Note: Descriptions are shown in the official language in which they were submitted.
WO941215~ 9 ~ 1~ PCT~S94/03~2
CARD ~R~T~ FORMS FOR AUTOMATED
EMBOS~ED CARD PACRAGE PRODUCTION ~Y~M
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation-in-part of U.S. patent application
Serial No. 08/019,865 of Hill et al. filed February l9, 1993
for "Automatic Embossed Card Package Production Apparatus and
Methods".
BACRGROUND OF THE l~v~..lON
l. Field of the Invention
This invention is related to card carrier forms to which
are mounted credit cards and the like for mailing and,
particularly, to such carrier forms in which the cards are
mounted automatically by mechanical, nonadhesive means.
2. DescriPtion of the Prior Art Includinq as Disclosed Under
37 CFR l.97 - l.99
It is well known to mount or insert credit cards and the
like to planar card carrier forms made of paper which, in
turn, are inserted into window envelopes. The carriers each
have a pair of parallel, preweakened fold lines which divide
the carrier body into three substantially equal sections: a
leading end section, middle section and a lagging section.
The cards are mounted to the middle section and the carrier is
folded along the fold lines to fold the leading and lagging
sections over opposite sides of the middle section. one of
the end sections bears the card owners name and address, and
the folded carrier form matches the size of a window envelope
in which the carrier form is "stuffed" or inserted. The name
and address on the end section is held in alignment by the
envelope for viewing through a translucent window of the
envelope.
In known carriers shown in U.S. Patents No. 4,38l,l96
WO94/21~22 a ! ~ PCT~S94/03~2
issued May 17, 1983 to McCumber et al. and No. 4,034,210
issued July 5, 1977 to Hill et al., the card is held against
removal from a pocket formed from a cut in the body of the
carrier by wedge trapping of at least one of two opposed edges
of the card by folding the end sections over the opposed edges
of the card at opposite sides of the middle section. In the
carrier of McCumber et al., a pair of corner pockets are also
formed by open slots cut out of the card body. These corner
pockets disadvantageously have unattractive entry holes or
open slots that result in the production of chaff when the
carriers are made and present an unattractive appearance. In
addition the pockets are formed by cuts exten~;ng along
diagonal lines which disadvantageously requires the use of
oscillating arms to open the pockets during insertion. In the
carrier form of Hill et al. on the other hand, the entire card
is inserted through a single edge slot and both edges are
wedge trapped by the ends section on opposite sides of the
middle section of the body.
~M~ARY OF THE INVENTION
It is therefore the principal object of the present
invention to provide card carrying mailing forms, or carriers,
with features which overcome the disadvantage of known
carriers noted above.
This objective is achieved in part by providing a carrier
form for carrying a card having two pairs of opposed corners,
comprising a flexible planar body for supporting at least one
card, a pair of spaced corner pockets carried by the body for
receipt of one of the pair of opposed corners of the card to
hold the card against movement in three of four possible
rect;l;ne~r directions and a flap carried by the body for
entrapping engagement with an edge of the card intermediate
another one of the opposed pair of corners opposite the one
pair of corners to releasably hold the card against movement
out of the corner pockets in a fourth of the four possible
WO94/21522 215 9 010 . PCT~S94/03~2
rectilinear directions.
Preferably, the corner pockets and flap are formed from
sheets cut through the body and they are located to hold the
card spaced from the peripheral edge of the card. Both the
pockets and the flap resiliently flex from the planar body
when the body is bent to open the pockets for receipt of the
card corners and for the flap to resiliently flex from the
planar body to ride up and over the edge of the card when the
body is bent and unbent while the card is in the corner
pockets.
Obtainment of the object of the invention is also
achieved in part by provision of a mailing form for carrying a
card, comprising a flexible planar body with one section
connected at a fold line to another section for supporting at
least one card, a pair of rectilinear slots cut in the body to
form a pair of opposed corner pockets spaced from the fold
line for receipt of opposed corners of the card to hold the
card adjacent the fold line, each rectilinear slot having a
pair of spaced slot sections parallel to each other and a
cross slot section transversely extending between the pair of
parallel spaced slot sections, said other sections foldable
over the one section to block removal of the corners of cards
from the corner pockets.
Preferably the pockets are formed from closed slots to
provide a pleasant appearance; the cross slot section extends
between adjacent ends of the pair of parallel slot sections,
and the distance between the outside ones of the parallel slot
sections is sufficiently greater than the dimensions of a card
to enable receipt of multiple cards.
BRIEF n~ZP"PTPTION8 OF THE: DRAWING~
The foregoing objects and advantageous features of the
invention will be explained in greater detail and others will
be made apparent from the detailed description of the
preferred embodiment of the present invention which is given
with reference to the several figures of the drawing, in
W094nl5~ ~ 15 9 0 10 PCT~S94/03~2
which:
Fig. lA is a perspective view of the preferred embodiment
of one type of carrier in folded condition in which the cards
are held by means of a pair of corner pockets and a flap at a
location spaced from the periphery of the carrier body;
Fig. lB is an enlarged detailed view of the carrier of
Fig. lA prior to folding;
Fig. 2A is a perspective view of the preferred embodiment
of another type of carrier in folded condition in which the
cards are held in corner pockets by means of a sectional fold
at the periphery of the carrier body which blocks removal of
the cards from the pockets when folded; and
Fig. 2B is an enlarged detailed view of the carrier of
Fig. 2A prior to folding.
DE8CRIPTION OF THE PREFERRED ENBODI~ENT8
Referring first to Figs. lA and lB the preferred
embodiment of the first kind of carrier form is seen to have a
rectangular planar paper body 12 with a leading fold line 14
and a lagging fold line 16. The fold lines divide the carrier
body 12 into three rectangular sections: a leading end
section 18, a middle section 20 and a lagging end section 22
which are approximately the same size.
Preferably, carrier form 10 has a name and address field
24 at which the name and mailing address of the individual to
whom the carrier is to be mailed is printed located at the
leading end section 26. In addition, the lagging end section
22 also has printed thereon in machine readable code at a code
field 26, also at the lagging end section 22, the account
number or other identifying information which should match the
account number embossed and magnetically encoded on the cards
to be mounted to the carrier. Preferably, this code is a
photoptically readable bar code such as: (1) interleaved two ?
of five code; (2) three of nine code; (3) Co~h~r UPC-A&E
code; (4) EAN-8 code; and (5) EAN-13 code.
The other end section 22 typically contains written
~ W094/21522 ~159 0 t 0 PCT~S94/03~2
. .
material, such as contract terms, graphics, or the like (not
shown). As next seen in Fig. lB, after one to a maximum of
four cards 30 are mounted to the middle section 20, the front
side of the middle section 20, as shown in Fig. lB, is folded
along fold line 16 over the top of the lagging section, as
shown in Fig. lB, and the leading end section 18 with the name
and address field 24 facing outwardly is folded over the back
side of the middle section 20.
Referring still to Fig. lB, substantially identical card
carrying stations 32A and 32B which respectively carry the
cards 30 in attractive side by side relationship in the middle
of the middle section 20 spaced from the periphery of the
carrier form defined by the pair of fold lines 14 and 16 and
the opposite parallel sides 34 and 36 of the carrier body 12
exten-ling between which the fold lines 14 and 16 extend.
Preferably, each of these card carrying stations 32A and 32B
are capable of carrying at least a pair of cards 30 stacked
one atop the other.
Referring to card carrying station 32A, Fig. lB, each of
the card carrying stations has a pair of spaced corner pockets
38 and 40 carried by the middle section 20 of the card body 12
for receipt of one of the pair of opposed corners 3 OA and 3 OB
on opposite sides of an edge 42 of the card. These pockets
3 OA and 3 OB hold the card 30 against relative movement in
either of the two rectilinear directions parallel to card edge
42 indicated by doubled headed arrows 44 and 46 and in one of
the rectilinear directions transverse to edge 42, indicated by
arrow 48.
A flap, or lip, 50 carried by the middle section 20 of
the body 12 engages an edge 52 of the card 30 opposite the
edge 42 intermediate the other pair of corners 30C and 30D to
releasably hold the card against movement out of the corner
pockets 38 and 40 in the fourth rectilinear direction away
from the corner pockets 38 and 40, indicated by arrow 54.
Preferably, the corner pockets 38 and 40 are formed from
slots 54A and 54B cut through the body which are closed, i.e.
with abutting edges, to avoid the unattractive slots or holes
WO94/21522 ~ 1~ 9 ~ ~ ~ PCT~S94/03~2
found in known carriers. The slots 54 of corner pockets 38
and 40 extend from first points 56A and 56B, respectively, on
the body 12 adjacent to the edge 42 of the card between the
corner pockets 38 and 40 when the card 30 is inserted into the
pockets to points 58A and 58B, respectively, on the body
adjacent the associated side edges 60 and 62 of the card 30.
The slots 54A and 54B form mirror images of each other; the
points 58A and 58B, and 56A and 56B, respectively, are aligned
parallel with each other and with the fold lines 14 and 16.
The slots 54A and 54B are generally L-shaped with each
having an elongate section 60 ext~n~l;ng generally transverse
to the fold lines 14 and 16 which mate with diagonal section
62 " at rounded corners 64. The diagonal section 64, rounded
corner 64 and a portion of the section 60 form an ear 66.
These ears resiliently flex from the planar body 12 when the
adjacent portion of the planar body is bent to open the
pockets 3 OA and 3 OB for receipt of the corners of the card 30.
This opening of the pockets 3 OA and 3 OB enables the card to be
inserted in between the ears 66 and the body 12 intermediate
the ears 66 and slid into full engagement with the pockets
with edge 42 adjacent end points 56A and 56B of slots 54A and
54B, as shown in Fig. lB. AS seen in Fig. lB, the distance
between side end points 58A and 58B is sufficiently greater
than the width of the card, and the diagonal sections 62
extend sufficiently rearwardly toward the direction of card
insertion from the side end points 58A and 58B, to enable
receipt of at least two cards 30 stacked on top of each other
(only one shown).
The flap, or lip 50, like the corner pockets, is formed
from closed slots cut 68 through the body 12. Preferably, it
has a triangular slope formed by the slot 68 exten~l;ng
inwardly toward the card edge 42 to a point 70 from two points
72 and 74 intermediate the corner pocket sections 60 between
the card corners 30C and 30D adjacent the edge 52 of card 30
when inserted in the corner pockets 3 8 and 40.
The flap 50 like the ears 60 of the ears 66 corner
pockets 38 and 40, resiliently flex from the planar body 12
WO94/21522 21~ ~ O 1~ ; s ~ PCT~S94/03~2
when the planar body 12 adjacent the flap S0 is bent out of a
planar configuration. More accurately, when the planar body
12 adjacent the ears 66 and the flap 50 are constrained to
conform to a curved surface but the ears 66 and flap 50 are
not so constrained the ears 66 and flap 50 maintain the normal
planar configuration to resiliently flex away from the curved
surface of the body 12. When the body 12 is returned to its
normal planar configuration, the ears and flap resiliently
return to alignment with the body 12 unless the card is
interposed therebetween. In that event, the card is
resiliently squeezed between the ears 66 and the flap 50
adjacent body 12 and against the flap 50 and the adjacent part
of body 12.
When the planar card 30 is within the corner pockets 38
and 40 while body 12 is curved, or bent away from the corner
pockets 38 and 40, the point 70 of flap 50 pivots about a line
between end points 72 and 74 and rides along the underside of
the card 30 toward the edge 52. After the tip 70 has ridden
past the edge, return of the body 12 to a planar condition
causes the tip 70 to ride up and over the edge 52 and to the
position overlying the front of the carrier body 12, as shown.
Employing the carrier form to maximum advantage is
achieved through use of automated equipment to insert cards
and fold the carrier. Suitable automated insertion is shown
and described in the parent of this application noted above as
well as in U.S. Patent Applications Serial No. 08/036,657 of
Hill et al. entitled "Automatic Verified Embossed Card Package
Production Methods" filed March 24, 1993; Ser. No. 08/036,159
of Hill et al. entitled "Card Package Production System With
Burster and Carrier Verification Apparatus" filed March 24,
1993; Ser. No. 08/036,664 of Hill et al. entitled "Embossed
Card Production System With Modular Inserters For Multiple
Forms and Card Verification Apparatus" filed March 24, 1993
and Ser. No. 08/036,439 of Kassabian et al. entitled "Card
Package Production System With Modular Carrier Folding
Apparatus For Multiple Forms" filed March 24, 1993, all of
which are contemporaneously filed herewith, and reference
-
WO94/21522 21 5 9 01~ PCT~S94/03~2
should be made to these applications for details of authorized
use of the carrier form. Briefly, when used in this automated
insertion equipment, the carrier lO is to run it through a
roller with direction of arrow 48 to first bend open the ears
66. Then, one or more cards 30 are automatically inserted
into at least one of the pockets of the card carrying stations
32A and 32B. The card 30 is held in the corner pockets while
the roller continues to move the conveyor away from the card
inserter. The card body 12 adjacent the flap 70 then passes
over the roller to pivot the flap 70 over the edge 52 of the
card. The carrier is then automatically fan folded into the
form shown in Fig. lA.
It should be appreciated that any other automated
equipment which bends the body 12 for purposes of entrapping
the card between the lower pockets 38 and 40 and the flap 50
could be successfully employed to automatically insert cards
into the carrier lO. Moreover, of course, cards 30 can also
be easily inserted into the carriers by manually h~; ng the
planar body 12 to open the ears 66 and flap 50 and manually
inserting the cards 30.
For purposes of automated use, preferably the location of
the name and address field 24 is located in the leading end
panel, or leading end section, 18 and the location of the code
field 26 is located in the lagging end panel, or lagging end
section, 22 and the pockets 38 and 40 face in the direction of
arrow 53 away from the leading end section and away from the
direction of automated carrier movement indicated by arrow 48.
Prior to use, a plurality of the carriers lO are
interconnected in fan folded fashion and each time an end one
of the carrier is removed from the other carriers by a
"bursting m~c-hAn;~m", the code in code field 26 is read to
make sure the carrier is the correct one for the cards
presented for mounting to the carrier. In addition, the
carrier has a mark, such as a hole 76, for automatic sensing
of the position of the carrier lO during the various steps of
automated card insertion. Consequently, the carrier is easily
folded into the folded condition shown in Fig. lA with the
W094/215~ 21~ 9 010 PCT~S94/03~2
address field 24 facing upwardly from leading end panel 18
which covers the back side of the middle section 20 and cards
30, which, in turn, overlies the front side of lagging end
section 22.
Referring now to Fig. 2A, a preferred embodiment of
another card carrying form, or carrier, 80 which also has a
rectangular planar body 82 made of resilient paper which
normally maintains a planar configuration, like body 12 of
carrier 10. Also, like carrier 10, carrier 80 is shown has a
leading preweakened fold line 84 and a lagging preweakened,
fold line 86 to divide the planar body 82 into three
substantially equal rectilinear sections: a leading end
section 88, a middle section 90 and a lagging end section 92.
The cards are held in pairs of cooperating pockets 98 and 100
by folding the front side of the leading end section 88 over
the front side of the middle section 90 and the cards 30. The
address field 94 and the code field 96 are not viewable after
the carrier is folded as shown in Fig. 2B, since, unlike
carrier 10, the carrier 80 has the name and address field 94
and the code field 96 located on the front side of the lagging
end section 92 for the address and name and code to be viewed.
The back side of the lagging end section 92 is folded over the
back side of the middle section 90 with the front side of the
lagging end section 92 facing downwardly, as shown in Fig. 2A.
Consequently, in order to have the name and address field 94
and the code field 96 facing upwardly after folding, as in the
carrier 10 of Fig. lA, the carrier form is flipped over prior
to stuffing into an envelope with an upwardly facing window.
The opposed corner pockets 98 and 100 are mirror images
of one another and are separated from each other by sufficient
distance to hold at least one card therebetween, and are
preferably capable of holding two cards, with a leading card
edge 102 adjacent fold line 84. The corner pockets 98 and 100
are formed by a pair of rectilinear slots 104 and 1106,
respectively. Each rectilinear slot 104 and 106 has a pair of
straight slot sections: an outside slot section 108A and 108B
and inside slot sections llOA and llOB which are located
WO94/21522 ~ 0 PCT~S94/03~2
parallel to each other and cross slot sections 112A and 112B
transversely ext~n~;ng between the pair of parallel spaced
slot sections 108A and llOA and 108B and llOB, respectively.
The distance between the outside parallel slot sections 108A
and 108B and the spacing between parallel slot sections 108A
and llOA, and between 1088 and llOB, enables receipt of
multiple cards within the pockets 98 and 100 in stacked
overlying relationship. As seen in Fig. 2B, preferably the
cross sections 112A and 112B extend between adjacent ends of
the pair of associated slot sections 108A and llOA and 108B
and llOB to form an opening for receipt of the corner of the
card 30.
These cross sections are opened, i.e. moved laterally
away from the plane of the planar body preferably by means of
pushing portion 82' of the planar body intermediate the inside
sections llOA and llOB. Additionally, unlike the carrier of
McCumber et al. which have diagonal cuts forming pockets
instead of rectilinear cuts forming the pocket, the
rectilinear cuts llOA and llOB are parallel to the direction
of movement of the carrier form 80 during automatic insertion.
This advantageously enables the opening of the pockets passing
the carrier form 80 over a roller with opposite end edges
located adjacent the inside parallel cuts llOA and llOB.
After the cards are inserted fully into the pockets 98 and
100, as shown in Fig. 2B, the carrier 80 passes from the
roller and the leading end section 88 is folded over the edge
102 of the card 30 to keep it in the pockets.
As with the carrier 10, reference should be made to the
aforementioned patent applications filed herewith for details
of preferred embodiments of the carrier package production
system which are designed to employ carrier form 80. Briefly,
as noted, a roller with edges adjacent the slot section llOA
and llOB is preferably employed to open the pockets 98 and
100 .
While a detailed description of the preferred embodiment
of the invention has been given, it should be appreciated that
many variations can be made thereto without departing from the
~ WO94/21522 ~15 9 010 PCT~S94/03232
scope of the invention as set forth in the appended claims.
