface 54 into contact with any debit card, substrate or other material to be printed. As a result, the continuously rotating print cylinder 52 can be driven up and then down at predetermined points to bring the printing surface 54 into contact with any substrate, such as a debit card, and vary the length of print “stripes” that are printed.
For example, it is possible to start and stop the printing of a print stripe at any point along the substrate or debit card. Selected portions of the printing surface 54 can engage surfaces to be printed by pivoting the print cylinder a predetermined number of times onto one surface of a substrate or debit card. By using smaller, more narrow print pads in parallel and extending around the periphery of the print cylinder, the number of print stripes on the card can vary. This system as described is not restricted to any length or type of product. By continually contacting the printing surface 54 on the printing cylinder along a long debit card or other very long substrate, a very long print stripe can be obtained. Also, multiple stripes of the same length can be printed if multiple parallel print pads as a printing surface are used. Examples of such printed patterns are shown in the cards in
Adjustments through the use of up and down stop members 90, 92 formed as screws as shown in
Many modifications and other embodiments of the invention will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the invention is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims.
