Note: Descriptions are shown in the official language in which they were submitted.
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INTEGRATED PLASTICIZED CARD IN A
PAPER CARRIER AND METHOD OF MANUFACTURE
TECHNICAL FIELD
The present invention relates to a carrier sheet form
having an integrated card having opposed plasticized
surfaces and preferably, but not exclusively, a magnetic
strip card, and the method of manufacture and use.
BACKGROUND ART
It is known to provide carrier sheets having
detachable cards printed thereon with the contour of the
card being die cut and retained in the sheet or form by
friction or uncut regions about the card. As discussed in
U.S. Pat. No. 5,131,686 it is also known to manufacture
identification cards produced as embossed plastic cards and
plain paper cards. However, embossed cards are relatively
expensive to make, while plain paper cards are inexpensive.
The problem with paper cards is that they are not long
lasting and do not convey a polished image on their outer
surface. The image can be chipped off paper fibers and these
cards are not water resistant.
To make plastic cards, it is necessary to utilize
plastic-coated paper and these are produced on an impact
printer and the printing has relatively poor quality and are
unable to form quality bar codes and graphics on such cards.
Plastic sheets are also environmentally wasteful as most of
the sheet is not utilized after the card is detached and
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they are also costly and produce a recycling problem.
Often, these cards also fall off the carrier sheets. Paper-
handling machines and printers have problems with handling
sheets of uneven thickness, such as sheets carrying cards
and portions thereof and often will jam in the machine
resulting in costly maintenance and destruction of the paper
stock. This is much more serious if the printing consists
of personalized information as this would require resetting
the machine and the computer and analyzing the printed forms
to determine which have to be destroyed. In summary,
previous attempts have been made using laser or ionographic
printers and have failed to produce acceptable carrier
sheets bearing plastic die cut identification cards.
[0005] In an attempt to remedy this problem, U.S. Patent
No. 5,131,686 discloses a method and a sheet stock wherein
the layer of printable plastic is adhered to a portion of an
upper surface of a sheet and a second layer of paper or
plastic is adhered over the remainder portion of the upper
surface of the sheet, whereby the sheet is of substantially
uniform thickness and can be handled in a printing process
of the laser type, ionographic or ink jet type. However,
this method is costly due to the fact that another sheet
needs to be adhered to the large remaining portion of the
carrier sheet.
SUMMARY OF INVENTION
[0006] It is a feature of the present invention to
provide a carrier sheet with an integrated printed card
having opposed card panels which, when folded and glued
together, has opposed plasticized surfaces and preferably,
but not exclusively, a magnetic strip card, and which
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substantially overcomes the above-mentioned disadvantages of
the prior art.
[0007] Another feature of the present invention is to
provide a method of forming a carrier sheet having an
integrated detachable magnetic strip card having opposed
plasticized surfaces and which substantially overcomes the
above-mentioned disadvantages of the prior art.
[0008] Another feature of the present invention is to
provide a novel method of booking a travel event using a
carrier sheet with an integrated magnetic strip card having
a user code encoded on the magnetic strip and wherein the
carrier sheet contains personal printed information.
[0009] Another feature of the present invention is to
provide a carrier sheet having an integrated magnetic strip
card formed by two plasticized panels containing printed
information and a magnetic strip and an adhesive backing
wherein when said panels are detached from said sheets and
folded on a straight interconnecting fold line, said panels
are juxtaposed at their rear surface and glued together,
whereby said card is plasticized on the front and rear
surface thereof.
[0010] Another feature of the present invention is to
provide a carrier sheet according to the above described
feature, wherein the magnetic strip is provided on a third
plasticized panel integrated in the carrier sheet, whereby
the third plasticized panel has an adhesive backing and is
folded over an interconnecting fold line to form the
plasticized card.
[0011] According to the above features, from a broad
aspect, the present invention provides a carrier sheet with
an integrated card. The carrier sheet has printed
information thereon. The printed information contains in
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part card information printed at a predetermined location on
a front face of the carrier sheet in a card region of the
sheet and oriented to be disposed on ari outer surface of a
front and a rear card panel of a card to be formed. A
siliconized liner patch, containing a pressure-sensitive
adhesive surface, is laminated on a back surface of the
carrier sheet and disposed to extend over the card region.
A face patch of clear poly material is immovably secured
over the card region on the front face of the carrier sheet.
A die cut delineates the front and rear panels disposed
adjacent one another and extends through the face patch and
carrier sheet. The die cut card panels are retained in the
carrier sheet by the pressure-sensitive adhesive of the
siliconized liner patch. A straight fold line is formed in
the face patch to form a fold line between the front and
rear card panels. The card is formable by peeling off the
front and rear card panels from the carrier sheet with the
pressure-sensitive adhesive releasing from the siliconized
liner patch whereby the adhesive now lies on a back face of
the front and rear card panels. The panels are folded along
the straight fold line to secure the back face of the panels
containing the adhesive together.
[0012] According to a further broad aspect of the present
invention, there is provided a carrier sheet as described
above wherein a magnetic strip patch is immovably secured
over the card region on an outer face of a magnetic strip
panel. The die cut also delineates the magnetic strip panel
adjacent the front panel. A straight fold line is formed in
the face patch between the magnetic strip and the front card
panels. The card is formable by peeling off the panels from
the carrier sheet with the pressure-sensitive adhesive
releasing from the siliconized liner patch whereby the
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adhesive now lies on a back face of the card panels, and
folding the panels along the straight fold lines to firstly
mate the back face of the front and rear card panels
together and then the back face of the magnetic strip panel
on the rear card panel.
[0013] According to a further broad aspect of the present
invention, there is a provided a method of forming a carrier
sheet having an integrated detachable card. The method
comprises the steps of printing a carrier sheet with
information containing in part card information printed at a
predetermined location on the front face of the carrier
sheet in a card regiori of the carrier sheet and oriented to
be disposed on an outer surface of the front and a rear card
panel of a magnetic strip card to be formed. A siliconized
liner patch, containing a pressure-sensitive adhesive
surface, is applied on a back surface of the carrier sheet
and attached by said adhesive to extend over the card
region. A face patch of clear poly material containing a
magnetic strip is secured over the card region on the front
face of the carrier srneet. The front and rear card panels
are then die cut about their peripheries. The die cut
extends through the face patch and the carrier sheet,
whereby the die cut card panels are adjacent one another and
solely retained in vhe carrier sheet by the pressure-
sensitive adhesive on the siliconized liner patch on the
back surface of the carrier sheet. When detached, the
panels are folded along a straight fold line which is formed
in the face patch between the adjacent front and rear card
panels, whereby to permit the adjacent card panels to be
folded and stuck together on their back faces along the fold
line when adjacent die cut card panels are pulled off the
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silicone liner patch and carry the pressure-sensitive
adhesive on their back surface.
[0014] According to a further broad aspect of the present
invention, there is a provided a method of forming a carrier
sheet as described above, wherein a magnetic strip patch is
secured over the card region on the front face of the
carrier sheet when securing the face patch of clear poly
material thereon, wherein a magnetic strip panel is die cut
with the front and rear card panels, and wherein a straight
fold line is formed between the front card panel and the
magnetic strip panel to permit them to be folded together.
[0015] According to a still further broad aspect of the
present invention, there is provided a method of booking a
travel event comprising receiving a customer identity and a
personal event request. The customer identity information
and an event schedule information customized to the request
is stored in a computer. A carrier sheet containing an
integral magnetic strip card is automatically addressed to
the customer and the magnetic strip card is encoded with a
user code to access the stored information at an event
location. The carrier sheet with the integral magnetic
strip card which has been encoded is then forwarded to the
customer who detaches the card. The customer enters the
card in a magnetic strip card reader at the event location
whereby the stored information is automatically accessed by
identifying the user code to record the arrival of the
customer at the event location and automatically print
additional personalized information that may be available to
the customer only at the event locat.Lon for use by the
customer.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0016] A preferred embodiment of the present invention
will now be described with reference to the accompanying
drawings in which:
[0017] FIG. 1 is a plan view showing a carrier sheet
with an integrated magnetic strip card and constructed in
accordance with the present invention;
[0018] FIG. 2 is a fragmented partly perspective view
showing how the card panels are detached from the carrier
sheet;
[0019] FIG. 3 is a plan view showing the card panels
detached from the carrier sheet;
[0020] FIG. 4 is a perspective view showing how the
card panels are folded together to form a plasticized card;
[0021] FIG. 5 is a plan view of the plasticized
magnetic strip card formed in accordance with the present
invention;
[0022] FIG. 6 is a partly exploded perspective view
showing the construction of the carrier sheet with two
integrated magnetic strip cards being formed thereon;
[0023] FIG. 7 is a side view of Fig. 6 showing the
location of the patches relative to the carrier sheet;
[0024] FIG. 8 is an exaggerated section view showing
the component parts of the carrier sheet. with the integrated
magnetic strip card and its die cut;
[0025] FIG. 9 is a block diagram of a computer control
system for the fabrication of the carrier sheet with an
integrated magnetic strip card, as well as the printing and
encoding of personal information on the carrier sheet and
the magnetic strip or simply the production of a carrier
sheet with an integrated card or a magnetic strip card which
is later automatically encoded for specific use;
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[0026] FIG. 10 is top plan view showing a carrier sheet
in accordance with a further embodiment of the present
invention;
[0027] FIG. 11 is a perspective vi_ew showing a first
sequence of how the card panels are folded together to form
a plasticized card; and
[0028] FIG. 12 is a further perspective view showing a
further sequence of how the card panels are folded together
to form a plasticized card.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0029] Referring now to the drawings and more
particularly to Figs. 1 and 6 through 8 there is shown a
carrier sheet 10, which could be formed of paper or suitable
synthetic material, and having an integrated magnetic strip
card 11, herein two cards 11 and 11' formed integral with
the carrier sheet 10. The carrier sheet has printed
information 12 printed thereon as well as card information
13 printed thereon at a predetermined card location on the
front face 14 of the carrier sheet. The lower portion of
the carrier sheet is a card region 20 and the printed
information 13 is oriented to be disposed on an outer
surface 15 of a front and rear panel 16 and 16' respectively
which forms the magnetic strip card 11 and as more clearly
shown in Fig. 5 after the panels are folded together as also
shown in Fig. 4.
[0030] As shown more clearly in Figs. 6 to 8, a
siliconized liner patch 17 containing a pressure-sensitive
adhesive 18 on a surface thereof is laminated on the back
surface 19" of the carrier sheet 10 with the adhesive placed
on the back surface of the carrier sheet and disposed to
extend over the card region 20.
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[0031] A face patch 19 of clear poly material, such as
polyester, polystyrene, etc., containing a magnetic strip 21
is immovably secured over the front face 14 of the carrier
sheet 10 and over the card region 20 with the magnetic strip
21 oriented across the rear panel 16' to be formed at a
specific location thereon. As shown in Fig. 1, the magnetic
strip 21 extends across both rear card panels 16' and
entirely across the face patch 19. The face patch may be
adhered to the carrier sheet by a hot press or a transparent
adhesive whereby it is laminated on the carrier sheet. It is
pointed out that both the patches 17 and 19 are very thin
films capable of withstanding temperatures of 340 F to 450 F,
as well as the magnetic strip, and do not cause any
interference when handled by a printing press or a patch-
applying laminating machine. They are also handled in an
interference-free manner in laser printers associated with
personal PCs. Accordingly, the plastic: film is of a type
capable to be printed in a laser printer. It is pointed out
that the composite carrier sheet can be computer printed
using simplex printing (laser, thermal or impact).
[0032] The carrier sheet 10 as shown in Fig. 6 is further
provided with opposed detachable perforated carrier strips 22
for feeding the carrier sheet or form in a high-speed printer
and a high-speed-patch applicating and butterfly die cutting
machine of the type known in the art. Alternatively, the
carrier sheet may be in sheet form, such as 81-~ x 11 inch
paper sheets. Indexing markings may also be provided on the
sheet for synchronous processing in a high-speed printer,
patch applicator, die cutting and paper- severing-machine
process.
[0033] After the patches 17,19 have been laminated on the
carrier sheet 10, the sheet undergoes a die cutting process,
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whereby a butterfly die cut 23 delineates the front and rear
card panels disposed adjacent one another, as better shown in
Fig. 1, and extends through the face patch 19, the magnetic
strip 21 which extends beyond the side edges of the rear card
panel 16' and the carrier sheet 10, as better illustrated in
Fig. 8. It is pointed out that in Fig. 8 the patches and the
carrier sheet as well as the magnetic strips are exaggerated
in thickness for ease of illustration and description but as
earlier mentioned, these patches as well as the magnetic
strips are thin film products. It is also pointed out that
the butterfly-type die cut card panels 16 and 16' are
retained in the carrier sheet 10 by the pressure-sensitive
adhesive 18 which is now transferred to the back surface 19"
of the carrier sheet due to pressure having been applied
during the printing and patch application process. A
straight perforation line 24 is formed in the face patch to
form a fold line between the front and rear panels 16 and 16'
as better illustrated in Fig. 1.
[0034] Referring now to Figs. 2 to 5, there is
illustrated the method of forming the magnetic strip card 11
and this is accomplished by detaching the front and rear card
panels 16 and 16' in the manner as illustrated in Fig. 2 by
grasping a corner of the panel and peeling it off the carrier
sheet 10 with the pressure-sensitive adhesive 18 having now
been stuck on the back surface 19" of the carrier sheet which
forms the back face of the card panels. This pressure-
sensitive adhesive simply releases from the silicone backing
patch as its adherence with the adhesive is minimal as
compared to the paper surface. The card panels having now
been detached, as shown in Fig. 3, can rlow be folded on the
fold line 24 to position their back adhesive surface
juxtaposed to create a permanent bond as illustrated in Figs.
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4 and 5. Accordingly there is now forrned a magnetic strip
card having a plasticized surface on both sides of the card.
[0035] As also illustrated in Figs. 3 to 5, the printed
information on the card surface, herein the rear card panel
16', may include one or more bar codes 25 which may be used
to identify the intended user of the card or for various
other uses. It is also pointed out that the magnetic strip
21 is compatible for use in an encoder/reader machine to be
encoded or read or both read and encoded. A window area 26
may also be printed on the rear panel to receive the
signature of the card user person. On the front panel 16
there is usually printed graphics 27 which is customized to
the card issuer. The information 12 printed on the carrier
sheet may also contain personalized information as well as
instructional information shown at 12' instructing the user
how to form the plasticized magnetic strip card 11 of the
present invention. As earlier described, the carrier sheet
as hereinshown contains two of these front and rear panels
disposed in side-by-side relationship with the magnetic strip
21 oriented across both of the rear card panels 16'.
[0036] With reference now to Fig. 9, there will be
disclosed the method of forming the carrier sheet with the
integrated detachable magnetic strip card as well as a method
of use of the card. In an automated system, it is
conceivable that a computer can control the entire
manufacturing process. The method comprises printing on the
carrier sheet 10 with information 12 containing in part card
information printed at a predetermined location on the front
face 14 of the carrier sheet and in a card region 20 of the
carrier sheet with the printed information oriented to be
disposed on an outer surface 15 of the front and rear card
panel 16 and 16' respectively of the magnetic strip card to
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be formed. As shown iri Fig. 9, the carrier sheet form 10 may
be printed in a printer 40 which is controlled by a control
device 50 which includes a computer programmable unit 51
providing a message to be printed on the carrier sheet as
well as the disposition of the printed material. Any
personalized information contained within the CPU is also
printed at a designated location on the carrier sheet by the
printer 40. This may be done in a different printing step as
shown at 41 in another printer section. After the carrier
sheet is printed with the general as well as personalized
information, graphics, and bar codes, etc., the patches 17
and 19 are applied to the carrier sheet by a patch applying
machine 42. The carrier sheet with the patches laminated
thereto are then fed between a die cut roll 43 where the card
panel outlines, having butterfly-type cut sections, is die
cut into the form to delineate the card panels. This process
can then be fed directly to a carrier detaching mechanism 44
wherein the carrier sheets with the integrated detachable
magnetic strip card are released into a stack form 45.
Alternatively, after the die cut roll, the form may be fed
into an encoder 46 wherein a used code, as well as other
personalized information, is encoded into the strip. The
carrier sheet can then be fed to a verification reader device
47 to verify all of the information on the form with the CPU
51. The carrier sheet form is then fed to the carrier
detaching machine 44.
[0037] The stack of carrier sheets 45, with uncoded
magnetic strips and unpersonalized information on the card,
can then be forwarded to intended users wherein the card can
then be utilized in a coding machine 48 whereby an encrypted
code can be encoded to the magnetic strip to provide
authorized use of the card. The coding machine 48 is
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connected to the central computer 49 of the card issuer.
Alternatively, the personalized carrier sheets including an
encoded message in the magnetic strip can be forwarded to the
intended user and placed into a write/read/print machine 52
for automatic processirig.
[0038] It is further pointed out that the carrier sheet
may contain printed information which is impersonalized and a
customer would then print personalized information in
designated areas for his customized use.
[0039] Referring now to Fig. 10, another embodiment in
accordance with the present inventiori is shown. This
embodiment involves a carrier sheet panel 110 of a continuous
fan-folded bundle. The panels 110 have a front face 114 and
a rear face 114'. The carrier sheet panel 110 has the shape
of an airline boarding card provided with an integrated
magnetic strip card 111 formed integral therewith. The
carrier sheet fan-folded bundle may be stored in a kiosk-type
card printing and dispensing machine. The three panel card
111 provides sufficient thickness in magnetic stripe region
when folded, i.e. in the range of 24-30 thousandth of an
inch, for handling by reading machines.
[0040] As best shown in Figs. 11 and 12, the magnetic
strip card 111 is formed from a front panel 116, a rear panel
116' and a magnetic strip panel 121. The front panel 116 and
the rear panel 116' may be illustrated according to the card
issuer's requirements. For instance, the front panel 116 of
Fig. 10 is shown having a window area 126, wherein card user
information may be printed, such as a name and/or an
identification number. Also, printed graphics 127 and 128
may be customized to the card issuer.
[0041] A face patch 119 of clear material, same as
hereinabove disclosed, is secured to the front face 114 of
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the carrier sheet 110 by a hot press or a transparent
adhesive, whereby it is laminated thereon. Thereafter, a
magnetic strip patch 121' is applied on the face patch 119 of
the carrier sheet 110, such as to be positioned across the
magnetic strip panel 121.
[0042] A siliconized liner patch containing a pressure-
sensitive adhesive (not shown) is applied on the rear surface
114' of the carrier sheet 110. The carrier sheet 110 is then
fed through a butterfly die cutting machine, such as to
delineate the front panel 116, the rear panel 116' and the
magnetic strip panel 121. It is pointed out that the
butterfly-type die cut panels are retained in the carrier
sheet 110 by the pressure sensitive adhesive of the permanent
adhesive patch transparent to rear face 114'. It is also
noted that the front panel 116 and the rear panel 116' are
interconnected at a common edge 124, whereas the front panel
116 is connected to the magnetic strip panel 121 at a common
edge 124'. Although the panels are herein shown as
delineated by a butterfly cut, the panels may be straight cut
to form a perfect rectangular card.
[0043] Referring to Figs. 11 and 12, there is illustrated
the method of forming the magnetic strip card 111. This is
accomplished by detaching the front panel 116, the rear panel
116' and the magnetic strip panel 121 from the carrier sheet
110 by grasping a corner of either panel and peeling them off
the carrier sheet 110 with the pressure sensitive adhesive
having now been stuck on the back surface 114' of the carrier
sheet 110, which forms the back face of the card panels. The
card panels having been detached, the rear panel 116' may be
folded on the front pariel 116 at the common edge 124 as shown
in Fig. 11, to juxtapose their back adhesive surfaces to
create a permanent bond, as illustrated in Fig. 12.
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Thereafter, the magnetic strip panel 121 may be folded on to
the rear panel 116' along he common edge 124'.
[0044] It is poirited out that some overlapping is
intended for the magnetic strip 121' to be thick enough for
magnetic strip reading. For instance, the magnetic strip
card may be used as a temporary card product, wherefore the
magnetic strip is passed through a reader/encoder device for
encoding information thereon.
[0045] The card is thus encoded for application use, such
as for airline loyalty services, e-commerce cash card or the
like. In respect to the airline loyalty services, the card
may have rectangular square punch holes at specific locations
whereby thermal printers and like equipment located at sales
service counters are accommodated.
EXAMPLE 1
[0046] A typical example of the use of the carrier sheet
and integrated magnetic strip card of the present invention
is for the travel industry and particularly for the booking
of cruises. For example, when a person books a cruise
through a cruiseline or a travel agent, his/her personal
information concerning its identity, as well as personal
event request is stored in a computer such as the CPU 51
shown in Figure 9. The event schedule information, as well
as the customer identity information makes it possible for
the CPU to print the customer identity information onto the
carrier sheet in the printer 40, as well as other personal
information, such as the person's name which could appear on
the card panels. The panels may be printed in the printer
41. The magnetic strip is then encoded in the encoder 46
with a user code as well as other coded information which
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could be generated depending on the event schedule
information stored in the computer. The user code will
permit the user to access the stored computer information at
an event location. The carrier sheet and the integral
magnetic strip card is forwarded to the customer or end user
who detaches the card from the carrier sheet in the fashion
as previously described. The customer thus possesses one or
two or more customized and plasticized magnetic strip cards
and when arriving at the scheduled event., such as a port of
departure of a cruise ship, the customer enters his
personalized card in a magnetic strip card reader such as the
write/read laser printer system 52 or a coder reader such as
48, and the user code provides access to the central computer
49 or 51 of the cruiseline to download to the user
information concerning the specific room that he/she has been
assigned on the ship, and the location of the room and other
information. Simultaneously, the computer could also code
the magnetic strip to activate the card so that the card user
may use the card throughout the paying events on the
cruiseliner for automatic billing by the computer system.
The card also records the arrival of the customer at the
event location so that the computer system can automatically
effect the management: of all bookings. This greatly
facilitates the handling of the customers which is usually
time consuming as large numbers of customers must be
processed before a ship can depart from the harbour. The
ships often contain 2000 to 4000 passengers and it could take
as long as eight to twelve hours to process that many people.
With this computer system, the processing would be done
virtually automatically and practically error free.
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EXAMPLE 2
[0047] In another embodiment, cards without magnetic
strips in the patch may be integrally formed with the carrier
sheet. For example, a telephone company could issue a card
to a person with the person's name appearing on the card
together with a personal access code. The carrier sheet
contains instructions for using the card together with a
toll-free telephone number, wherein the person receiving the
card may dial the telephone number to activate the card by
the personal access code and the persori's pin number. The
card can then be sent to someone you want to receive a call
from at your expense and at a lower rate depending on the
applicable time that the call is made. Such a system would
provide to the card holder, the enjoyment of pre-paid long
distance rate. The telephone company could offer the best
available savings based on your long-distance savings plan
and have no call connection fees for calls made from within a
country without the assistance of an operator. You can also
receive overseas calls with the assistance service by dialing
an 800 number with no risk of call blocking.
[0048] The above examples are only to indicate a few uses
of the carrier sheet with integrated card and there are
countless other uses imaginable.
[0049] It is within the ambit of the present invention to
cover any obvious modifications of the preferred embodiment
described therein, provided such modifications fall within
the scope of the appended claims.
