Note: Descriptions are shown in the official language in which they were submitted.
This application is a divisional of copending Canadian Patent
Application Serial No. 261,~45 filed September 17, 1976 in the name of
Dynetics Engineering Corp.
This invention relates to special preprinted "credit"-type card
carrier forms, apparatus for automated insertion, foldingJ pulling and stuff-
ing, and methods of production and manual or automated use thereof. More
particularlyJ this invention relates to single-sheetJ multiple-flap credit
card carriers having slits or slots in one or more panels for receiving and
retaining by wedge trapping credit cards during manual or automated procedures
of issue and mailing of the cards to card users. Special information is
provided on the carrier to insure that the appropriate number of correctly
matched cards are inserted in their appropriate carrier, and for manual or
automated "pulls" after insertion.
In the United States there were about 500 million credit cards in
circulation in 1974, and an additional 200 million were issued that year on
new accounts or to cover maintenance (renewal~. These numbers do not include
the emerging debit card field ~for bank or S~L account access), nor the ID
and security card fields~
Such cards ~called herein "credit cards" for simplicity) being
equivalent to or providing access to money, property or credit, must be
handled with accuracy under stringent security during issue of the cards, i.e.,
manufacturing, preparing or distributionJ and actual distribution ~e.g., by
mailing) to the cardholder-customer. The correct number of cards must be
correctly embossed and/or encoded with the cardholder's account number and
other data. The embossed cards must be protected ~rom theft until they are
in the hands of the cardholders.
The preparation for distribution of the cards must likewise be done
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accurately under stringent security precautions. The cards are normally
placed in what is called a carrier and mailecl (first-clas-s registered or
certified mail) to the cardholders. Advance notice and/or follow-up verifi-
cation mailings may also be used to help insure against theft or notify
promptly of non-receipt by the addressee-card user.
It is an extremely serious matter when the wrong cardholder receives
the wrong card or wrong number of cards. If a cardholder is supposed to get
two or three cards and receives only one, or if a cardholder receives a card
of another account, there is a chance for theft of goods by credit cards.
The average loss is in the four-figure range with highest losses in five
figures. The matter is even more serious in the case of debit cards. Such
cards give access to a person's checking and/or saving account. Cards going
~o the wrong person creates a theft potential. This highlights the need for
carrier forms and manual or machine methods of accurate inserting and prepara-
tion for distribution.
Currently, carriers for cards are typically heavy paper stock
having two or four straight, diagonally oriented, separated slits rO hold t~o
or four corners of the cards. Most cardholding carriers are single sheets of
card stock slightly smaller than number 9 or 10 envelope size so that they
can be insertad in a mailing envelope. Pocket-type carriers are made of two
sheets of paper glued or secured together to provide a pocket therebetween.
A slit in the upper sheet for access to the pocket may be provided, or access
may be at the sheet edges. Other currently used carriers may be single sheets
having a single fold to provide two flaps of slightly smaller than envelope
size; these are commonly used in carriers having two diagonal slits in one of
the flaps. A few current carriers have a second fold to provide a third flap,
and some of these have no slits for retaining the cards. Some carriers (no
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longer in extensive use) employed pressure-sensitiye glue or tape to securc
tlle cards thereto.
TypicalLy, currently availa~le carriers ~ave space for two cards
oriented horizontally, that is, with the long axis of the card oriented
parallel to the printing and/or long axis of the carrier ~as folded for mail-
ing). Simple, single-flap carriers are relatively inexpensive, running around
$10-30/thousand, while the multi-layer, pocket-type carriers are very expen-
sive, running $35-80/thousand.
Most cards are inserted manually in the two-slit, no-slit or pocket
carriers. There are two basic approaches. In one, the person inserting the
card has a stack of precut, single-sheet carriers having no account informa-
tion thereon, and a stack of presequenced cards. They also have a stark of
separate sheets of thin paper which are presequenced mailers with address
and account information. The inserter compares the account number on the
card to that on the separate mailer. The cards are inserted by hand into the
slits or pockets of the carrierl assembled with the mailer, and then placed
in envelopes. The second approach involves having account information typed
onto the individual carriers which are presequenced and assembled with pre-
sequenced cards. A top-rated inserter is capable of inserting 1,500 accounts
in an 8-hour day with an average of 1.7 cards per account. The average accept-
able rate is generally 1,000 accounts per day, and low is 750/day.
Correct presequencing of the cards and carriers or inserts is
critical to any reasonable rate of manual lnsertion and to reducing the fre-
quency of mismatch errors. Further, such manual insertion rates require many
workers in order -to keep up with the rate of production of credit or debit
cards. For example, automated embossing machines have a current card emboss-
ing rate ranging from 350 to 1,500 cards/hour. The rates are the same for
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encoding cards bearirlg magnetic stripes.
~e believe there is a machine available that can insert a card in
a four-slit carrier by flcxing the card along both its major and minor axis
so the four corners can be popped into four respective corner slits. An-
other machine is capable of putting a clab of glue on the carrier and deposit-
ing the card thereon. ~lowever, neither machine matches the cards and carriers,
so mismatch errors will occur unless exact sequencing is maintained. In
automated equipment of this non-verifying type, once a sequence error occurs,
all subsequent insertions will continue to be mismatched.
Current hand and machine inserting depends on the accurate pre-
sequencing of the cards and mailers or carriers. Further, where cardholders
are to receive three cards, a second carrier must be used or the cards must
~e piggy-backed. Carriers have positions for either one or two cards held in ;
horizontal orientation. For issues having mcre than two cards, the cards are
stacked or placed piggy-back in one or both positions. Generally, no more
than two cards are piggy-backed in any one position allowing a maximum of
four cards in a two-position carrier.
The current carriers render methods of inserting relatively slow
and prone to errors. The~ are not particularly adaptable to both hand and
machine inserting, folding and stuffing, and normally require separate
address inserts. There is thus a need for improved credit card carriers that
are simple, rapid and inexpensive to manufacture, to preprint with account
and verification information, and which are useful for manual or machine in-
serting. The instant carrier satisfies those needs and is particularly adapt-
ed to automated mechanical vertification and insertion of credit cards in the
apparatus and method shown and described herein.
It is an object of this invention to provide an improved method and
apparatus for the automatic verifi_ation and retentive engagement of credit
cards in association wi.th carriers therefor.
~ ccording to one broad aspect of the present inventionJ there is
provided method of automatic verification and insertion of credit cards in
carriers therefor comprising the steps of:
(a) providing carriers adapted to retain credit cards in .
association therewith,
(b) providing credit cards having thereon machine readable infor-
mation uniquely identifying a cardholder or account,
(c) inserting the correct number of credit cards into each saidcarrier in accordance with information on the number of cards authorized for
said cardholder or account,
(d) identifying said carrier with information uniquely identify-
ing the cardholder or account cards insertcd therein.
According to another broad aspect of the present invention, there
is provided apparatus for automatic verification and retentive engagement of
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credit cards in association with carriers therefor comprising:
a) means for providing carriers adapted to retain credit cards in
association therewith;
b) means for providing credit cards having thereon machine read-
able information uniquely identifying a cardholder or account; .
c) means for retainingly engaging the correct number of credit .
cards into association with each said ca.rrier in accordance with information
on the number of cards authorized for said cardholder or accounts; and
d) means for identifying said carrier with information uniquely
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identifying the cardholder or account.
The present invention, together with that of Canadian Application
Serial No. 261,~45, will IIOW be described in greater detaîl with reference
to the accompanying drawings, in which:
Figure l is a plan view of the front 6ide of a two-wide carrier
web as printed by a line printer, also showing separation into an "L" and a
"R" stream for fan-folding and removal of the sprocket drive marginal por-
tions;
Figure 2 is a plan view~ partly in section of one embodiment of
a special carrier of this invention having cards inserted therein, and -~
showing the location and arrangement of one embodiment of a machine-scannable
code on the carrier which provides information on the account and number of
cards;
Figure 3 is a plan view of a l-up web of ca.rriers adapted for
printing by a drum printer, and hav m g various optional types of card sl Cs
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or slots in the ~ panel and an optional tab on the C panel;
Figure 4 is a plan view of a portion of another carrier embodiment
showing an alternate positioning of the machine-readable carrier code, and A
panel slits for receiving four retail-type cards in a vertical orientation;
Figure 5 is a plan view of a portion of another carrier embodiment
showing a single line code arrangement, and slits in the A panel for receiving
single or piggy-~ack cards in a horizontal (transverse) orientation;
Figure 6 is a highly simplified, partly schematic overview of an
apparatus and method for mechanica]. insertion and folding of cards in the
special carriers of this invention;
Figure 7 is a plan view of another carrier embodiment having tear-
out wallet cards for individual cardholders of the same group;
Figure 8 is a plan view of the preferred carrier embodiment of
this invention showing the cri~ical location, spacing and dimenslons for 3
panel carriers having three pockets for standard credit-sized cards;
~igure 9 is a schematic diagram of the method of producing carriers
in accord with the invention.
The invention includes continuous and single-sheet~ plural-
cardholding, multi-panel ~or flap) credit card carriers, their method of manu~
facture and use, and apparatus and method for verification and insertion of
cards in the carrier. The carriers are used for retaining the cards during
certain credit card issue proceduresJ includlng mailing to the cardholders. ~.;
A first marginal panel, the A panel, contains from one ~io four specially - ~
designed slits for receiving the cards by manual or automated insertion, in ~ :
ver~ical (preferred) or horizontal orientation. The cards may be inserted
sequentially or sirnultaneously, singly or piggy-backed (two or more in a
single slit). The A panel cooperates upon folding along internal perf lines
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with a central B p~nel and a second Marginal panel, the C panel, to retain
the cards by wedge trapping without loss or misalignment (cocking) during
handling and mailing.
The A panel contains special positions thereon for receiving and
carrying information relating to the account which may be read visually by
manual inserters or by checker-operators, or may be read automatically by
mechanical, optical, electromechanical, electro-optical, magnetic and/or
electronic scanner means to provide information during automated insertion or
thereafter, e.g., stuffing or pulling operations. Typically, the information
is in the form of alphabetic, numeric or optical characters ~e.g., I-bar code)
or mag stripes and contains information about the account, the card issue,
number of cards to be placed in the particular carrier, and the like.
Account indicia, for example,;may be numeric and positioned adjacent to an
internal perforation ~carrier form fold line~ so that account numbers may be
presented for visual scanning when the carriers are completely inserted, fold-
ed and stacked ready for insertion into mail mg envelopes.
The C panel contains speclal positions thereon~for receiving and
carrying other account information that may be in any of the modes described
abo~e for the A panel. Typically, the information is m the form of alphabetic
and numeric indicia, for example, name and address of cardholder, account
n~ber, number or cards~ credit limlt and the like. The address indicia is
specially positioned for juxtaposition ~ith a window in standard or special
window-type mailing envelopes.
The carriers may be printed with informational, instructional,
contractual or advertising information on one or both sides. The completed
carrier, in the folded fvrm with cards inserted, is slightly smaller than
standard "long" mailing envelopes, i.e., 3 1/2" wide x 8.~" long (8.89 cm
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x 21.3~ cm) and is adapted for manual or automatcd stuffing into such mailing
envelopes. In one embodiment, thc ~ panel is perforated to provide rom one
to four wallet-sizcd or postal-sized cards. Special information for the
cardholder may be printed in special areas of the cards, for example, all the
information required for loss notification.
The carriers are produced by a multi-step process, broadly broken
down in two stages: Stage 1 is production of blank carriers or carrier webs
in continuous form or single sheets. Stage 2 involves printing of the
individual issue and account information by data processing equipment to
ready the carriers for card insertion, folding, pulling and stuffing into
mailing envelopes.
Typically in Stage 1, suitable sheet material, such as paper of
weight ranging from 15-45 lbs and gauge of .002" to .010", is provided in pre-
determined widths to produce one- or two-wide carrler forms. Producing con-
tinuous forms from a weh roll of paper stock is preferred, but single sheet
printing may be employed. The sheet material or web is printed in any
suitable manner, preferably by conventional lithographing techniques, with
preselected indicia of an instructional~ informational, contractual and/or
advertising nature on one side (preferred~ or both sides in single or muleiple
colors. Selected areas of a first~ face side of the form remain unprinted
to receive thereon special in~ormation provided at a later step. The web
advances to perforating stations where the web is perforated parallel to the
web travel with perforation wheels, and across ~transverse) to the sheets or
web travel by cylinder or drum perforating knives. Special slots are also
cut through the web or sheets to receive credit cards. -
The perforations provided are of two types: lhe first is called
the "internal perf" (internal with respect to the carrier). Two internal
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perfs are provided in each form to clefirle therein the -three carrier panels.
Ihe carrier panels In~y be folded along these perfs. The second is called
tlle burst or fold perf. Ihis perforation permits fan folding of the web of
forms and separa~ion of individual carriers Erom the web or sheets, or sets
of two-wi~e carrier forms into two separate single ones or trains of carriers.
The web or sheets optionally may also be perEorated along a line
or lines spaced from one or more margins to provide a strip which is punched
with holes adapted to receive web or carrier advancing means, such as a
tractor, sprocket or pin drive mechanism. There perfs are of a type which
permits the strip to be removable prior to stuffing the carrier into mailing
envelopes. These drive strip-defining perfs may be omitted with the drive
holes remaining in the finished carrier. Drive holes may be omitted where
the carrier is to be manually inserted and stuffed with a mailer piece. The
pin drive holes may be punched into the marginal edges of the carrier forms
without marginai perf lines definine a removable drive strip.
The carriers may be fan folded along the second perf lines (called
burst/fold lines~ and boxsd for shipment to data processing centers of the
card issuer or service organization. Alternately the carrier web or sheets
may be fed directly to the Stage 2 imprinting operations.
Alternate manners of handling the web or sheets are contemplated,
such as bursting and stacking individual carrier forms for use, particularly
manual insertion, or forming a roll of the completed carrier web. Individual
sheets may be glued end to end to provide a roll or fan fold of carriers.
Where the web or sheets are produced two-wide, a center perf parallel to the
outer margins defining therebetween the two carriers may be boned, slit or
burst to form two sets, streams or trains of one-wide carrier forms, and these
streams interleaved (an-folded together~, stacked, or rolled up together.
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St~gc 2 imprinting involves a~pplylns individual account informa-
tion to the front an~/or back face of the individual carrier forms, typically
by data processing equipment such as impact (line or drulll) or non-impact
printers. Such printers may be computer controlled and apply preselected in-
formation about the accounts to individual carrier forms in the proper
sequence. These printers may also apply machlne-readable code, such as I-bar
code, variable space or variable width bar code, and the like to preselected
portions of the carriers. These codes are positioned on the carriers to co-
operate with read heads in automatic card inserting machines and to supply
instructional (command) or veriication information to such machines.
In one embodiment, a special I-bar binary code presents informa-
tion which identifies the number of cards to be inserted in the carrier, the
card issue (run number), the issuer number, cardholder account number, spaces,
and an end signature instruction. This carrier information is compared by
the machine with information on the cards~ and command logic initiates
mechanical insertion of the appropriate number of correctly matched cards in
*heir appropriate carrier.
Prior, intermediate or subsequent steps, as required, of separating
individual carriers from the web or sheets, strlpping, cutting or boning pin
drive margins Erom the carriers, and folding carrier panels are done manually
or by automation. The code information also permits last minute automated
pulling of bad accounts after insertion and just before stuffing by permitting
in-line or stack scanning of completed inserted/folded carriers to produce
an up-dated issue. The up-dated issue of completed/folded carriers is then
stuffed into ~ndow-type mailing en~elopes with the address indicia oriented
for visual reading.
The instant verification and insertion system (VIS) apparatus and
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method involves: scnsing information in or on cards (embossed, magnetic
stripes, printed, punchecl, inlaid, pcrmancnt magnetic code embedded cards,
and the like); ~eeding continuous carriers or single-sheet carriers into the
VIS apparatus; in the case of continuous carriers, separating individual car-
riers Eron~ the web; sensing information carried on the instant carriers;
comparing the information on the cards and carriers; automatically inserting
the appropriate number of correctly matched cards ln the appropriate carrier;
and folding the carrler in a form ready for automated stuffing into mailing
envelopes; pulling bad accounts after folding, and stuffing in mailing
envelopes. Reject, pause and search mode;s of operatîon are provided.
Any mode of printing or applying the preselected information in
Stages 1 and/or 2 may be employed. For example, non-impact printers, with or
without computer control, of spray or other type operation may be advantage-
ously employed in Stage 2. The information may be in any "language", such as
standard letters or characters, or optically readable special font9 such as
7B ~ont, or OCR 1428 (IBM*), or may be electronically encoded in a magnetic
stripe of material (e.g., iron oxide, chromium oxide or the like) app]ied to
the carrier or carrier web in a preselected position. The information may~be
in the form o punched apertures (Hollerith) in one or more carrier flaps,
or embossings in the carrier sheet material.
I~ should be undcrstood that throughout, credit card is a shorthand
reference to any type of card susceptible of being or requiring transporting
or handling by a carrier, and includes by way of example credit cards, bank
cards, debit cards, retail cards, identification cards, account cards, security
cards, pass cards, key cards, photo ID cards, charge cards and the like.
The following detailed description is by way of illustration and
not by way of limitation of the principles of the instant invention. In many
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of the dra~ gs hercin single figures are used to illustrate multiple embodi-
ments for concise~ess and not as limiting the invention. While continuous
forrns, strips or liebs are discussed in most detail herein, i~ should be under-stood that the principles of the invention apply to single sheet forms and
their manner of use.
In Figure 1 a two wide (or two-up~ carrier form set 1 is shown,
face or front side up. This form set comprises an 1. stream and an R stream
(for Left and Right streams, respectively), so designated at the top of the
form set. These two streams are defined on either side of a central (longi-
tudinal) line of perforations 2. The forms or streams preferably have
removable marginal strips 3 and 4, but they are not required as illustrated
by carriers I and II (Figure 1). Carriers III and IV (Figure 1) are shown
as having marginal strips ~also called drive strips) which are defined between
side edges 5 and 6, respectively, and lines of perforations 7 and 8 spaced
inwardly therefrom (with respect to the edges~. These marginal strips may
contain any convenient type of apertures 9 which are adapted to be engaged by
driving or guiding mechanisms during production or use of the carrier forms,
e.g., by pin drives, tractor drives, pin chains, pin belts3 indexing mechan-
isms, pin guides and the like. As shown in carrier forms II of Figure 1 and ;~
III of Figure 3, the drive, indexing or guide apertures 9' are spaced inwardly
of the carrier margins 2, 12, 7 and 8, respectively. The drive strips 3, ~
are left on, or optionally may be separated from the form edges ll and 12 as
shown at 13. The form sets are separated as at 10 along the central perf
line 2, e.g., by slitting or boning with one or more rotary or fixed knife
cutters, into continuous single (or one-up) carrier form streams L and R.
Four complete, individual carriers (carrier forms) are shown in
Figure 1, being numbered I, II, III and IV, as shown. This numbering reflects
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the sequence of separation (burstillg~ of indivi~ual forms from the two-wide
sets stream 1 during decollating, folding and inscrtion in the automated
verification and insertion system devicc (VIS) of our above-identified co-
pending applicatioll. The form sets of Figure l are fed face down as inter-
leaved streams L and R into the VIS; hence the left carrier is separated
first.
Figure 1 also illustrates several alternate embodiments, the first
of which comprises a form set of two individual carriers I and II separated
by perf line 2 but having narrower marginal edges 11 and 12 and no marginal
drive strip. In a typical two~wide stream, the carriers would be alike, but
are shown different for purposes of illustrative conciseness. Carrier I has
no drive or indexing holes~ while carrier II shows drive holes 9' adjacent
the margins. The carrier I embodiment is particularly useful for manual in-
sertion of carrier forms, and for automated olding and/or insertion processes
not requiring sprocket or p m drives, indexing mechanisms, or guides and the
like. For example, automated devices can employ pinch rollers or belts for
movement of the carriers which do not require the marginal strip. The carrier
II embodiment is useful where there is no objection to cardholders receiving
carriers with holes. While the carrier II embodiment is shown narrower than
carrier III or IV; it should be understood that by omitting perf lines 7 and
8~ a wider form of carrier II is produced. The perf lines 7 and 8 are not
absolutely required, as slitters or cutters can strip off a marginal strip
from carriers III and IV without aid of those perf lines 7 and 8.
Still another alternate embodiment is illustrated by the carrier
forms III and IV of Figure l ~with or without the marginal drive strips 3 and
4). This is a double carrier, in which the perf line 2 is replaced by a fold
line 14. The old line is preferably an embossed groove to assist in folding,
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but may also be a line of perforatio~s spaced widely enougll apart to assist
in ~o1ding but not so numerous to permit easc of sepQration of carrier III
from IV. The doublc carrier provide twice the number of card pockets, and
a~ter insertion may be folded along line 14 to fit into a standard envelope.
Individual carrier forms comprise three panels extending between
form margins 11 and 12, respectively (or drive strip perforation lines 7 and
8, respectively) and the central perf line 2 or fold line 14, as the case may
be. These panels are designated as the "A", "B", and "C" panels, respective-
ly, and each performs a separate and distinc~ function as well as being
adapted to be cooperatingly interrelated in combination to provide the improv-
ed properties of the ~orm. Viewing form I of Figure l, the "A" panel is shown
. in this embodiment as defined between transverse stream burst/fold line 15 ;
and transverse form fold line 16. In this embodiment, panèl "A" has the
smallest width (in the longitudinal direction) between perf line 15 and fold
line 16, and-includes three specially designed and placed V-shaped slits I9
20 and 21, each for receiving one end of indivldual credit cards.
A note about terminology: Line lS is a line of perforations adapt-
ed by approprlate cut and tie spacing to permit tearlng or bursting of ~he
form, here form I, from the carrier stream, here stream L. The carrier stream
is also foldable along line 15, e.g., when the carrier streams are fan folded
singly or interleaved with stream R. Thus, with respect to the stream, line
15 is a stream fold line while at the same time, with respect to the carrier,
is a burst line. These are called burst/fold lines. The same is true of
perforated lines 18 and 22. In contrast, lines 16 and 17 are embossed,
scored, or lightly perforated lines (internal perfs) along which panels of
the individual forms are folded. These lines are thus fold lines with respect
to the forms, and called form fold lines or internal perfs to distinguish them
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from the strc~n burst/~old lines. The dircction along the stream, from the
bottom of Figure l to the top (or vice versa~ is called the longitudinal
direction, or axial direction, or tlle clirection of stream travel during pro-
d~lction. ~e direction o-f the stream burst/Eold and form fold lines ~internal
perf.s) in Figure 1, at 90 to the longitudinal direction, is the transverse
direction. Note, however, that in l:igure 3, the directions are reversed,
that of the form fold lines being longitudinal and the stream burst/fold lines
being transverse.
As described in more detail below, the "A" panel also has provided
thereon visually readab].e or machine readable information means 23~ such as
indicia 24, magnetic stripe 25 ~Figure 3), punched holes 26 ~Figure 3) and
the like. The spacing and placement of these information means are important
as discussed below.
The "B" panel is defined between form fold l m es ~lnternal perfs)
16 and 17. This panel is slightly wider .than the length or width of the
credit card being received by the carrier depending on whether the card is
held vertically or horizontally. For example, for a standard credit card of
dimensions 3.375 x 2.125 inches ~8.573 x 5.398 cm) held vertically ~see Pigure
2 orientation o~ the card ~ith respect to the carrier), the "B" panel width
~distance between fold lines 16 and 17) is ~3.5 inches ~8.89 cm). For a
standard card retained horizontally ~Figure 5), the "B" panel width is 2.250
inches ~5.715 cm~, while for a retail card retained vertically ~Figure 2), the
width is 3.625 inches (9.21 cm). For the retail card retained horizontally,
the "B" panel width is 1.844 inches ~4.683 cm). Generally,.the "B" panel is
.125" wider than the relevant dimension of the card sought to be trapped.
This provides an excellent frictional wedge-trapping of the card in the fold,
yet it is not so tight that folding is difficult.
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In anothc~ embodiment the panel also has tear-out wallet cards
79, 80, 81 such as shol~n in Figure 7 and described in more detail below. The
"B" panel can be imprintecl with information-conveying indicia~ such as the
cardllolder contract, lost and found information, advertlsing information,
use instructions and the like. The panel width is adapted to securely wedge
trap and grip the ends of the credit cards in carrier folds defined along
form fold lines (internal perfs) 16 and 17 without binding the form stock.
Likewise, the "B" panel is not so much larger (wider) than the cards that they
become canted or loose in the folded carrier and tear the slits permitting
them to become lost or misplaced during carrier insertion or use.
Panel "C" (~igure 1~ is defined between form fold ~internal perf)
17 and the upper marginal edge of the form which is defined by stream burst/
fold line 18. This panel width is carefully designed to form a flap over the
exposed portion of the credit card projecting from the retaining slits (see
Figure 2), while selectively revealing all or a portion of the information
means 2~ such as alphabetic and/or numeric indicia 24a and/or bar code 24b
(shown by way of example as I-bar code in Figures 2, 4, 5, 6 and 7). The
folded-over panel thus assists in retaining the card in the carrier during use
while permitting visual or automated checking off at least a portion o the
information 23 when the carriers are inserted, folded and stacked ready -for
envelope stuffing, or for pre-stuffing pulling Typically, the width of the
"C" panel for a standard credit card is 3 inches (7.62 cm) between form fold
line 17 and stream burst/fold line 18. The "C" panel also typically carries
address indicia 27 and account information indicia 28. Optionally, the indicia
is positioned on the panel so as to be visible through the window of a stand-
ard No. 9 or No. 10 envelope when the inserted/folded carrier is stuffed into
such an envelope.
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~ igure 2 shows a single carrier I in the folded condition and
having two standarcl credit cards 29, 30 inserted into pockets 19 and 20. In
the embodiment shown, each limb of the slit 19a, l9b is inclined at an angle
defined between the slit limb and a line parallel to the carrier end 15 and
touciling the V-slit tongue 46, of between 5 and 45, preferably 10-20. The
angle ~ as shown in Figurc 2 is 12. The spacing between the end of the slit
39 and the card margin 29a may range from .02 to .1" (.051 to .254 cm~ and is
typically .062" (.157 cm) as shown in Figure 2.
A first end 31 of the card 30 is slipped into the V-shaped slit 20
and is trapped in the fold 16 of the "A" and "B" panels. The second end 32 of
the credit card overlies the marginal portion 33 of the "A" panel lying be-
tween the slits 19, 20, 21 and the edge 15 and is trapped in the fold 17 of
the "C" and "B' panels. The upper marginal edge 18 of the "C" panel leaves
the indicia 24a or 24b visible for verification of the carrier aft-er it is
in the folded condition. Thus,~lt is possible to scan an entire stack of
inserted/folded carriers to locate or verify any particular ones therein.
This is particularly useful in pulling or checking operations. Card accounts
often must be terminated for a variety of reasons (poor credit9 theft, moving,
etc.) just prior to issue. For current conventional insertion, it is not
feasible to automatically locate the bad accounts and pull them prior ~o mail-
ing. In the instant invention, it is possible using the indicia or code ~see
24b in Fig~lre 5) to scan ~visual or automated) the completed carriers just
prior to stuffing and pull the bad accounts, or pulling after stuffing.
~he address indicia is positioned to lie adjacent to and be visible
through the window of standard No. 9 or No. 10 mailing envelope, shown in
phantom in Figure 2 as item 3~. Portions of the account information 28 may
also be positioned adjacent to the window 34, if deslred, or alternately, one
, - 17 -
or Inore special ~indows 35 may be provided in the mailing envelope 36, both
shown in pllantom lines in Figurc 2.
~ i~ure 3 ill-lstrates a one-up strcam of carrier forms orientèd at
90 to that of ~igure 1~ i.e., with the form fold lines (internal perfs) 16,
17 in the longitudinal direction ~from lcft to right in Figure 3). The stream
fold/burst lines 15, 18, 22 are oriented transversely. This embodiment is
particularly suited to drum or roll printing as distinct from line prlnting
which is particularly suited to one- or two-wide form streams oriented as in
Figure 1. Any type of printing the common and individual information on the
forms may be used, whether impact or non-impact types of printing. The
marginal strips 3, 4 may be omitted, or only one strip employed, as required,
with or without drive holes 9, 9'.
Figure 3 also shows a number of card-retaining slit and slot varia-
tlons. V-shaped slits oriented as in Figure 1 i~ith the V tip adjacent the
carrier margin 8 are preferred. However, a reverse oriented V-shaped slit 37,
called herein an "A" slit, may be employéd. The V slit is superior, and whlle
we do not wish to be bound by theory, we believe that the presence of a lead-
ing tongue or lip 46 assists in guiding the card into the slit if the cards
are slightly misaligned during insertion. To assist in preventing tearing,
the slit area may be reinforced, or the slit ends 38, 39 may terminate in a T
or a small aperture.
T effect insertion, the marginal area 33 of the "A" panel between
the slit 19 and edge 8 may be depressed relative to the medial area 41 of the
A panel lying between the slit 19 and fold line 16, and the card is then in-
serted. The same is true for the A-slit. Slits 42, 43 and 44 in carrier II
of Figure 3 are respectively identified as a U-shaped, a W-shaped and an
inverted U-shaped slit, Oval or rectangular slots 45, and straight slit 40
- 18 -
,
.
, . : . , -
.
' " ' '
'
~3~
are shown in carrier 1. Figure 3 also sllows a marginal lip 47 in panel "C"
having marginal or leading edge 48 which is shorter than the slot opening.
The lip is tilUs adapted to be inserted into the slot, effecting a positive
interlocking o~ the card into the folded carrier This flap or lip 47 may
be of any shape adapted to providc the interlock, and may be used with any o~
the card slits or slots.
Figures 4 and 5 are plan views o~ folded carriers, partly in sec-
tion showing alternate slit and card arrangements. Figure 4 shows a carrier
having 4-slits 49, 50, 51, 52 specially adapted for retail~ cards 53, 54, 55,
56 held in the vertical orientation, i.e.J the long dimension of the card
across the width of the "B" panel. The retail cards have dimensions of 3.50
x 1.8~ inches (6.35 x 4.683 cm) and thus, for fit the carrier of this inven-
tion as shown. Since the B panel of Figure 4 lS longer than the B panel in a
carrier for a standard credit card (Figure 2) the A and/or C panels may be
made smaller in width (between respectlve carrler fold and stream burst lines),
or the overall width of the carrier (ln the longitudinal direction in Figure
1, the transverse in Figure 3) may be increased. Special mailing envelopes
to accommodate the increased width may be provided.
Figure 5 illustrates a two-slit carrier ~or standard credit cards.
The slits 57, 58 are dimensioned for the long axis of the standard card 29,
30. Also slit 5~ is shown as accepting a second card 59 carried piggy-back
on card 30 to provide for a 3-card account. Card 29 could also be piggy-back-
ed providing for a ~-card account. There is enough space between slits to
provide for lengthening them. With longer slits, retail cards may be carried
singly or piggy-backed in the horizontal orientation. The "B" panel is
shorter than in carriers of Figures 1 and ~ to accommodate the horizontal
orientation. Narrower envelopes may be provided, or the "C" panel enlarged
- 19 -
,
'' ~' ,: ' ~ ' ,
~3~
to just short o:t tl~c width of a standard No. 9 envelope to project upwardly
(in Figure 5) bcyoll~ the u~per edge 16 o:f the "~" yanel, as shown in phantom
in Figure 5 as item 60. This insures thc inserted/folded carrier is properly
oriented in the envelopc, so the address indicia is presented opposite the
envelope windo~; no sI~ecial envelopes are required. In this alternate embodi~
ment some of the information means 23 ma.y be placed on or repeated on the
projecting edge 60 of the "C" panel. For example, the code information 24b
may be placed on the marginal edge of the "C" panel extension 60 for the
location and identiflcation purposes described abov0.
Figures 2, 3, 4 and 5 also illustrate another special feature of the
invention. The information means 23 may include machine readable information
24b for use in automated printing, inserting, folding and/or envelope stuffing
machines. The information may be presented or carried on the carriers as
visua].ly readable indicia, or for reading by optical character recognition -
~ype devices, or as magnetic s~ripes or bars which are electromagnetically
and electronically encoded and read (see mag stripe 25 in Figure 3). The in-
formation may also be presented as Hollerith type punches (see punches 26 in
Figure 3), as bar codes readable by optical scanners (item 24b in Figures 2, `~
4, 5, 7 and 8), as embossings readable optically or by mechanical devices
having sensing fingers, as OCR readable font (such as IBM 142~ in ASA si~es
A, B or C), as OCR readable delta distance code ~like the universal product
code found on grocery items~, as codes or indicia printed in fluorescent ink
or struck from fluorescent ribbon and OCR readable under ultra-violet illumina-
tion, as mark sense codes, as bars printed in magnetic ink or struck from
magnetic ribbon and readable by electromagnetic readers, as visually or OCR
readable color bars, as magnetic ink or struck ribbon font readable by elec-
tromagnetic readers (like MICR readable font on checks), and the like. By way
'
- 20 -
'~
~ .
' ' '' , ' ' ' '" ' '
, .
.5~;~
of example, thc bar code form is shown llerein, but it should be understood
that the principles oE thc invention ayply equall~ to the othcr ~orms mention-
ed or contemplated.
Thc information means 23, and more particularly machine readable
information 24b, may be placed on any panel, on a label disposed on a panel
(see label 180 in Figure 3~, or on an envelope or label on an envelope. The
information should be disposed in a position to be scanned visually or by the
mechanical reading means of inserting, vertifying, pulling and/or stuffing
devices. The information 24b is particularly suited to be disposed on a
carrier panel ju~taposed opposite a special window in the envelope, e.g.,
window 35 (Figure 2), so that it is readable therethrough. This permits veri-
fication (sealed envelope detection) and pulling of accounts even after stuff-
ing in envelopes. In another embodiment, information 24b is printed in
transparent fluorescent ink over the address indicia 27 and is readable under
ultra-violet illumination through a standard envelope window, yet the code
does not obscure the address and is not detectable by ordinary means.
The bar code specifically illustrated is I-bar code in Figures 1-3,
4, 5 and 8, and I-bar code in Figure 7, as ~hese are printable by standard
printing devices, such as line printers, drum or roll printers, non-impact
printers and the like. I-bar is preferred over l-bar code as the top and
bottom crossbars assist in producing reject error messages (cross talk) if
vertical line weave occurs. The code 24b is different for each carrier, and
contains information which serves a plurality of functions including identifi-
cation of the particular carrier as that of a particular account (person),
instructions as to the number of cards to be inserted, the card number to be
inserted for verification (matching) of cards being supplied, the issuer
numbcr, issue nutnber, run number, series number, carrier sequence number, and
- 21 -
: ,
-
' '
,
the like.
In ~igure 2 thc I-bar code is shown as disposed in four horizontal
rows, in ~igure ~ as two sets of two rows, and in ~igure 5 as a single row.
This code is a binary code of Eour bits l, 2, 4 and 8, the bars in each row
representing one bit value. Referring to Pigure 2, the uppermost row 61, each
I represents a one, the next row below that 62 contains the twos bars, the
~hird row 63 contains the fours bars, and the bottom row 64 contains the eights
bars. In ~igure 4 the rows are paired with a first pair ~o the left of a
second pair, for example, the ones and twos rows 61, 62 to ~he right of the
fours and eights rows 63, 6~. In the alternative, the ones and fours rows may
be spaced to the left with twos and eights to the right. In short, any con-
venient pattern of rows may be employed so long as the scanning device for
reading the bar code is oriented appropriately:
l 4 , or l 2 , or 1 8 , or 8 2 , etc.
2 8 4 8 ~ 2 l 4
In Figure S the rows are spaced along a single line with the rows
order illustrated being 1, 2, 4, 8; of course, any convenient sequence may~be
employed: 1, 8, 2, 4; 4, 1, 8, 2, etc.
- Another form of s mgle line code th~t may be used is double fre-
quency coherent phase encoding (an encoding technique developed by Aiken in
1954). The data is comprised o~ data and clocking bits together. An inter-
mediate bit occurring between clocking bits signifies a "one", the absence of
an intermediate bit between clocking bits signifles a "zero". Of course,
other techniques of encoding, single or multiple line, may be employed.
The areas 65, 66, 67, 68 represent initial starting portions that
scanner heads look at when the carrier is properly indexed into the automated
card insertion/carrier ~oldi1~g apparatus. When the carrier and scanner heads
- 22 -
i . ~ ~ ' . '
5~
are moved relative to each other, e.g.~ in the direction shown by arrow 69
in Figures 2, 4 ~nd 5, the four binary bit rows are scanned simul~aneously.
In the alternat:ive, the rows may be scanned sequentially, if desired, by
adaptations of the scanner head or controlling the carrier motion. For ex
ample, a single scanner can scan the four rows on the carrier of Figure 5 in
sequence as it moves from left to right (in ~igure 5) across the rows.
Vertical spacing of the rows is not particularly critical. Stand-
ard vertical spacing of line printers is either 1/8 inches or 1/6 inches.
"I" symbols are preferre~l3 rather than plain vertical bars to detect vertical
crosstalk. Only the center portion of the "I" bar is optically scanned;
therefore, vertical spacing drift into the row above or below results in a
much longer dark pulse width producing a detectable error from the optical
character reader with an alarm to notify the operator to correct the vertical
alignment of the line printer.
Similar error detection has been designed into the system for hori-
zontal spacing errors. For example, ln the four line bar code should one or
more lines drift left or right, the phase of the four channels would be not
synchronous. In the event the horizontal drift or error becomes so larg'e as
to approach a full space (l/lO inch), the logic is arranged to require a
binary code 11, 12 or 13 in the first digit, a binary code 14 in all blank
digits, and a binary code 15 in the last digit space. It is obvious that
these conditions would not be met, and the horizontal error would be immediate-
ly detected. Of course, other unique logic arrangements can be used to
detect misalignment errors due to faulty printer set up. For the ~1" bar code
spacing shown, the printer can shift position ~.050". i.e., a half-space, yet
the code is readable. Ability to accept carriers within such a latitude is an
important aspect of the invention. ~hile all the embodiments of Figures 2,
~ 23 -
~¢~
~ and 5 are suited to compute-r controlled line printing, that of r'igure 5 can
be prillted the fastest as it is completed in one line.
The code sequences of indicia 2~a are important, and the binary I-
bar code relresentation 24b of the indicia 2~a is specially adapted for the
instant carrier invention. Code sequence 70 (see ~igure 2) has a number of
subunits, some of wllich are optional. Unit 71 is the zip code of the account
(cardholder). Unit 72 is conveniently the batch number of cards in that
particular issue. Unit 72 may also be or include an issue number, a batch
number, quantity number, process date (Julian day), or an issue and batch
number, or an issue, batch, card or carrier sequence number depending on the
number of digits and spaces. While shown as a three-digit number, it may be
any number of digits to include the desired identification. Units 71 and 72
may be to the left of unit 73 as shown, or to the right of unit 78.
Unit 73 is the number of cards in the account, e.g., I to 3 in the ~ -
example of ~igure 2 ~or l to 6 if piggy-backed)~, 1 to 8 in Figure 4 and 1 to ~ ;
12 for the double carrier III and IV of ~igure~l. An important aspect of this
invention is the binary des1gnation of 11 for one card, 12 for 2 cards ~as
shown in Figure 2), and 13 for 3 cards in the account. ~ere there are up to
eight cards in a carrier (four retail card slits carrying two cards each in
piggy-back configuration), the unit 73 may be 2 or 3 digits (spaces) wide for
the appropriate binary code. Thus, binary 13 in the ~irst space followed by
binary 13 in the second and binary 11 in the third indicates 7 cards total
(3~3~ ; 13, 12, 10 (or 14) indicates S cards ~3+2~0), and the like. In normal
binary code the values are 0 through 9, whereas in the present code the values
are 1-10. In normal binary, nothing (no mark) in a space means zero. In the
present codc, zero is an error and detectable as such in the present binary
bar codo. ~or spaces between numbors or Ullits, a binary 14, i.e., a 2 bar
- 24 -
plus 4 bar plus 8 bar is used in the instant code, and is detcctable as such.
There is no confusion between a zero and a space in the cocle of this in~ention.
Unit 74 is the number of the issuer, e.g., thc bank, savings and
loan, company, etc. Unit 75 is the branch nwllber of the bank, factory number,
type of account, state code or the like, as desired. Unit 76 is the account
holder number. Unit 77 may be unused and provides Eor growth in the number of
accounts, or may be used as a carrier sequence number, or the like. Unit 78
is a stop scan command number.
There are a maximum of 19 digits, including spaces, in a credit
card account number. In the carriers of this invention we provide a minimum
of twenty-one and a maximum of twenty-eight words, including spaces, in the
field 73-78. Nineteen of these words correlate to the credit card account
number, and one word is for an end sentinel (stop scan signal) 78. In the
figures, one ~ord (position~ space, character or binary digit) has been provid-
ed for the number of cards 73 for our minimum of 21. ~hen more than three
cards are inserted in the carriers, up to two additional words are provided for
the number of cards 73. Optionally, we provide one word for start scan and
one for a parity check, for a total of twenty-five words in the field length.
In the embodiments illustrated in Figures 1-3, 7 and 8, the distance between
adjacent slit center lines is 2.8 inches ~7.112 cm) for standard credit cards
(see Figllre 8). That is the scan path length since the carrier moves relative
to the OCR 95 that length each time the carrier is indexed into insertion
position. This permits expanding the field length to twenty-eight words to
satisfy other functions, e.g., for sequence numbers, issue code numbers, batch
numbers, and the like. Non-account information, such as 71, 72 (Figure 2)
may lie to the right or left of the field 73-78.
Note also that the binary 1~ is a space in the I-bar code 24b,
,, -25-
while the stop scan is a binary lS. rrllus, the binary representations of num-
bers 1-9 are conventional, zero is binary 10, and 11-15 have special meaning
as described above. Tllus, if an 11-15 appears in a number space due to
printer misalignment of the bars, it is detected as an error signal. As
seen in Figures 4 and 5, the zip code and issue or batch numbers may be omitted
where desired Erom the indicia line 24a. The brackets 73-78 above the indicia
24a correlate to the brackets 73-78 below the I-bar code 24b7 and the I-bar
code can be visually read if desired.
Figure 7 shows another embodiment of a carrier form in which the
"B" panel contains a plurality of tear-out wallet cards 78, 80 and 81 which
are defined between fold lines 16 and 17, the marginal edge 2, and tearable
perforation lines 82, 83 and 84 spaced inwardly from the margin. While three
cards are shown, to correlate with the number of cards issued to that account
73, there may be any des1red number of cards of smaller or larger slze, space
permitting. For example, four cards slightly smaller in width may be spaced
between margins 2 and 11l or the space above card 78 in the "C" panel may be
used to provide additional cards.
Figure 7 also identifies line-by-line the printer layout for a
debit or account-type card. The lines are numbered Ll through L26~along the
,0 left side in the figure for convenience in this description, but ordinarily
would be omitted in carriers used in practice. The information on a line-by-
line basis is: ~
Line 1: Name o-f card issuing bank,
Line 2: Phone number of that bank to call if cardholder has a question about
his or her card;
Line 3: Person to ask for when calling;
Line 4: Credit card account number, number of cards and credit limit;
Line 5: Savings account number;
- 26 -
.
.. , . ~
, , . . ; .; ~ :~
. ' '~ ~ -. ' ' ' '
.
.5S~
Line 6: Checking account number, machi~e cash withclrawal limit;
Line 7: Primary account holder name;
Line 8: Address line one;
Line 9: Addrcss line two;
Line 10: City, state, zip code;
Line 11: First name and middle initial on cardholders 1, 2 and 3;
Line 12: Credit card account number taccount #l);
I.ine 13: Savings account number ~account #2~;
Line 14: Checking account number (account #3);
Line 15: Withdrawal; the types of accounts from which that cardholder may
withdraw;
Line 16: Deposits; the types of accounts into which that cardholder may make
deposits;
Line 17: Transfers ~rom (out); the types of accounts between which that card-
holder may transfer funds;
Line 18: Transfers to (in); the types of accounts between which that card-
holder may transfer flmds;
Line 19: Credit limit;
Line 20: Authorized cash removal (by machine~ in the designated time period;
Line 21: Number to call if cardholder has any questions;
Line 22: Zip code, batch number, sequence numberJ card quantity and credit
card account number followed by stop scan code;
Line 23, All "I" code binary representation of card quantity, aTId embossed
2~, 25, account number.
26
Example
Figure 8 illustrates a carrier of the type shown in Figure 1 in
the face-up orientation. The dimensions of the carrier are marked in the
~igure. Also, numbering vertically down the form from the top, the line-by-
line positions of the indicia discussed above are identified with the prefix
, ' ' ' , ' .,
'~L", as ~L15" to identify the city~ state ancl zip code. These positions are
the positions for an IB~ Moclcl 1~01 linc printer o~ 132 ~osition capacity, but
any available capacity machine may be cm~loyed, e.g.~ 120-16~ posltion
printers. The character positions across the carrier form ~from left to right
in Figure 8) are also identified with the prefix "P", as P53 to identify the
end signature (stop scan~ binary code. The L or R following a P number refers
to the left or right carrier orientation in a two-wide carrier stream. The
carrier shown is the left carrier, or carrier I in the L stream of Figure 1.
Thus, the end signature on this carrier is position P53L. The identical end
signature for carrier II in Figure I would be P137R. 18L,102R and 51L,135R
are the start and the end, respectively, of the address space for the Left and
Right streams.
This carrier may be used for hand or automated stuffing of standard
sized credit or debit cards. In automated stuffing, the VIS machine using
the carrier of Figure 8 is capable of inserting 1200 carriers/hr wlth three
cards/carrier ~account). This compares to 150 carriers/hour with an average
of 2.7 cards/carrier by hand stuffing for carriers of the prior art.
Figure 6 shows in perspective one embodiment of a verifier-inserter
system for automatic folding and inserting of credit cards in the carriers
of the present invention. The two-wide carrier form set 1 of Figure 1 is
split or boned along perf 2 to provide an L stream and an R stream which are
fan folded into two stacks 85 and 86~ respectively. The stacks are shown
separately in Figure 6 but they may be interleaved as shown by arrow 87. The
streams are fed into the VIS unit 88 upside down with the L carrier stream
under the R stream. The L stream is advanced into the VIS unit by pin or
friction drive 89 engaging the carrier stream web or holes 9 in the marginal
drive strips 3, ~. The marginal drive strip 3 is peeled off the carrier form
\
- 28 -
~3~.55~
prior to the first folding ste~ and is withdrawn at slot 90. SimilarlyJ the
R carrier stream is advanced by drive strip 4 co-acting with a corresponding
pin dri~e (not shown) and that strip is peeled off the carriers.
It is preferred to slit or bone off the drive strips with a
decollator prior to the carrier streams entering the VIS unit. Boning is
breaking the ties (pieces of paper between cuts; a cut plus tie is a perf),
and this may be accomplished in a conventional decollator~ for exampleJ a
Moore Business FormsJ Inc. Model 284B decollator. Boning is preferred to slit-
ting as the operator may misalign the central and marginal slitters to produce
the wrong-si~ed forms. Where the strips are boned or slit prior to feeding
into the VISJ advancement of the carrier forms through the VIS are by friction
drive rather than by pin drive.
The carriers enter the unit "C" panel first. The ca~rier form is
then separated (burst~ from the subsequent carrier along stream fold/burst
lines 15 or 18 (as the case may be~, e.g.J by drawing the carrier under ten-
sion across a relatively sharp edge or wire (burst bar~. The "A" panel of
the separated carrier 91 is simultaneously or sequentially folded back toward
the "B' panel as shown by arrow 92 and retained at an acute included angle
as shown at 93 in Figure 6. The carrier is then advanced or indexed sideways J
as shown by arrow 94 so that read head 95 scans the information means 24b.
In this embodimentJ the read head is an optical character reader scanning I-
bar code. The head may be any other type above described to scan the appro-
priate mode of information from the carrierJ i.e. J mag stripe, mag code, delta
distance code, punch holesJ embossed characters or the like. The scanned
information is transmitted by line 96 to a logic and command module 97 (LCM).
The LCM stores the information about the carrier including account identifi-
cation number and number of cards to be inserted in that carrier.
- 29 -
,., ~ .
A st~ck of credit cards 98 is placed in a receiving tray of the
VIS unit. The cards are advanced by pusher 99 to a picker lO0 as shown by
arrow lOl. The cards are removed from the stack one by one and advanccd
through an embossed charac-ter reader (ECR) 102 as shown by arrow 103. The
ECR reads the account number embossed on the card and the information is trans-
ferred to the LCM 97 via line 104. It should be understood that the card
reader may be any type of reader and is not limited to an embossed character
reader. For example, the reader may contain heads for reading magnetic
stripes, indicia or bars on or embedded in cards, or an optical reader for
reading characters, indicia, fonts, color bars and the like printed on or em-
bossed in the cards.
The LC~ compares the inormation from the carrier and the card,
e.g., bar code to embossed, or embossed to magnetic, magnetic to magneticJ
punched to embossed, punched or embossed to magnetic, and the like, or vice
versa. If there is a match, the card is placed into an insertion mechanism
105 by a laydown mechanism 106 and inserted into the first slot 19 of the
carrier. If the card does not match the carrier, the card is ejected to
reject tray 107, or the carrier is advanced to reject tray 108. The LCM then
mitiates a search mode in which cards 98 aré advanced through the read
station 102 until the correct card for the carrier is found. Al~ernately, the
VIS can search through the carrier by advancing them through the read station
95 until the matching carrier is found. It is preferred to search the cards
since the rejects may be replaced, in sequence, from reject tray 107 to the
card feed tray 101 more simply than refeeding carriers after finding the
correct card. Purther, if one or more cards have been inserted in the carrier
and an additional one or more is required, it is better to find the card than
advance the carrier.
- 30 -
's ~ .
'`
.
.
Irhere there is verification, i.e., a match between card and carrier,
the card is laid down and inser~ed. Where the information from the carrier
indicates a second card is required, thc carrier is advanced to align a second
pocket with the insert mechanism. The cards and carriers are advanced simul-
taneously so that the card will be in place for insertion in the pocket upon
indexing (advancing~ of the carrier pocket into position. When the correct
number of cards are inserted in the carrier, two are shown in Figure 6 in
pockets 19 and 20 at position 109, the carrier is advanced again out of the
insert mechanism and the "C" panel folded over the exposed cards in the "A"
panel as sho~n by arrow 110. The completed, inserted and folded carrier is
then stacked as at 111, or forwarded direc~ly to a mailing envelope stuffing
operation or to be scanned prior to stuffing in a pre-mailing pulling and
checking operation.
The command outputs from the LCM 97 are shown in F1gure 6 in
schematic as carried by line lll to activate the VIS motor ll2 which transfers
power to the various subunits described above by jack shaft;113. ~Power is
selectively transferred to the individual subunits by selectlve activation of
clutch means on the jack shaft~on~command from the LCM via lines 114 through
119; to the power clutch~(line 114); motor start ~line 115); picker and card
laydown mechanism 116. Likewise~ power is activated off the jack shaft via
line 117 for indexillg the~carrier, via lines 118 and 119 advancing the carrier
streams into the VIS unit, and for the final fold all by clutches on command
from the LCM.
Figure 9 shows in schemat1c the overall process steps for producing,
inserting and folding the carriers of this invent1on. A webroll 120 of suit-
able sheet material 121 is printed on a web press l22 with a desired design
and instructional and/or contract indicia. Figure 9 then shows $hree alter-
- 31
~ "
.
.
,~. ,:. :
' '" ' '
3 ~.~5~
nate modes of perfing, punching and slitting or boning, as identified by
follo~ g webs 121a, 121b or 121c. Following first web 121a, roller punch
123 punches out the sproclcet drive holes 9 or 9' (see Figures 1 and 3) in the
carriers or marginal drive strips. The web is then transversely perforated
(lines 15, 16, 17, 18 in Figure 1) by transverse perf rollers 12~. T~he print-
ed web is then perforated axially (longitudinally) by perf rollers 125 in
one to three parallel lines, perfs 2, 7 and 8. Simultaneously, or before or
after the horizontal perfing, the slits or slots are cut into the web by
roller-mounted cutters 126.
Web 121b shows these operations 123-126 sequentially with one under-
web pressure roller 170, and web 121c shows these operations 123-126 in a
2-roll press. The operations 123-126 may occur in any desired sequence.
Af~er these operations the web 127, containing completed blank
carriers, goes to one or more of four optional operations. The web may be
rolled up at 128 as a roll of completed carriers for transport and/or future
use. The web may be fed to a rotary chopper 129 and stored as~ a stack of ;~
completed carriers in individual sheets 130. This is particularly useful in
the case of carriers for hand insertion, such as carriers I and II of Figure
1 not having drive margins. The carriers may be separated down the central
longitudinal line 2 ~Figure 1) before chopping and stacking. In the third
alternative the carrier form sets may be folded along fold lines 15, 18, 22
(Figure 1) to form a fan-folded stack 131. Another alternative lnvolves
splitting (separating) or boning the web longitudinally by a roller~type
slitter and fan folding the resultant L and R streams (shown in Figure 9) to-
gether so they are interleaved as a single interleaved stack 132.
Any of these forms of the carrier sets are then forwarded to the
second stage of operations, that of printing or encoding individual account
- 32 -
.~Ad
~V.l~ Si4
information in individual carriers, inserting cards and folding them. The
continuo-ls web of carriers 127a coming directly from the carrier preparation
operation, or the various alternatc forms oE carriers 127b, is fed to a
printer (imaging device~ or encoder unit 134 which is controlled by a process
control and customizing computer (or computer-generated tape~ 135 which
contains data on the individual accounts. In the example shown, printer 134
is a line printer that prints information on the carrier of the type shown in
Figures 2, 4, 5~ 7 and 8, including the I-bar code. The printad two-wide
carrier stream 136 is then slit or boned, and the marginal drive strips 141
and 142 removed, e.g., in a decollator operation 137, forming two streams, an
L stream 138 and an R stream 139 and fed into the VIS unit, singly or inter-
leaved, as shown by the arrows. Alternately a one-wide stream 140 can be fed
directly into the VIS from the printer 134.
In the VIS the stripped form sheets, streams or webs 138, 139, 140
are passed over a burst bar 143 and separated into individual carriers 144a,
144b along lines 22, 15 and 18 ~Figure 1). The "A" panel of the carrier is
then folded over as shown by arrow 145 and the carrier advanced ~arrow 146)
past read station 9S into the first insertion position. The read head 95
optically or electromagnetically reads the I-bar code, and information is
transferred to LCM 97 as earlier described.
Plastic credit card core stock 147 (shown as 147a in roll form,
147b in sheet form~ is printed on the front side 148a or b, and on thc back-
side 149a or b, in one or more colors. The printed stock is then laminated
on one or both sides with transparent plastic sheets 150a and/or 150b in roll
press lSla or sheet press 151b. Individual cards are produced from the core
stock 152a or laminated sheet 152b by reciprocating punch 153 to produce
virgin credit cards 154. The virgin cards are embossed or encoded (mag stripe)
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,,
with individual account information in embossing or mag stripe encoding unit
155 (e.g., a Data Card embossing or mag strip encoding unit~, which is fed
the appropriate information on the same or different computer 135 or LCM 97.
155a represents embossing, 155b represents encoding a mag stripe, and 155c
represents other impressing or encoding information by other means. For
example, when the carriers are read by scanner means 95 and information
transferred to LCM 97, the LCM can command the embossing or encoding unit
155 to emboss or encode virgin plastics with the correct information so that
the cards and carriers are in proper sequence. The cards are then passed
directly to the insertion means 105. Conversely, the-embossing/encoder can
control the VIS insertion operations by location of the computer ~or tape)
135/LCM 91 in the embosser/encoder 155.
The embossed cards 98 are forwarded to the VIS unit where the em- -
bossed or encoded information is read by reader 102 ~102a embossing, 102b mag
strip reader, 102c "other" reader), which forwards individual card information
to the LCM 97 which may be part of computer 135. In the LCM 97, the informa-
tion from the carrier via reader 95 is compared with information from the
cards via reader 102. If there is a match ~verification) the LCM commands
the VIS unit to insert the card in the waiting, partly folded carrier 156, the
output command function being shown schematically via line 157. The direction
of card insertion is shown by arrow 162 in Figures 2, 4, 5 and 9.
~Vhere, for example, the account information indicates only one or
two cards are appropriatc for the carrier, the carrier will be cycled sequen-
tially through two or one insertion positions, respectively, without cards
being inserted. This is accomplished by a command function which causes the
card picker to retract or stop, while the carrier continues to be advanced.
The retracted picker may cycle without picking and advancing cards through
~ 3q ~
r
3~ ~54~
tlle card read station, laydown door and inscrtion tray. In addition, where
there is a carrier/card mismatch, ~he logic/command module operates to cycle
through a plurality of cards while the carrier remains stationary. Rejected
cards are retained in a reject tray and may be recycled to ~he load tract.
This search mode may be repeated as desired by an operator.
Thc carrier with its individual complement of cards 10~ is then
advanced through a fold station 16~ where the "C" panel is folded along fold
line 17 completing the folding of the carriers 158. The folded carriers 158
exit the apparatus folded and in account sequence. T~e completed carriers
are oriented in a manner that account information is presented in a suitable
position, e.g.~ along the upper edge (see Figure 2), so that it may be
selectively read or sensed for further processing or checking, e.g., pulling
or checking.
In ~he verification operation, verifier uni~ 181 checks the number
of cards inserted in a folded carrier. Th~is is done by serially passing
completed, inserted and folded carriers 158 horizontally (e.g., direction of
arrow 69 in Figure 2) between the nip~of a pair of rollers, one fixed and the
other movable, and determining the thickness of the carriers 158 at the posi-
tion of each pocket by sensing the relative deflection of the movable roller.
This sensed verification information is forwarded via line 193 to computer/LChl
135/97 and compared to the proper number of cards that should be in the
carrier as sensed by read head 95 (or as instructed by computer or tape data
in 135/97~. Where there is a mismatch, the computer/LCM 135/97 commands the
verifier to reject the carrier at 182. The verified carriers may pass direct-
ly to an envelope stuffer 161 via lines 183, 18~ or pass to a pulling unit
185 via line 186.
In the pulling operation 185 the inserted carriers 158 are scanned
. ~ :
5~
or read by a reacl head 159 whicll transmits information to LCM 97 and/or com-
puter 135 which compares the da~a with an updated approved list. If there
is neecl for a last-minute PU11J the computer, tapo or LCM activates a reject
unit 160. I-t is ~referred to pass the carriers 158 through the pulling unit
serially, as described above for the verifier unit, with read head 159 scan-
ning the information (23, 24, 25, 26, 27, 28, 180 Figures 1-8) on the carrier
as the completed carriers pass the head, and pulled carriers being rejected
as bad accounts are identified. In the alternative, as shown in Figure 9, the
carriers may be scalmed in a stack 187, with pulled carriers being rejected
at 188. The updated batch of completed carriers are then forwarded to mailing
envelope stuffer 161.
The completed carriers, alone or with other mailer information, are
then inserted or stuffed into envelopes by hand or in an automatic mail in-
serting unit 161 (such as a Pitney Bowes 3144 "Insertamax*" high-speed auto-
matic mail insertion unit, or a Bell ~ Howell/Phillipsburg automatic envelope
inserter).
The completed, stuffed envelopes 163 are mailed or delivered to
customers (account holders) directly, completing the process, or may be pro-
cessed in a sealed envelope detector (SED) 189 having a scanner unlt like
units 95 or 159 (not shown in detail~. The information 23, 24a or 24b is
positioned to be read through the envelope, e.g., windows 34 or 35 on the
front or back of the envelope (see Figure 2 and accompanying description
above), or from the envelope itself, e.g., label 180 applied directly to the
front or back of the envelope. The scanned information, e.g., in the for~ of
optical, electronic or electrically detectable pulses, is passed to the
computer/LCM 135/97 via line 190 where it is compared to the updated approved
list. If the particular account is bad, the computer LCM 135/97 commands
*Trade marl~ l
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the detector to pull tile envelope sholm at 191. The sealed envelope detector
(SED) also senses the number of cards in the carrier and rejects incorrect
ones at 192 in the mamler above described for -the vcriEier unit 181. The
SED may have its ol~n scanner, or may use information from scanner 95 or 159
without need to scan the envelopes or windows. This is preferred where the
SED is integrated with the VIS unit o-f Figure 6.
~Yithin the spirit of the invention we may position information 23
and/or bar code 24b or the like, on the B panel (see information 23, 24a, 24b
on carrier II in Figure 3) so that when the completed carrier is stuffed into
an unsealed envelope, the bar code is revealed in the triangular area between
the upper edge of the ellvelope flap and the back panels o the envelope. The
bar code is thus presented for automated or manual ~visual) "reading" for
verification and pulling just prior to sealing. In an alternate embodiment,
the back of the envelope may have a special window juxtaposed opposite informa-
tion (23, 24a, 24b) for verification and/or pulling after sealing by reading
through the window. In still another~embodiment, a line printer may be used
to print the information 23, 2~a, 24b on labels which may be applied to bldnk ~;carriers, mailers or envelopes. The labels may then be applied to the carriers
or mailers by the VIS unit, and to the envelopes by the verification, pulling,
envelope stuffing, or SED units in accord with information in computer/LCM
135/97 sensed from credit cards as they are inserted in the carriers.
Likewise, the principles of automated scanning, insertion, verifi-
cation, pulling, stuffing and sealed envelope verification and pulling dis-
closed herein may be applied to other types of carriers, including prior art
carriers and future carriers. Thus, information 23 and/or information 24a
(e.g., bar code) may be applied to single panel carriers, pocket carriers,
mailing inserts, envelopes, and to labels applied to carriers, ~nvelopes and
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mailers and the like, ~or automated insertingJ veri-fication, pulling and
sealcd cnvelope detection at various stages of operation as disclosed herein.
I`he slits of the invention may also be straight slits, parallel to
an edge (e.g., a straight slit ~0 in carrier I of Figure 3), or a single
straight slit may be inclined at an acute angle (with respect to an edge),
e.g., in Figure 2, extending limb 19a of slit 19 to the right for the full
slit width. In another embodiment, slits or slots may be omitted, with the
cards being wcdge-trapped between the panels. The first end oE the card
(31 in Figure 2) is trapped between the A and B panel, while the other end
(32 in Figure 2) is trapped between the card B panels.
The carriers of the instant invention can iorm their own envelope.
For example, Figure 2 shows the three panels stapled together by staple 178 at
the left edge. The right edge is similarly stapled (not shown) J and an op-
tional glue spot or stripe 179 along the inner (back side) edge 18 of the
C panel completes the seal of the C panel to the A panel. ~The mailing
address 27 may remain on the C panel or be placed on the B panel. Figure 6
shows glue stripes 175J 176, 177 adjacent the side edges 12 and 2 respectlvely,
and on the C panel of carrier lV ad~acent fold/burst line 15. This glue is
on the backside of the carriers. When folded, the carrier is sealed by the
adhesive forming a completed envelope.
Various inclusive definitions used herein apply to terms in the
~laims as well. For exampleJ reference to "credit cards" should be understood
to include any type o~ card whether a credit, debit, account, access, identi-
ficiation, key, pass card or the like. "Carriers" or "credit card carriers"
includes carriers of any kind and includes mailers and/or envelopes therefor
where applicable. "Information'i includes information relating to the card-
holder and/or account as applicable and includes any form of representation.
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~ ~ ,
,
,
J
"Indicia" or "number" includes markirlgs of all sorts, numbers, letters,
designs, fonts, cocies and the like. "Pulses" includes any form of in~orma-
tion bit transfers whether mecllanical, electrical or in the electromagnetic
wave spectrum, for example, electrical signals, visible, ~V or IR light waves,
microwave, magnetic bubbles and the like. "Readable" or "scannable" includes
any manual (visual) or mechanical manner of ascertaining information from the
carriers or labels, and by "mechanical" is meant to be included in whole or
in part any optical, electro-optical, magnetic, electronic, electromechanical,
electric, and purely mechanical methods and apparatus. Reference to "card-
holder account number" or "account number" includes any unique identifying or
code number relating to an individual cardholder and is not restricted to a
financial-type account. It may include a number assigned to an employee
permitting access to certain buildings, rooms, files and the like. "Web"
includes an extent of sheet material whether in s-ingle sheet form or continu-
ous form.
It should be understood that various modifications within the
scope of this invention can be made by one of ordinary skill in the art with-
out departing from the spirit thereof. We therefore wish our invention to be
defined by the scope of the appended claims as broadly as the prior art will
permit, and in view o~ this specification if need be.
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