The present invention refers to an embossed printing system, in particular for the embossed printing of plastic cards or embosser, for example of the type used for printing plastic cards, such as credit cards, identity cards and the like.

Embossed printing systems or embossers are known in the art, and comprise punches and matrixes for the embossed printing of characters associated with respective drums and arranged on their perimeter, which are controlled by a cam mechanism driven by solenoids or electric motors.

These systems comprise punches and matrixes made through coining or electro-erosion; the outlines of the characters to be printed are obtained on faces of the punches and of the matrixes and must be made with a good accuracy to obtain a good quality printing both as regards the height of printed characters and their uniformity.

These embossed printing systems or embossers however are not satisfactory and have the following problems: the systems comprising punches and matrixes made through coining, though being inexpensive da make, have a scarce accuracy for making the outline of the character to be printed.

The systems comprising punches and matrixes made through electro-erosion instead, though allowing to make characters made with high accuracy, which allow obtaining an optimum quality of the printed characters, have a high production cost .

Object of the present invention is solving the above prior art problem, by providing a system for the embossed printing of plastic cards comprising punches and matrixes having a small cost, which allow making, on the punches and on the matrixes, characters having outlines made with a high definition to obtain a good quality printing as regards both the height of the printed characters and their uniformity.

The above and other objects and advantages of the invention, as will appear from the following description, are obtained with a system for the embossed printing of plastic cards as claimed in the independent claim. Preferred embodiments and non-trivial variations of the present invention are the subject matter of the dependent claims.

It is intended that all enclosed claims are an integral part of the present description.

The present invention will be better described by some preferred embodiments thereof, provided as a non-limiting example, with reference to the enclosed drawings, in which:

- Figure 1 is a sectional view of an embodiment of an embossed printing system according to the present invention;

- Figure 2 is a side view of the embossed printing system according to the present invention;

- Figure 3 is a perspective view of a part of the embossed printing system according to the present invention;

- Figure 4 is a sectional view of a part of an actuating and regulating device for the printing system of Figure 3; and

- Figure 5 is a sectional view of a punch and of a matrix of the actuating and regulating device for an embossed printing system according to the present invention.

With reference to the Figures, a preferred embodiment of the embossed printing system of the present invention is shown and described. It will be immediately obvious that numerous variations and modifications (for example related to shape, sizes, arrangements and parts with equivalent functionality) could be made to what is described without departing from the scope of the invention as appears from the enclosed claims.

With reference to the Figures, the embossed printing system 10 of the invention comprises a first punch 11 associated with a first drum 12 rotatable around a vertical axis X-X, a second punch or matrix 21 associated with a second drum 22 rotatable around the vertical axis X-X, a punch regulating assembly 15, 45 associated with at least one between the first punch 11 and the second punch 21 and adapted to regulate its position in a direction Xl-Xl perpendicular to a printing plane 31 of a plastic card 32 to be printed, and a punch actuating assembly 25, 55 associated with at least one between the first punch 11 and the second punch 21 and adapted to actuate it when printing.

The first drum 12 and the second drum 22 are assembled, for example keyed-in, on a shaft 20 with vertical axis X-X and have respective seats 14, 24 in which the first punch 11 and the second punch 21 are sliding assembled, free of moving along a direction parallel to the vertical axis X-X direction; in particular, the first drum 12 and the second drum 22 have a plurality of seats 14, 24, in which a plurality of first punches 11 and of second punches 21 can respectively be inserted; every first punch 11 has a character 35 to be printed made as embossed, and the second corresponding punch 21 has a character 35' to be printed made as etched; embodiments are further provided wherein the character 35 is made embossed on the second punch 21 and the first corresponding punch 11 has a character 35' made as etched, or only one of the due punches 11, 21 has a character made as embossed.

Preferably, the first punches 11 and the second punches 21 are made through molding, preferably through metal die-casting, for example with an alloy known as Zama or Zamak, or through thermo-injection molding, for example with a glass- charged resin; the characters 35, 35' are made, always during the molding operation, on an end of the punches 11, 21, while the opposite end has an arm 36 adapted to make an abutment for the punch 11, 21 in its seat 14, 24; the arm 36 is further adapted to make an abutment for an elastic element adapted to exert a detachment force of the punch 11, 21 at the end of the embossing or printing operation; alternatively, the first punches 11 and the second punches 21, and their related characters 35, 35' are made through sintering.

In a first embodiment of the embossed printing system 10 of the invention, shown in Figures 1 and 2, the punch regulating assembly 15 is associated with the first punch 11 and is adapted to regulate its position along a direction Xl-Xl perpendicular to the printing plane 31 of a plastic card 32 to be printed, and the punch actuating assembly 25 is associated with the second punch 21 and is adapted to actuate it when printing.

The punch regulating assembly 15 comprises a positioning cam 16 rotatable around a first positioning axis Y-Y, which is transverse, preferably perpendicular, to the vertical axis X-X and associated with the first punch 11 to regulate its position along a direction Xl-Xl perpendicular to the printing plane 31 of a plastic card 32 to be printed; the punch regulating assembly 15 comprises first actuating means, preferably a stepped electric motor, connected to the positioning cam 16 and adapted to rotate it around the first positioning axis Y-Y.

The outline of the positioning cam 16 is variable in such a way as to allow regulating the position of the first punch 11 associated therewith, rotating the positioning cam 16 around the first positioning axis Y-Y, thereby obtaining an approach or an away movement of the first punch 11 from the printing plane 31 along a direction XI- XI perpendicular thereto.

Preferably, the punch regulating assembly 15 further comprises a first lever 18 and a first intermediate element 19 associated with the positioning cam 16 and with the first punch 11 to transmit the motion from the positioning cam 16 to the first punch 11, transforming the rotary motion of the positioning cam 16 into a translation motion of the first punch 11.

In particular, the first lever 18 is assembled rotatable around a second positioning axis Yl-Yl, which is transverse, preferably perpendicular, to the vertical axis X-X; the first lever 18 has a first end in contact with the positioning cam 16 and a second end in contact with the first intermediate element 19, which in turn is abutted onto the first punch 11 and is assembled sliding along a direction parallel to axis X-X, to transmit the motion from the positioning cam 16 to the first punch 11.

The punch actuating assembly 25 comprises an actuating cam 26 rotatable around a first actuating axis Y'-Y', which is transverse, preferably perpendicular, to the vertical axis X-X and associated with the second punch 21 to arrange the actuating cam 26 in a rest position wherein the second punch 21 is far from the printing plane 31, and in a printing position wherein the second punch 21 is near the printing plane 31; the punch actuating assembly 25 comprises second actuating means, preferably an electric motor with direct current power, connected to the actuating cam 26 and adapted to rotate it around the first actuating axis Y' -Y' .

The actuating cam 26 has two plane faces 38, preferably mutually parallel, which are connected by two, preferably semi-cylindrical faces 39; the plane faces 38 extend on a plane which is transverse, preferably perpendicular, to the first actuating axis Y'-Y' and allow arranging the actuating cam 26 in the rest position wherein the actuating cam 26 is in contact with one of the two plane faces 38 and the second punch 21 is far from the printing plane 31, and in the printing position wherein the actuating cam 26 is in contact with one of the two faces 39 and the second punch 21 is near the printing plane 31.

Preferably, the punch actuating assembly 25 further comprises a second lever 28 and a second intermediate element 29 associated with the actuating cam 26 and with the second punch 21, to transmit motion from the actuating cam 26 to the second punch 21, transforming the rotary motion of the actuating cam 26 into a translation motion of the second punch 21.

In particular, the second lever 28 is assembled rotatable around a second actuating axis Yl'-Yl', which is transverse, preferably perpendicular, to the vertical axis X-X; the second lever 28 has a first end in contact with the actuating cam 26 and a second end in contact with the second intermediate element 29, which in turn is abutted onto the second punch 21 and is assembled sliding along a direction parallel to axis X-X, to transmit motion from the actuating cam 26 to the second punch 21.

Preferably, axes Y-Y and Y'-Y' are perpendicular to a plane passing through the vertical axis X-X and are mutually parallel.

In a second embodiment of the embossed printing system 10 of plastic cards of the invention, shown in Figures 3 and 4, the punch regulating assembly 45 is associated with the second punch 21 and is adapted to regulate its position along a direction Xl-Xl perpendicular to the printing plane 31, and the punch actuating assembly 55 is associated with the first punch 11 and with the second punch 21 and is adapted to actuate them when printing.

The punch regulating assembly 45 comprises first actuating means, preferably composed of a stepped electric motor 58, connected to a second lever 48 through connecting means 60, composed for example of a connecting shaft 60, to rotate the first actuating means 58 integrally with the second lever 48 around a second actuating axis Yl'-Yl', which is transverse, preferably perpendicular, to the vertical axis X-X.

Preferably, the punch regulating assembly 45 comprises a second intermediate element 29 and a bearing plane 49 of the second intermediate element 29, composed for example of a chute 49 connected by means of a connecting rod to the electric motor 58; the second lever 48, the bearing plane 49 and the second intermediate element 29 are associated with the second punch 21 to transmit motion from the first actuating means 58 to the second punch 21, transforming their rotary motion into a translation motion of the bearing plane 49, of the second intermediate element 29 and of the second punch 21, thereby obtaining and approach or an away-movement of the second punch 21 from the printing plane 31.

In particular, the second lever 48 is assembled rotatable around the second actuating axis Yl'-Yl', which is transverse, preferably perpendicular, to the vertical axis X-X; the second lever 48 has a first end in contact with an actuating cam 46 and a second end in contact with the second intermediate element 29, which in turn is abutted onto the second punch 21 and is assembled sliding along a direction parallel to axis X-X, to transmit motion from the actuating cam 46 to the second punch 21.

The connecting rod of the electric motor 58 to the chute 49 is adapted to keep constant the distance of the second intermediate element 29 and of the second punch 21 from the second lever 48 when the second lever 48 rotates around axis Yl ' - Yl' .

In the second embodiment of the system 10 of the invention, the punch actuating assembly 55 comprises the actuating cam 46 rotatable around an actuating axis Y'-Y', which is transverse, preferably perpendicular, to the vertical axis X-X and associated with the second punch 21 to arrange the actuating cam 46 in a rest position wherein the second punch 21 is far from the printing plane 31, and in a printing position wherein the second punch 21 is near the printing plane 31; the punch actuating assembly 55 comprises second actuating means, preferably an electric motor with direct current power, connected to the actuating cam 46 and adapted to rotate it around the first actuating axis Y'-Y'; alternatively, an eccentric can be used instead of the actuating cam 46.

The outline of the actuating cam 46 or of the eccentric is variable in such a way as to allow arranging the actuating cam 46 or the eccentric in the rest position wherein the second punch 21 is far from the printing plane 31, and in the printing position wherein the second punch 21 is near the printing plane 31.

In particular, the punch actuating assembly 55, through the second lever 48 and the second intermediate element 29 associated with the actuating cam 46, or the eccentric, and with the second punch 21, is adapted to transmit motion from the actuating cam 46 to the second punch 21, transforming the rotary motion of the actuating cam 46 into a translation motion of the second punch 21.

In the second embodiment of the system 10 of the invention, the punch actuating assembly 55 further comprises a first lever and a first intermediate element, not shown in the Figures, also associated with the actuating cam 46, or the eccentric, and with the first punch 11, to transmit motion from the actuating cam 46 to the first punch 11, transforming the rotary motion of the actuating cam 46 or of the eccentric into a translation motion of the first punch 11.

In particular, the first lever is assembled rotatable around an actuating axis, which is transverse, preferably perpendicular, to the vertical axis X-X; the first lever has a first end in contact with the actuating cam 46 or with the eccentric and a second end in contact with the first intermediate element, which in turn is abutted onto the first punch 11 and is assembled sliding along a direction parallel to axis X-X, to transmit motion from the actuating cam 46, or from the eccentric, to the first punch 11.

The operation of the system 10 for the embossed printing of plastic cards according to the present invention will now be described.

In a first embossed printing step of the system 10 of the invention, the drums are actuated by rotating them in a known way, in order to take the first punch or punch 11 and the second punch or matrix 21 to the printing position, in which the first intermediate element 19 and the second intermediate element 29 are respectively above the first punch 11 and the second punch 21.

Now a regulating step starts, in which the punch regulating assembly 15, 45 performs the regulation of the position of the first punch 11 in the first embodiment of the system 10 of the invention, or of the second punch 21 in the second embodiment of the system 10 of the invention, along a direction Xl-Xl perpendicular to the printing plane 31.

In the system 10 according to the first embodiment of the invention, the step of regulating the position of the first punch 11 along a direction Xl-Xl perpendicular to the printing plane 31 comprises the steps of:

rotating the positioning cam 16 around the first positioning axis Y-Y, preferably by means of the stepped electric motor;

transmitting motion from the positioning cam 16 to the first punch 11, preferably by means of the first lever 18 in contact with the first intermediate element 19.

In the system 10 according to the second embodiment of the invention, the regulating step comprises the steps of:

actuating the first actuating means 58, preferably composed of the stepped electric motor 58;

transmitting motion from the first actuating means 58 to the second punch 21, preferably by means of the bearing plane 49 and of the second intermediate element 29.

After having ended the regulating step, the actuating step starts, in which the punch actuating assembly 25, 45 performs the actuation of the second punch 21, and preferably of the first punch 11, to perform the printing of the plastic card 32.

In the system 10 according to the first embodiment of the invention, the actuating step comprises the steps of:

rotating the actuating cam 26 around the first actuating axis Y'-Y' by means of the second actuating means, preferably composed of the electric motor with direct current power;

transmitting motion from the actuating cam 26 to the second punch 21, preferably by means of the second lever 28 and of the second intermediate element 29, to take the actuating cam 26 from the rest position, wherein the second punch 21 is far from the printing plane 31, to the printing position, wherein the second punch 21 is near the printing plane 31.

In the system 10 according to the second embodiment of the invention, the actuating step comprises the steps of:

rotating the actuating cam 46 around the first actuating axis Y'-Y' by means of the second actuating means, preferably composed of the electric motor with direct current power; transmitting motion to the first punch 11 and to the second punch 21, preferably by means of the first lever, of the second lever 48, of the first intermediate element 19, of the second intermediate element 29 and of the bearing plane 49, to take the first lever and the second lever 48 from the rest position, wherein the first punch 11 and the second punch 21 are far from the printing plane 31, to the printing position, wherein the first punch 11 and the second punch 21 are near the printing plane 31.

Advantageously, the embossed printing system of the invention allows making a system comprising punches and matrixes with a small cost, which allows regulating the position of a punch and of the respective matrix with respect to the surface of the card to be printed without working of the punches and of the matrixes.

Moreover, the embossed printing system of the invention allows making a system comprising punches and matrixes which allow applying an embossing force which is perfectly vertical when printing.

Advantageously, the punch and matrix further allow exerting a detachment force for them at the end of the embossing or printing operation.