JP7529546B2 - Image forming device - Google Patents

Description

The present invention relates to an image forming device that forms an image on a recording medium such as an ID card, an identification card, or a membership card.

Conventionally, image forming devices that form images such as facial photographs or text information on card-shaped recording media such as plastic cards are widely known. Many of these card-shaped recording media are used to print facial photographs or personal information such as driver's licenses, various membership cards, employee ID cards or ID cards of individuals who possess the cards, and are not used to print large amounts of information on multiple sheets.

In recent years, printer systems that are connected to computer networks and perform on-demand printing have become known. Such printer systems simultaneously print the face photo of the individual who holds the card, print indications such as the issuer and the type of card, and record electronic data such as personal information. Dye-sublimation transfer devices are known as printers used in such printer systems.

Such dye-sublimation transfer devices transfer and print characters, images, etc. onto cards using an ink ribbon on which multiple types of ink panels of a predetermined width corresponding to the printing width of the card are arranged in face-sequential order. Methods for transferring and printing onto cards include a direct method in which printing is done directly onto the card, and an intermediate transfer method in which printing is done by first transferring to a transfer film and then secondarily transferring from the transfer film to the card. Regardless of the method, the printing is done by passing ink panels of each color, such as yellow, magenta, cyan, and black, of the ink ribbon in sequence over the transfer surface of the card or transfer film.

In addition, with such dye-sublimation transfer devices, even if the area on a card such as a driver's license or membership card where color printing such as a photograph is small, each ink panel of the ink ribbon consumes ink equivalent to the area of one card. In response to this, special ink ribbons have been known in the past in which the area of the color ink panels is limited to half the area of the black ink panel in order to reduce running costs.

In this situation, Patent Document 1 discloses an image forming device that realizes high-speed transfer printing. In the image forming device of Patent Document 1, N consecutive transfer areas set on a transfer film are arranged in the reverse order of the arrangement of the first to Nth ink panels, as the first to Nth transfer areas. Then, using the first to Nth ink sets, a transfer operation is repeated K=1 to K-N times to transfer ink from the first to Kth ink panels to the Kth transfer area for the N transfer areas. In this way, Patent Document 1 realizes high speed by performing continuous printing without moving the transfer film and the ink ribbon.

JP 2018-47554 A

However, in Patent Document 1, when using an ink ribbon in which the ink panels are different sizes, continuous transfer operations are not possible. Therefore, in this case, when using a special ink ribbon in which the ink panels are different sizes, such as when the area of the color ink panels is limited to half the area of the black ink panel, there is a problem that productivity cannot be improved.

In addition, in order to achieve the effect of increased speed, Patent Document 1 requires that one job consists of printing multiple sheets, and there is an issue that productivity cannot be improved when printing a small number of sheets, such as one sheet.

The object of the present invention is to provide an image forming apparatus that can improve productivity when using a special ink ribbon or when transferring a small number of images onto a transfer medium.

The image forming apparatus of the present invention is an image forming apparatus that transfers an image to a transfer medium using an ink ribbon in which a black ink panel having a predetermined width in the sub-scanning direction and a color ink panel having a first width in the sub-scanning direction smaller than the predetermined width are arranged in face-sequential order, and is characterized by having an image forming means that performs a cueing of the ink ribbon and the transfer medium and transfers an image to the transfer medium using the ink ribbon, and a control means that controls the transfer to be performed by the black ink panel without performing the cueing when the black ink panel is in the transferable position when the transfer using the final color ink panel, which is the color ink panel adjacent to the black ink panel downstream in the transport direction of the ink ribbon, is completed.

The present invention can improve productivity when using a special ink ribbon or when transferring a small number of images to a transfer medium.

1 is a schematic diagram illustrating a configuration of an image forming apparatus according to an embodiment of the present invention. 1 is a schematic diagram showing a part of a configuration of an image forming apparatus according to an embodiment of the present invention; 1 is a block diagram showing a configuration of an image forming apparatus according to an embodiment of the present invention; 2A and 2B are diagrams showing an example of the configuration of an ink ribbon used in an image forming apparatus according to an embodiment of the present invention and an example of a recorded card. FIG. 4 is a flowchart showing an image forming process according to the embodiment of the present invention. FIG. 4 is a flowchart showing a first half of a primary transfer process according to the embodiment of the present invention. FIG. 11 is a flowchart showing a second half of the primary transfer process according to the embodiment of the present invention. 11A to 11C are diagrams illustrating a procedure for performing transfer without cueing of a black ink panel in the image forming process according to the embodiment of the present invention. 11A to 11C are diagrams illustrating a procedure for performing transfer by aligning a black ink panel in the image forming process according to the embodiment of the present invention.

The following describes in detail the embodiments of the present invention with reference to the drawings.

<Overall Configuration of Image Forming Apparatus>
The overall configuration of an image forming apparatus 1 according to an embodiment of the present invention will be described in detail with reference to FIGS. 1 to 3. FIG.

The image forming device 1 records information such as magnetic information or electronic information (IC information) on, for example, ID cards for various certificates or credit cards for commercial transactions, and forms (prints) images such as characters, photographs, or marks. The image forming device 1 here is exemplified as an intermediate transfer type image forming device.

The image forming device 1 has a first transport path P1, a second transport path P2, a third transport path P3, a film transport path P4, and an ejection path P5.

The first transport path P1 is provided downstream of the transport direction of the card K when an image is transferred to the card K as a recording medium of the inversion unit 20, and is arranged extending in the left-right direction (horizontal direction) in FIG. 1, transporting the card K in the left-right direction in FIG. 1. The first transport path P1 extends parallel to the direction in which the card K is fed out in the media supply unit C (X direction in FIG. 1). The transport direction of the card K in the first transport path P1 when an image is transferred to the card K is opposite to the direction in which the card K is fed out in the media supply unit C.

The second transport path P2 is arranged to extend in the up-down direction (vertical direction) in FIG. 1, and transports the card K in the up-down direction in FIG. 1.

The first transport path P1 and the second transport path P2 are arranged to extend in directions that form a predetermined angle with each other in FIG. 1. Here, the predetermined angle is set taking into consideration the degree of density of each transport path, and is preferably in the range of 90 degrees to 180 degrees.

The third transport path P3 transports the card K in a direction different from that of the second transport path P2.

The film transport path P4 transports the ink ribbon 41 and the transfer film 46.

The discharge path P5 is arranged to extend in the same direction as the first transport path P1, and transports the cards K transported from the first transport path P1 to the storage stacker 60.

Specifically, the image forming device 1 has a device housing 2, an information recording section A, an image transfer section B, a media supply section C, an image forming section D, a media standby section E, a film standby section F, and a storage section G. The image forming device 1 also has a reversing unit 20, a reject stacker 25, a barcode reader 28, a decurling roller 36, a transport roller 37, a transport roller 38, a sensor Se12, and a control module 90.

The device housing 2 is provided with an information recording section A, an image transfer section B, a media supply section C, an image forming section D, a media standby section E, a film standby section F, a storage section G, and a control section H. The device housing 2 is also provided with a reversing unit 20, a decurling roller 36, a transport roller 37, a transport roller 38, a sensor Se12, and a control module 90.

The information recording unit A records information such as magnetic information or electronic information on the card K transported from the reversing unit 20 as a pre-processing step of image transfer in the image transfer unit B. The information recording unit A transports the card K on which the information has been recorded to the reversing unit 20. The configuration of the information recording unit A will be described in detail later.

The image transfer unit B is disposed on the first transport path P1, and transfers (secondary transfer) the image transported from the film standby unit F and transferred by the image forming unit D onto the transfer film 46 as a transfer medium, onto the card K transported from the media standby unit E. The image transfer unit B transports the card K onto which the image has been transferred to the transport rollers 37 or the media standby unit E. The image transfer unit B includes a transfer platen 31, a heating roller 33, and a fan fn2.

The transfer platen 31 passes the card K and the transfer film 46 between it and the heating roller 33.

The heating roller 33 is raised and lowered between a position where it is pressed against the transfer platen 31 and a position where it is separated from the transfer platen 31 by a lifting mechanism (not shown). When the heating roller 33 is in a position where it is pressed against the transfer platen 31, it presses and heats the card K and the transfer film 46 between the transfer platen 31 and the transfer platen 31, thereby transferring the image formed on the transfer film 46 to the surface of the card K (the lower surface in FIG. 2).

The media supply unit C transports the stored cards K to the reversal unit 20. The media supply unit C includes a paper feed cassette 3, a card storage unit 4, a paper feed opening 7, a picker opening 11, and a pickup roller 19.

The paper feed cassette 3 has a box-shaped cassette housing and stores multiple cards K aligned in an upright position.

The card storage section 4 is provided within the cassette housing of the paper feed cassette 3 and has a storage space capable of storing multiple cards K aligned in an upright position.

The paper feed opening 7 connects the card storage section 4 to the information recording section A, and separates the cards K one by one by a separation gap.

The picker opening 11 is an opening that opens the inside of the card storage section 4 to the outside.

The pickup roller 19 protrudes into the card storage section 4, and by rotating, transports the front row of cards K stored in the card storage section 4 to the information recording section A through the picker opening 11 and the paper feed opening 7.

Fan fn2 expels heat generated within the device housing 2 to the outside of the device housing 2.

The image forming unit D, which serves as an image forming means, transfers an image (primary transfer) onto the transfer film 46 using the ink ribbon 41, and transports the transfer film 46 onto which the image has been transferred to the film standby unit F. Details of the configuration of the image forming unit D will be described later.

The media standby section E is disposed on the first transport path P1 and is provided between the reversing unit 20 and the image transfer section B. The media standby section E is configured to temporarily stop the transport of the card K transported from the reversing unit 20 to hold the card K in standby, and to transport the held card K to the image transfer section B at a predetermined timing. The configuration of the media standby section E will be described in detail later.

The film standby section F is equipped with a sensor Se9. The film standby section F is configured to temporarily stop the transport of the transfer film 46 to hold the transfer film 46 on standby, and to transport the held-up transfer film 46 to the image transfer section B at a predetermined timing. The distance between the film standby section F and the image transfer section B is equal to the distance between the image transfer section B and the media standby section E, so that the card K and the transfer film 46 held on standby in the media standby section E can be transported to the image transfer section B at the same timing.

The sensor Se9 detects the amount of transport of the transfer film 46 transported by the transport roller 49 by detecting markers formed at predetermined intervals on the transfer film 46, and outputs the detection result to the control unit H.

The storage unit G stores the cards sent from the image transfer unit B in the storage stacker 60. The storage stacker 60 detects the top card K with a level sensor (not shown), and is configured to move downward in FIG. 1 with the lifting mechanism 61 in response to this detection result.

The reversing unit 20 is provided below the media supply section C and is disposed at one end side (the right end in FIG. 1) of the device housing 2. The reversing unit 20 is disposed at the connection point between the first transport path P1, the second transport path P2, and the third transport path P3. The configuration of the reversing unit 20 will be described in detail later.

The reject stacker 25 is provided on the outer periphery of the reversing unit 20. Cards K that have experienced recording errors in the non-contact IC recording unit 23 or the magnetic recording unit 24 are discharged from the reversing unit 20 to the reject stacker 25.

The barcode reader 28 is provided on the outer periphery of the reversing unit 20 and reads the barcode printed in the image transfer section B of the card K discharged from the reversing unit 20 to determine the suitability of the print result (error determination). The barcode reader 28 transports the card K whose print result has been determined to be suitable to the reversing unit 20.

The de-curl roller 36 is provided between the transport rollers 37 and 38, and corrects the curl of the card K by pressing the center of the card K held between the transport rollers 37 and 38.

The transport roller 37 is connected to a transport motor (not shown) and rotates when the transport motor is driven to transport the card K transported from the image transfer unit B to the transport roller 38.

The transport roller 38 is connected to a transport motor (not shown) and rotates when the transport motor is driven to eject the card K transported from the transport roller 37 into the storage section G.

The sensor Se12 detects the removal of the card K from the transport roller 38 to the storage section G and outputs an electrical signal according to the detection result to the control section H.

The control module 90 controls the overall operation of the image forming device 1. Details of the configuration of the control module 90 will be described later.

Here, the image forming device 1 employing the intermediate transfer method illustrated in FIG. 1 is suitable as an image forming device that transfers an image to a card K that has an uneven surface due to the incorporation of an IC that records electronic information. Also, the image forming device 1 employing the intermediate transfer method is suitable as an image forming device that transfers an image to a card K whose surface is coated with a hologram or the like.

<Configuration of Information Recording Unit>
The configuration of the information recording section A of the image forming apparatus 1 according to the embodiment of the present invention will be described in detail with reference to FIG.

The information recording unit A includes a feed roller 22, a non-contact IC recording unit 23, a magnetic recording unit 24, and sensors Se1, Se2, Se3, Se5, Se6, and Se7.

The carry-in rollers 22 are provided downstream of the paper feed opening 7 in the transport direction of the card K, and transport the card K transported from the paper feed cassette 3 through the picker opening 11 and the paper feed opening 7 into the reversal unit 20.

The non-contact IC recording unit 23 is provided on the third transport path P3 and records electronic information on an IC built into the card K transported by the reversing unit 20. The non-contact IC recording unit 23 transports the card K with electronic information recorded on the IC to the reversing unit 20.

The magnetic recording unit 24 is provided on the second transport path P2 and is composed of a read/write head. The magnetic recording unit 24 records magnetic information on the magnetic stripe of the card K transported by the reversing unit 20, and reads the recorded magnetic information to determine whether it is correct or not. The magnetic recording unit 24 transports the card K with the recorded magnetic information to the reversing unit 20.

In this way, the non-contact IC recording unit 23 and the magnetic recording unit 24 electrically or magnetically input data to the card K transported from the reversing unit 20.

Sensor Se1 operates under the control of control unit H to detect the transport of card K from media supply unit C to information recording unit A and output an electrical signal according to the detection result to control unit H.

Sensor Se2 operates under the control of control unit H to detect the transport of card K from the reversing unit 20 to the reject stacker 25 and output an electrical signal according to the detection result to control unit H.

Sensor Se3 operates under the control of control unit H to detect the transport of card K from reversing unit 20 to magnetic recording unit 24, or the transport of card K from magnetic recording unit 24 to reversing unit 20, and outputs an electrical signal according to the detection result to control unit H.

The sensor Se5 operates under the control of the control unit H to detect the transport of the card K from the reversing unit 20 to the media waiting unit E, or the transport of the card K from the media waiting unit E to the reversing unit 20, and outputs an electrical signal according to the detection result to the control unit H.

The sensor Se6 operates under the control of the control unit H. The sensor Se6 detects the transport of the card K from the reversing unit 20 to the non-contact IC recording unit 23, or the transport of the card K from the non-contact IC recording unit 23 to the reversing unit 20, and outputs an electrical signal according to the detection result to the control unit H.

Sensor Se7 operates under the control of control unit H to detect the transport of card K from reversing unit 20 to barcode reader 28 and output an electrical signal according to the detection result to control unit H.

<Configuration of Image Forming Unit>
The configuration of the image forming section D of the image forming apparatus 1 according to the embodiment of the present invention will be described in detail with reference to FIGS.

Image forming section D includes pinch roller 32a, pinch roller 32b, thermal head 40, ribbon cassette 42, image forming platen 45, transfer roller 49, and film cassette 50. Image forming section D also includes sensor Se10, sensor Se11, and cooling fan fn1.

Pinch roller 32a and pinch roller 32b are arranged on film transport path P4, and press the transfer film 46 against transport roller 49 to transport it along film transport path P4.

The thermal head 40 is disposed opposite the image forming platen 45 and is equipped with a heating element (not shown). The thermal head 40 heats the dye-sublimation ink ribbon 41 and the transfer film 46 with the heating element, which is selectively heated and controlled by the head control IC 74x (described later), to transfer an image onto the transfer film 46.

The ribbon cassette 42 is removably attached to the device housing 2. The ribbon cassette 42 has a rotatable supply spool 43 and a take-up spool 44, and contains a film-like ink ribbon 41 wound around the supply spool 43 and the take-up spool 44.

The winding spool 44 is connected to the wind motor Mr1 and rotates when the wind motor Mr1 is driven.

The image forming platen 45, which serves as a platen, can be moved by a push-out mechanism (not shown) between a position where it clamps the ink ribbon 41 and the transfer film 46 with the thermal head 40 and a position where it does not clamp them. When the image forming platen 45 is in a position where it clamps the ink ribbon 41 and the transfer film 46 together with the thermal head 40, it transfers an image onto the transfer film 46 using the ink ribbon 41.

When the ribbon cassette 42 is attached to the device housing 2, the ink ribbon 41 is inserted between the image forming platen 45 and the thermal head 40. Between the image forming platen 45 and the thermal head 40, a film transport path P4 is formed along which the ink ribbon 41 transported from the ribbon cassette 42 and the transfer film 46 transported from the film cassette 50 run.

The transfer roller 49 is disposed on the film transfer path P4 and is connected to a drive motor (not shown), which drives the transfer film 46 at a constant speed. When an image is formed on the transfer film 46, the transfer roller 49 rotates in the counterclockwise direction indicated by the dashed arrow in FIG. 2, and transports the transfer film 46 to the image transfer section B at the same speed as the ink ribbon 41.

The film cassette 50 is configured as a unit separate from the device housing 2, and is removably attached to the device housing 2. The film cassette 50 includes a take-up spool 47 and a supply spool 48, and contains the transfer film 46 wound around the take-up spool 47 and the supply spool 48.

The winding spool 47 is connected to the winding motor Mr2, which is a stepping motor, and rotates when the winding motor Mr2 is driven.

The supply spool 48 is connected to the payout motor Mr3, which is a stepping motor, and rotates when the payout motor Mr3 is driven.

The take-up motor Mr2 and the pay-out motor Mr3 are connected to the spool shaft via coupling means (not shown) attached to the device frame, and rotate in the same direction with the same feed amount.

The sensor Se10 operates under the control of the control unit H to detect the position of the ink ribbon 41 transported by driving the take-up spool 44, and outputs the detection result to the control unit H.

The sensor Se11 operates under the control of the control unit H to detect the position of the transfer film 46 transported by the drive of the take-up spool 47 and the supply spool 48, and outputs the detection result to the control unit H.

Cooling fan fn1 cools the thermal head 40.

<Configuration of the media standby section>
The configuration of the media standby unit E of the image forming apparatus 1 according to the embodiment of the present invention will be described in detail with reference to FIGS.

The media waiting section E includes a first roller pair 29, a second roller pair 30, and a sensor Se8.

The first roller pair 29 is connected to a transport motor (not shown) and is configured to be able to switch between forward and reverse rotation. The first roller pair 29 transports the card K transported from the inversion unit 20 to the second roller pair 30, or transports the card K transported from the second roller pair 30 to the inversion unit 20.

The second roller pair 30 is connected to a transport motor (not shown) and is configured to be able to switch between forward and reverse rotation. The second roller pair 30 rotates forward to transport the card K transported by the first roller pair 29 to the image transfer unit B, or rotates reversely to transport the card K transported from the image transfer unit B to the first roller pair 29.

The first roller pair 29 and the second roller pair 30 are arranged to have a distance Ld that is shorter than the length Lc of the card K in the transport direction, as shown in FIG. 2. The first roller pair 29 and the second roller pair 30 stop transporting the card K and temporarily wait while holding the card K when a transmission clutch (not shown) provided between them and the transport motor is turned OFF.

The transport mechanism for the card K in the media waiting section E is not limited to being composed of the first roller pair 29 and the second roller pair 30, but may also be a belt.

The sensor Se8 is disposed close to the second roller pair 30. The sensor Se8 operates under the control of the control unit H to detect the leading edge of the card K in the transport direction as it is transported from the first roller pair 29 to the second roller pair 30, and outputs the detection result indicating whether or not the card K is present in the media standby unit E to the control unit H.

<Configuration of the inversion unit>
The configuration of the reversing unit 20 of the image forming apparatus 1 according to the embodiment of the present invention will be described in detail with reference to FIG.

The reversing unit 20 includes a unit frame 18 and a plurality of roller pairs 21a and roller pairs 21b.

The unit frame 18 is supported by a bearing on a device frame (not shown) so that it can rotate, and is rotated by a rotation motor (not shown) such as a pulse motor, and deflects the card K in a predetermined direction while it is nipped by roller pair 21a and roller pair 21b. The unit frame 18 rotates at predetermined angles so that the nipped card K can be transported to the first transport path P1, the second transport path P2, the third transport path P3, the reject stacker 25, or the barcode reader 28.

The roller pair 21a and the roller pair 21b are arranged at a distance from each other and are axially supported so as to be freely rotatable on the unit frame 18. The roller pair 21a and the roller pair 21b are rotated in the forward direction by a transport motor (not shown) to transport the card K into the unit frame 18, or rotated in the reverse direction by the transport motor to transport the card K out of the unit frame 18.

The pivoting movement of the unit frame 18 and the rotation of the roller pairs 21a and 21b are not limited to being driven by different motors, but may be driven by a single pulse motor and switched by a clutch.

<Control module configuration>
The configuration of the control module 90 of the image forming apparatus 1 according to the embodiment of the present invention will be described in detail with reference to FIG.

The control module 90 includes a control unit H, a ROM 71, a RAM 72, an IC R/W control IC 73x, a magnetic R/W control IC 73y, and a head control IC 74x. The control module 90 also includes a reversing unit pivot motor control circuit 80, a first conveying path conveying motor control circuit 81, a second conveying path conveying motor control circuit 82, and a wind motor control circuit 83. The control module 90 also includes a winding motor control circuit 84, a payout motor control circuit 85, and a transfer roller drive motor control circuit 86.

The control unit H, which serves as a control means, controls the overall operation of the image forming device 1 by executing a control program stored in the ROM 71 and using the RAM 72.

Specifically, the control unit H controls the operation of the IC R/W control IC 73x, the magnetic R/W control IC 73y, the head control IC 74x, the reversing unit pivot motor control circuit 80, and the first transport path transport motor control circuit 81. The control unit H also controls the operation of the second transport path transport motor control circuit 82, the wind motor control circuit 83, the winding motor control circuit 84, the payout motor control circuit 85, and the transfer roller drive motor control circuit 86. The control unit H includes a CPU 70, a data input control unit 73, an image formation control unit 74, a film transport control unit 75, a sensor control unit 76, and a card transport control unit 77.

When the control unit H receives magnetic data, electronic data, or image data to be recorded on the card K from a higher-level device such as a host computer (not shown), it controls the transfer of an image and the recording of information on the card K according to the received magnetic data, electronic data, or image data. Specifically, the control unit H controls the recording of a combination of magnetic information and image information on the card K, the recording of a combination of electronic information and image information, or the recording of a combination of magnetic information, electronic information, and image information on the card K.

The CPU 70 executes a control program stored in the ROM 71, and controls the operation of the image forming device 1 while using the RAM 72. The CPU 70 executes the control program to control the operation of the data input control unit 73, the image forming control unit 74, the film transport control unit 75, the sensor control unit 76, and the card transport control unit 77 based on the detection results input from the sensor control unit 76.

The data input control unit 73 operates under the control of the CPU 70 and outputs a command signal that controls the transmission and reception of input data to the magnetic R/W control IC 73y. The data input control unit 73 operates under the control of the CPU 70 and outputs a command signal that controls the transmission and reception of input data to the IC R/W control IC 73x.

The image formation control unit 74 operates under the control of the CPU 70, outputs a control signal to the head control IC 74x to control the thermal head 40, and outputs a control signal to the wind motor control circuit 83 to control the transport of the ink ribbon 41.

The film transport control unit 75 operates under the control of the CPU 70 and outputs control signals to the winding motor control circuit 84, the payout motor control circuit 85, and the transport roller drive motor control circuit 86 to control the transport of the transfer film 46.

The sensor control unit 76 operates under the control of the CPU 70 and outputs the detection results input from the sensors Se1 to Se12 to the CPU 70 by controlling the operation of the sensors Se1 to Se12.

The card transport control unit 77 operates under the control of the CPU 70 and outputs control signals to the inversion unit pivot motor control circuit 80, the first transport path transport motor control circuit 81, and the second transport path transport motor control circuit 82 to perform drive control.

The ROM 71 stores the control program in advance.

RAM 72 functions as a work area for CPU 70.

The IC R/W control IC 73x is provided in the non-contact IC recording unit 23. The IC R/W control IC 73x records electronic information in the IC built into the card K based on a command signal that controls the transmission and reception of input data input from the data input control unit 73.

The magnetic R/W control IC 73y is provided in the magnetic recording unit 24. The magnetic R/W control IC 73y records magnetic information on the magnetic stripe of the card K based on a command signal that controls the transmission and reception of input data input from the data input control unit 73.

The head control IC 74x applies pulses to the thermal head 40 based on a control signal input from the image formation control unit 74 to control the heating of the thermal head 40.

The reversing unit rotation motor control circuit 80 controls the drive of the rotation motor (not shown) to rotate the reversing unit 20 based on a control signal input from the card transport control unit 77.

The first transport path transport motor control circuit 81 transports the card K along the first transport path P1 by controlling the drive of the transport motor (not shown) to drive the first roller pair 29 and the second roller pair 30 based on a control signal input from the card transport control unit 77.

The second transport path transport motor control circuit 82 transports the card K along the second transport path P2 by controlling the drive of the transport motor (not shown) and driving the roller pair 21a and the roller pair 21b based on a control signal input from the card transport control unit 77.

The wind motor control circuit 83 controls the drive of the wind motor Mr1 to transport the ink ribbon 41 based on a control signal input from the image formation control unit 74.

The winding motor control circuit 84 controls the drive of the winding motor Mr2 to unwind or wind the transfer film 46 based on a control signal input from the film transport control unit 75.

The payout motor control circuit 85 controls the drive of the payout motor Mr3 based on a control signal input from the film transport control unit 75 to pay out or wind up the transfer film 46.

The transport roller drive motor control circuit 86 controls the drive of the transport roller 49 to transport the transfer film 46 based on a control signal input from the film transport control unit 75.

<Configuration of Ink Ribbon>
The configuration of the ink ribbon 41 used in the image forming apparatus 1 according to the embodiment of the present invention will be described in detail with reference to FIG.

In Figure 4, Figure 4(a) shows the configuration of the ink ribbon 41, and Figure 4(b) shows an example of a card K onto which an image has been transferred from a transfer film 46.

The ink ribbon 41 is a dye-sublimation ribbon. In the ink ribbon 41, ink panels Q1, Q2, Q3, and Q4 for Y (yellow), M (magenta), C (cyan), and B (black) are arranged in a band shape in face sequence.

Here, ink panels Q1 to Q3 are color ink panels and are formed from dye ink. Ink panel Q4 is a black ink panel and is formed from pigment ink. Ink panel Q3 is the final color ink panel adjacent to ink panel Q4 on the downstream side in the transport direction of the ink ribbon 41. Note that ink panels Q1 to Q3 may be formed from inks other than dye ink, and ink panel Q4 may be formed from inks other than pigment ink.

The width L of the B (black) ink panel Q4 in the sub-scanning direction (left-right direction in FIG. 4A) parallel to the transport direction of the ink ribbon 41 has a predetermined width corresponding to the printing width of the transfer film 46. The width A as the first width in the transport direction of the ink ribbon 41 of the Y (yellow), M (magenta) and C (cyan) ink panels Q1, Q2, Q3 is shorter than the width L of the ink panel Q4 (L>A). Specifically, the width A of the ink panels Q1, Q2, Q3 is 50% to 70% of the width L of the ink panel Q4.

This type of ink ribbon 41 is used when transferring an image onto a card K, such as a driver's license or membership card, which has a small area for recording in color, such as a face photograph, as shown in Figure 4(b), as an example of the card K.

<Operation of Image Forming Unit>
The operation of the image forming section D of the image forming apparatus 1 according to the embodiment of the present invention will now be described in detail.

First, the transfer film 46 is taken out from the take-up spool 47, and is transported to the start position for image transfer by the transport roller 49 rotating clockwise in FIG. 2. The ink ribbon 41 is transported to the start position for image transfer by the take-up spool 44 rotating counterclockwise in FIG. 2. At this time, the transport directions of the transfer film 46 and the ink ribbon 41 are opposite to each other.

The transfer film 46 may be transported upstream of the thermal head 40 in the transport direction of the transfer film 46 during transfer, and then transported in the same direction as the transport direction of the ink ribbon 41 to the cue position. This reduces the effect of backlash from the drive motor transporting the transfer film 46 when starting transfer after transport to the cue position.

Next, the image forming platen 45 is moved toward the thermal head 40 by a push-out mechanism (not shown) and comes into contact with the thermal head 40 with the transfer film 46 and the ink ribbon 41 sandwiched between them, as shown in FIG. 2.

The take-up spool 44 then rotates in synchronization with the thermal control of the thermal head 40, winding up the ink ribbon 41 at a predetermined speed. The transport roller 49 also rotates counterclockwise in FIG. 2, transporting the transfer film 46 in the same direction as the ink ribbon 41 by an amount corresponding to the printing width of one card K. As a result, an image is transferred and formed on the transfer film 46.

When the image transfer by one ink panel is completed, the transfer roller 49 rotates again in the clockwise direction in FIG. 2, and pulls the transfer film 46 back to the leading edge position by an amount corresponding to the printing width of one card. In addition, the ink ribbon 41 is transported in the winding direction, so that the next ink panel is aligned with the transfer film 46 at the leading edge position.

This kind of head-on control involves sequentially aligning the Y (yellow), M (magenta), C (cyan) and B (black) ink panels with the transfer film 46 at the head-on position. After this alignment, the image forming unit D repeats heat transfer using the thermal head 40 and image forming platen 45 to transfer images such as face photos and text to be printed on the front and back sides of the card K to the transfer film 46 using the ink ribbon 41.

In the image forming unit D, in order to shorten the total time required to transport the ink ribbon 41 for the leading edge, an operation is performed to omit the leading edge operation that is performed before transfer using the ink panel Q4, depending on the relationship between the printing positions of the ink panels Q3 and Q4. The details of this operation will be described later.

<Image Formation Processing>
The image forming process according to the embodiment of the present invention will be described in detail with reference to FIG.

The image formation process shown in FIG. 5 begins when the main power supply of the image forming device 1 is turned on.

First, the control unit H removes the transfer film 46 from the supply spool 48 and rotates the transfer roller 49 counterclockwise in FIG. 2 to perform a film initialization process to transport the transfer film 46 to the cue position (S1).

Next, the control unit H executes an ink ribbon initialization process in which the take-up spool 44 transports the ink ribbon 41 to the start position for image transfer (S2).

Next, the control unit H determines whether or not a job start signal has been received (S3).

If the control unit H has not received a job start signal (S3: No), it repeats the process of step S3.

On the other hand, when the control unit H receives a job start signal (S3: Yes), it supplies the card K by transporting the card K from the media supply unit C to the reversal unit 20 (S4).

Next, the control unit H controls the reversing unit rotation motor control circuit 80 to rotate the reversing unit 20 based on the detection result input from the sensor Se1 that detects the leading edge of the card K in the transport direction. As a result, the card K is transported to the first transport path P1, the second transport path P2, or the third transport path P3.

The control unit H also controls the take-up motor Mr2 and the pay-out motor Mr3 based on the detection result of the pay-out amount of the transfer film 46 input from the sensor Se9 to transport the transfer film 46 to the image forming unit D. Here, the transfer film 46 is marked for each frame of a predetermined width that corresponds to the printing width of the area where an image is formed on the card K. Therefore, the control unit H controls the pay-out amount of the transfer film 46 based on the detection result of the sensor Se9 that detects these marks.

Next, the CPU 70 of the control unit H transfers the magnetic data or electronic data to be recorded on the card K received from a higher-level device (not shown) to the data input control unit 73. The CPU 70 also transfers the image data received from the higher-level device to the image formation control unit 74 (S5). Note that since the processing time of step S5 differs depending on the data volume or the status of the transfer means, other processing carried out in parallel with the processing of step S5 may precede the processing of step S5.

Next, when the control unit H has finished transporting the card K to the information recording unit A, it records magnetic information on the card K using the magnetic R/W control IC 73y based on the magnetic data, or records electronic information on the card K using the IC R/W control IC 73x based on the electronic data. When the control unit H finds an error in the recorded magnetic information or electronic information, it drives the reversing unit 20 to rotate using the reversing unit rotation motor control circuit 80, and ejects the card K to the reject stacker 25. Then, the control unit H controls the transport of a new card K from the media supply unit C to the reversing unit 20.

Next, the control unit H controls the head control IC 74x to set the head temperature of the thermal head 40 to an appropriate value. The control unit H cools the thermal head 40 when the head temperature is excessively high relative to the appropriate value, and controls the thermal head 40 to heat up when the head temperature is excessively low relative to the appropriate value. Since cooling takes time when the head temperature is excessively high relative to the appropriate value, the control unit H controls the winding motor control circuit 84, the unwinding motor control circuit 85, and the transport roller drive motor control circuit 86 to keep the transfer film 46 on standby until the head temperature reaches the appropriate value.

Next, when the head temperature is set to the appropriate value, the control unit H executes a primary transfer process in which the ink ribbon 41 is used to transfer an image onto the transfer film 46 (S6). Details of the primary transfer process will be described later.

Next, the control unit H determines whether the primary transfer process has been completed (S7).

If the primary transfer process has not been completed (S7: No), the control unit H repeats the process of step S7.

On the other hand, when the primary transfer process is completed (S7: Yes), the control unit H moves the transfer film 46 to the film standby unit F based on the detection result input from the sensor Se9. Specifically, the control unit H controls the winding motor control circuit 84, the payout motor control circuit 85, and the transport roller drive motor control circuit 86 to drive and control the winding motor Mr2 and the payout motor Mr3 to move the transfer film 46 to the film standby unit F. The control unit H also controls the first transport path transport motor control circuit 81 to drive and control the first roller pair 29 and the second roller pair 30 to move the card K to the media standby unit E.

The leading edge of the card K in the transport direction while it is waiting in the media waiting section E is upstream of the heating roller 33 in the transport direction, so it is not heated by the heating roller 33. This eliminates the risk of unevenness in the image transferred to the card K.

In addition, in the image forming device 1, a media waiting section E is disposed in the first transport path P1 between the reversal unit 20 and the image transfer section B. This allows separate control of a job for recording magnetic information in the second transport path P2 and a job for recording electronic information in the third transport path P3, and a job for forming an image in the first transport path P1.

Next, the control unit H judges whether the temperature of the heating roller 33 is at an appropriate value. At this time, if the card K has not reached the media standby unit E, if the transfer film 46 has not reached the film standby unit F, or if the temperature of the heating roller 33 is not at an appropriate value, the control unit H waits until each of the conditions is met.

Next, when the temperature of the heating roller 33 reaches an appropriate value, the control unit H transports the card K from the media standby unit E toward the image transfer unit B, and transports the transfer film 46 from the film standby unit F toward the image transfer unit B.

At this time, the card K waits in the media waiting section E, and the transfer film 46 waits in the film waiting section F, so that the transfer film 46 and the card K can reach the image transfer section B from the waiting position simultaneously and at the same speed. Therefore, it is possible to reduce the positional misalignment between the transfer film 46 and the card K.

Next, when the card K and the transfer film 46 reach the transfer platen 31, the control unit H raises the heating roller 33, which is in a standby position separated from the transfer platen 31, to a position where it is in pressure contact with the transfer platen 31.

Next, the control unit H simultaneously transports the card K and the transfer film 46, and heats and presses the image transferred to the transfer film 46 onto the card K to perform the secondary transfer process (S8).

Next, the control unit H ejects the card K to the storage stacker 60 (S9). The control unit H then controls the winding motor control circuit 84 and the payout motor control circuit 85 to control the driving of the winding motor Mr2 and the payout motor Mr3, thereby winding up the transfer film 46 by the winding spool 47.

<Primary Transfer Processing>
The primary transfer process according to the embodiment of the present invention will be described in detail with reference to FIGS.

The primary transfer process shown in Figures 6 and 7 begins when step S5 in the image formation process shown in Figure 5 is completed.

First, the control unit H clears the operation reduction flag stored in the RAM 72, for example to "0" (S21).

Next, based on image data received from a higher-level device (not shown), the control unit H sets the transfer start positions of the ink panels Q1 to Q4 of each color to be the same as the transfer start positions during full-surface transfer, in which the transfer process is performed on the entire surface of the transfer film 46. In addition, based on the image data received from the higher-level device, the control unit H sets the transfer end positions of the ink panels Q1 to Q4 of each color according to the transfer image size (S22).

Next, the control unit H acquires the width L of the transfer film 46 as the third width (see Figures 8 and 9) (S23). The width L of the transfer film 46 is stored in advance, for example, in the ROM 71. Here, the width L of the transfer film 46 is the width of the area to be transferred onto one card K, and is the same width as the width parallel to the transport direction of the ink panel Q4.

Next, the control unit H obtains the width A (see Figures 8 and 9) of the ink panel Q3 of C (cyan) as the final ink panel (S24). The width A of the ink panel Q3 is stored in advance in, for example, the ROM 71.

Next, based on the image data received from the higher-level device, the control unit H sets the transfer start position of each color ink panel Q1 to Q4 so that the entire transferred image falls within each color ink panel Q1 to Q4. The control unit H then obtains the transfer start position of the B (black) ink panel Q4 on the transfer film 46 (S25).

Next, the control unit H obtains the transfer image size S by the ink panel Q4 based on the image data received from the higher-level device (S26).

Next, the control unit H determines whether the width b from the cue position of the ink panel Q3 to the transfer start position of the ink panel Q4 is greater than the width A of the ink panel Q3, and whether the width b plus the transfer image size S (fourth width) is included within the width L of the transfer film 46 (S27).

That is, by making the former judgment in step S27, the control unit H judges whether the transfer start position of the ink panel Q4 is upstream of the width A of the ink panel Q3 in the transport direction of the transfer film 46. Also, by making the latter judgment in step S27, the control unit H judges whether the transfer area from the transfer start position to the transfer end position of the ink panel Q4 is included within the width L. In this way, the control unit H judges whether the cueing can be omitted based on the width L of the transfer film 46, the width A of the ink panel Q3, the transfer start position of the ink panel Q4, and the transfer image size S of the ink panel Q4.

As shown in FIG. 8(a), when width b is greater than width A and the sum of width b and transfer image size S is included within width L (S27: Yes), control unit H determines that the start of the transfer can be omitted. Then, control unit H sets the transfer start position of ink panel Q4 to the upstream side in the transport direction of transfer film 46 by width b from the start of the transfer position of ink panel Q3 (S28).

Next, the control unit H sets the operation reduction flag to "1" and stores it in the RAM 72 (S29).

Next, the control unit H controls the head control IC 74x to switch the thermal head 40 to dye ink and control the heating (S30). In this heating control, the head control IC 74x applies to the thermal head 40 a pulse whose applied energy is changed in stages according to the density of the pixel to be transferred in order to perform a multi-tone transfer process on the transfer film 46.

On the other hand, if width b is equal to or smaller than width A as shown in FIG. 9A, or if the sum of width b and transfer image size S is not included within width L (S27: No), control unit H determines that the start-up cannot be omitted and skips to step S30. As a result, the operation reduction flag is cleared.

Next, the control unit H executes a Y ink head-up process to head the Y (yellow) ink panel Q1 (S31). Specifically, the control unit H controls the wind motor control circuit 83 to control the driving of the wind motor Mr1, rotates the take-up spool 44 counterclockwise in FIG. 2, and transports the ink ribbon 41 to the head-up position of the ink panel Q1.

Next, the control unit H controls the driving of the take-up motor Mr2 and the pay-out motor Mr3 to remove the transfer film 46 from the supply spool 48, and transports the transfer film 46 to the cue position by rotating the transport roller 49 counterclockwise in FIG. 2 (S32). As a result, as shown in FIG. 8(a) and FIG. 9(a), the transfer start position of the transfer film 46 and the transfer start position of the ink panel Q1 are aligned at the cue position.

Next, the control unit H moves the image forming platen 45 so that the ink ribbon 41 and the transfer film 46 are nipped between the image forming platen 45 and the thermal head 40 (S33).

Next, the control unit H starts the primary transfer by the ink panel Q1 (S34).

Next, the control unit H determines whether the primary transfer by the ink panel Q1 has been completed (S35).

If primary transfer by ink panel Q1 has not been completed (S35: No), control unit H repeats the process of step S35.

On the other hand, as shown in Figures 8(b) and 9(b), when the primary transfer by the ink panel Q1 is completed (S35: Yes), the control unit H moves the image forming platen 45 in a direction away from the thermal head 40 (S36).

Next, the control unit H executes an M ink head-up process to head the M (magenta) ink panel Q2 (S37). Specifically, the control unit H controls the drive of the wind motor Mr1 to rotate the take-up spool 44 counterclockwise in FIG. 2, and transports the ink ribbon 41 to the head-up position for image transfer on the ink panel Q2.

Next, the control unit H controls the driving of the winding motor Mr2 and the unwinding motor Mr3 to rewind the transfer film 46, and rotates the transport roller 49 clockwise in FIG. 2 to transport the transfer film 46 to the cue position (S38). As a result, as shown in FIG. 8(c) and FIG. 9(c), the transfer start position of the transfer film 46 and the transfer start position of the ink panel Q2 of the ink ribbon 41 are aligned at the cue position.

Next, the control unit H moves the image forming platen 45 so that the ink ribbon 41 and the transfer film 46 are nipped between the image forming platen 45 and the thermal head 40 (S39).

Next, the control unit H starts the primary transfer by the ink panel Q2 (S40).

Next, the control unit H determines whether the primary transfer by the ink panel Q2 has been completed (S41).

If primary transfer by ink panel Q2 has not been completed (S41: No), control unit H repeats the process of step S41.

On the other hand, as shown in Figures 8(d) and 9(d), when the primary transfer by the ink panel Q2 is completed (S41: Yes), the control unit H moves the image forming platen 45 in a direction away from the thermal head 40 (S42).

Next, the control unit H determines whether the operation reduction flag stored in the RAM 72 is "1" (S43).

When the operation reduction flag is "1" (S43: Yes), the control unit H executes a C ink cueing process to cue the C (cyan) ink panel Q3 (S44). Specifically, the control unit H controls the driving of the wind motor Mr1 to rotate the take-up spool 44 counterclockwise in FIG. 2, and transports the ink ribbon 41 to the cueing position for image transfer on the ink panel Q3.

Next, the control unit H controls the driving of the winding motor Mr2 and the unwinding motor Mr3 to rewind the transfer film 46, and rotates the transport roller 49 clockwise in FIG. 2 to transport the transfer film 46 to the cue position (S45). As a result, as shown in FIG. 8(e), the transfer start position of the transfer film 46 and the transfer start position of the ink panel Q3 of the ink ribbon 41 are aligned at the cue position.

Next, the control unit H moves the image forming platen 45 so that the ink ribbon 41 and the transfer film 46 are nipped between the image forming platen 45 and the thermal head 40 (S46).

Next, the control unit H starts the primary transfer by the ink panel Q3 (S47).

Next, the control unit H determines whether the primary transfer by the ink panel Q3 has been completed (S48).

If primary transfer by ink panel Q3 has not been completed (S48: No), control unit H repeats the process of step S48.

On the other hand, as shown in FIG. 8(f), when the primary transfer by ink panel Q3 is completed (S48: Yes), the control unit H controls the head control IC 74x to switch the thermal head 40 to pigment ink and control the heating (S49). In this heating control, the head control IC 74x controls whether or not to apply a pulse to the thermal head 40 in order to perform a two-level black and white transfer process. In this way, the control unit H controls the thermal head 40 to perform different heat treatments for the ink panels Q1 to Q3 formed with dye ink and the ink panel Q4 formed with pigment ink.

Then, because the ink panel Q4 is in a position where transfer is possible, the control unit H performs primary transfer using the ink panel Q4 without cueing the transfer film 46 and the ink panel Q4. This allows primary transfer using the ink panel Q4 to be performed immediately after primary transfer using the ink panel Q3 without a cueing operation, thereby shortening the printing time.

Next, the controller H determines whether the primary transfer by the ink panel Q4 has been completed (S50).

If primary transfer by ink panel Q4 has not been completed (S50: No), control unit H repeats the process of step S50.

On the other hand, as shown in FIG. 8(g), when the primary transfer by the ink panel Q3 is completed (S50: Yes), the control unit H moves the image forming platen 45 away from the thermal head 40 (S51) to complete the primary transfer process.

If the operation reduction flag is not "1" (S43: No), the control unit H executes a C ink cueing process to cue the C (cyan) ink panel Q3 (S52). Specifically, the control unit H controls the driving of the wind motor Mr1 to rotate the take-up spool 44 counterclockwise in FIG. 2, and transports the ink ribbon 41 to the cueing position for image transfer on the ink panel Q3.

Next, the control unit H controls the driving of the winding motor Mr2 and the unwinding motor Mr3 to rewind the transfer film 46, and rotates the transport roller 49 clockwise in FIG. 2 to transport the transfer film 46 to the cue position (S53). As a result, as shown in FIG. 9(e), the transfer start position of the transfer film 46 and the transfer start position of the ink panel Q3 of the ink ribbon 41 are aligned at the cue position.

Next, the control unit H moves the image forming platen 45 so that the ink ribbon 41 and the transfer film 46 are nipped between the image forming platen 45 and the thermal head 40 (S54).

Next, the control unit H starts the primary transfer by the ink panel Q3 (S55).

Next, the control unit H determines whether the primary transfer by the ink panel Q3 has been completed (S56).

If primary transfer by ink panel Q3 has not been completed (S56: No), control unit H repeats the process of step S56.

On the other hand, as shown in FIG. 9(f), when the primary transfer by the ink panel Q3 is completed (S56: Yes), the control unit H moves the image forming platen 45 in a direction away from the thermal head 40 (S57).

Next, the control unit H executes a B ink cueing process to cue the B (black) ink panel Q4 (S58). Specifically, the control unit H controls the driving of the wind motor Mr1 to rotate the take-up spool 44 counterclockwise in FIG. 2, and transports the ink ribbon 41 to the cueing position for image transfer on the ink panel Q4.

Next, the control unit H controls the driving of the winding motor Mr2 and the unwinding motor Mr3 to rewind the transfer film 46, and rotates the transport roller 49 clockwise in FIG. 2 to transport the transfer film 46 to the cue position (S59). As a result, as shown in FIG. 9(g), the transfer start position of the transfer film 46 and the transfer start position of the ink panel Q4 of the ink ribbon 41 are aligned at the cue position.

Next, the control unit H moves the image forming platen 45 so that the ink ribbon 41 and the transfer film 46 are nipped by the image forming platen 45 and the thermal head 40 (S60).

Next, the control unit H starts the primary transfer by the ink panel Q4 (S61).

Next, the control unit H determines whether the primary transfer by the ink panel Q4 has been completed (S62).

If primary transfer by ink panel Q4 has not been completed (S62: No), control unit H repeats the process of step S62.

On the other hand, as shown in FIG. 9(h), when the primary transfer by the ink panel Q4 is completed (S62: Yes), the control unit H moves the image forming platen 45 away from the thermal head 40 (S63) to complete the primary transfer process.

In this way, the control unit H transfers the four colors Y (yellow), M (magenta), C (cyan) and B (black) onto the transfer surface of the transfer film 46 in the above order.

In this embodiment, when the primary transfer using ink panel Q3 is completed, if ink panel Q4 is in a position where the primary transfer can be performed, the primary transfer is controlled to be performed by ink panel Q4 without performing cueing. This makes it possible to improve productivity even when using a special ink ribbon.

The present invention is not limited to the above-described embodiment, and it goes without saying that various modifications are possible without departing from the spirit of the invention.

Specifically, in the above embodiment, an intermediate transfer type image forming device 1 using a transfer film 46 is shown, but the present invention can also be applied to a direct type image forming device that transfers directly onto a recording medium such as a card K as a transfer medium.

In addition, in the above embodiment, the ink panels of the ink ribbon are arranged in the order of yellow, magenta, cyan and black, but the order of the ink panels can be changed as appropriate, and multiple black panels may be provided. The ink ribbon may also be combined with a heat seal panel, peel-off panel, UV panel, overcoat panel, or the like. In the above embodiment, panels that do not contain these inks are also included in the ink panels.

A Information recording section B Image transfer section C Media supply section D Image forming section E Media standby section F Film standby section H Control section K Card Mr1 Wind motor Mr2 Take-up motor Mr3 Pay-out motor Q1 Ink panel Q2 Ink panel Q3 Ink panel Q4 Ink panel 1 Image forming device 20 Reversing unit 40 Thermal head 41 Ink ribbon 42 Ribbon cassette 43 Supply spool 44 Take-up spool 45 Image forming platen 46 Transfer film 47 Supply spool 48 Take-up spool 49 Transport roller 50 Film cassette 70 CPU
74x Head control IC
83 Wind motor control circuit 84 Winding motor control circuit 85 Feed-out motor control circuit 90 Control module

Claims (1)

1. An image forming apparatus that transfers an image onto a transfer medium using an ink ribbon in which a black ink panel having a predetermined width in a sub-scanning direction and a color ink panel having a first width that is smaller than the predetermined width in the sub-scanning direction are arranged in a frame sequential manner,
an image forming means for performing a cueing operation for the ink ribbon and the transfer medium and for transferring an image onto the transfer medium using the ink ribbon;
a control means for controlling the transfer to be performed by the black ink panel without performing the cueing when the black ink panel is in a position where the transfer can be performed when the transfer using a final color ink panel, which is the color ink panel adjacent to the black ink panel on the downstream side in the transport direction of the ink ribbon, is completed;
An image forming apparatus comprising:

Images