Abstract:
Apparatuses and methods for packaging electronically powered cards are provided for maintaining electronically powered cards in a deactivated state. In an embodiment, a housing having a face panel and two side panels attached to the face panel at opposite sides is configured to provide an offset distance between an activation device on the card and the housing so that the activation device is prevented from being activated by a force exerted on the housing. Annular or circular devices can also be provided for establishing an offset distance between activation devices on the card and planar substrates.

Description:
[0001]    This application claims the benefit of U.S. Provisional Application No. 60/877,634, filed Dec. 29, 2006, which is herein incorporated by reference in its entirety. 
     
    
     BACKGROUND 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates generally to powered ISO 7816-compliant cards and, more particularly, to apparatus for mailing powered cards in compliance with applicable postal regulations. 
         [0004]    2. Background of the Invention 
         [0005]    As a convenience for their customers, businesses (e.g., financial institutions), retailers, and advertisers routinely deliver transactional cards and promotional cards to their customers through the mail. The convenience of receiving a card through the mail saves a customer the trouble of visiting a retail location to pick up a card. As a result, the United States Postal Service (“USPS”) annually handles the mailing of millions of transactional cards, such as credit cards, debit cards, electronic cash cards, gift cards, pre-paid calling cards, Internet access cards, membership cards, identification cards, and smart cards. 
         [0006]    Recently, card makers have developed ISO-compliant, self-powered cards, in which batteries, circuitry, and electronic components are embedded. The electronic components give the cards additional functionality, providing features such as sound, lights, and alphanumeric displays for secure token value generation. Powered cards having such features are produced by Innovative Card Technologies of Los Angeles, Calif. and are described, for example, in U.S. Pat. Nos. 5,412,199; 5,434,405; 5,608,203; 5,856,661; 6,176,430; and 6,902,116, which are herein incorporated by reference in their entirety. 
         [0007]    Powering the cards, however, has introduced difficulties in complying with USPS postal regulations, which dictate that any device powered by dry-cell batteries must have the batteries removed or deactivated to prevent activation of the device in the mail. 
       SUMMARY OF THE INVENTION 
       [0008]    In accordance with an embodiment of the present invention, a mailing apparatus is provided for maintaining an electronically powered card in a deactivated state. The apparatus includes a housing having a face panel and two side panels attached to the face panel at opposite sides. The side panels extend from the face panel in a direction generally perpendicular to the face panel. The apparatus further includes an electronically powered card that has an activation device on a surface thereof and an offset mechanism that establishes an offset distance between the electronically powered card and the face panel so that a force exerted upon the face panel is resisted by the face panel and prevented from causing activation of the activation device of the card. 
         [0009]    In accordance with another aspect of the present invention, a mailing apparatus is provided for maintaining an electronically powered card in a deactivated state. The apparatus includes an electronically powered card that has an activation device on a surface and a prevention element attached to the surface of the electronically powered card. The prevention element is disposed around the activation device and is raised above the surface of the card. The prevention element has a thickness sufficient to prevent the activation of the activation device when a force is applied to a planar substrate disposed over the prevention element in a direction generally perpendicular to the planar substrate. 
         [0010]    In accordance with another aspect of the prevent invention, a method of packaging and maintaining an electronically powered card in a deactivated state is provided. In the method, a housing is provided that has a face panel and two side panels attached to opposite sides of the face panel and an electronically powered card is inserted into the housing so that an offset distance is established between the face panel and all activation device located on a surface of the card facing the face panel. The housing with the inserted electronically powered card is mailed. The housing and the card have an interface that establishes the offset distance between the face panel and the activation device during transport so that the activation device is not activated by a force exerted on the face panel in a direction generally perpendicular to the face panel. 
         [0011]    In accordance with another aspect of the prevent invention, a method of packaging and maintaining an electronically powered card in a deactivated state is provided. In the method, a prevention element is adhered onto an electronically powered card. The electronically powered card has an activation device on a surface thereof and the prevention element is disposed adjacent the activation device. The electronically powered device and adhered prevention element is inserted into an envelope or mailing container and the envelope or mailing container is mailed with the electronically powered card and adhered prevention element inserted therein. The prevention element has a thickness sufficient to prevent the activation of the activation device when a force is applied to an envelope or mailing container disposed over the prevention element during transport in a direction generally perpendicular to the activation device. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  is a schematic diagram of a powered card according to an embodiment of the present invention. 
           [0013]      FIG. 2A  is a schematic diagram of a perspective view of a powered card and a mailing apparatus, with the mailing apparatus having slots that receive the powered card, according to an embodiment of the present invention. 
           [0014]      FIG. 2B  is a schematic diagram of a partial cross-sectional view of the powered card and mailing apparatus of  FIG. 2A , taken along line B-B. 
           [0015]      FIG. 2C  is a schematic diagram of a partial cross-sectional view of a powered card and mailing apparatus, with the mailing apparatus having a front panel, a back panel, and two side panels, and having slots that receive the powered card, according to an embodiment of the present invention. 
           [0016]      FIG. 2D  is a schematic diagram of a cross-sectional view of the powered card and mailing apparatus of  FIG. 2A  taken along line B-B and showing a force applied to the mailing apparatus, according to an embodiment of the present invention. 
           [0017]      FIG. 3  is a schematic diagram of a cross-sectional view of a powered card and a mailing apparatus, with the card having slots that receive protrusions of the mailing apparatus, according to an embodiment of the present invention. 
           [0018]      FIG. 4A  is a schematic diagram of a cross-sectional view of a powered card and a mailing apparatus, with the mailing apparatus having interior protrusions, according to an embodiment of the present invention. 
           [0019]      FIG. 4B  is a schematic diagram of a partial cross-sectional view of a powered card and a mailing apparatus, with the mailing apparatus having an interior protrusion protruding from its side panel, according to an embodiment of the present invention. 
           [0020]      FIG. 4C  is a schematic diagram of a partial cross-sectional view of a powered card and a mailing apparatus, with the mailing apparatus having an interior protrusion protruding from its face panel and a side panel, according to an embodiment of the present invention. 
           [0021]      FIG. 4D  is a schematic diagram of a partial cross-sectional view of a powered card and a mailing apparatus, with the mailing apparatus having a single interior protrusion, according to an embodiment of the present invention. 
           [0022]      FIG. 5A  is a schematic diagram of a cross-sectional view of a powered card and a mailing apparatus, with the mailing apparatus attached to a face of the card, according to an embodiment of the present invention. 
           [0023]      FIG. 5B  is a schematic diagram of a powered card and a mailing apparatus, with the mailing apparatus covering only a portion of a face of the card, according to an embodiment of the present invention. 
           [0024]      FIG. 6A  is a schematic diagram of a cross-sectional view of a powered card and a mailing apparatus, the mailing apparatus comprising one or more projections adhered to a face of card proximate to the switch, according to an embodiment of the present invention. 
           [0025]      FIG. 6B  is a schematic diagram of a partial perspective view of the powered card and mailing apparatus of  FIG. 6A . 
           [0026]      FIG. 7  is a schematic diagram of a cross-sectional view of a powered card and a mailing apparatus, the mailing apparatus comprising a compressible release liner adhered to a face of card, according to an embodiment of the present invention. 
       
    
    
       [0027]    For clarity and ease of understanding, the components shown in the figures are not drawn to scale. 
       DETAILED DESCRIPTION 
       [0028]    Embodiments of the present invention provide a mailing apparatus for a powered card. The mailing apparatus prevents activation of the powered card during mailing. 
         [0029]    An exemplary powered card comprises a thin, flexible substrate (e.g., paper, thin cardboard stock, or plastic) having an embedded battery and electrical circuitry. The powered card is preferably equal in size to a conventional credit card, and may meet at least the flexibility requirements of ISO 7816. Powered by the battery, the circuitry can activate electronic output devices that, for example, display an encrypted light array, display alphanumeric characters or graphics, or play a voice message. From this output, a user can obtain information necessary to complete a transaction, for example, authenticating access to a financial account. The card can be branded or printed and may be traded, collected, or distributed as part of a promotion. 
         [0030]    The electrical circuitry can be activated by any means suitable for a particular application. For example, the circuitry can be activated by light sensors, audio sensors, motion sensors, wireless sensors, or mechanical switches (e.g., membrane switches). With light, audio, and motion, the powered card would be activated when the appropriate stimulus is received. With wireless sensors using, for example, radio frequency identification (RFID), Bluetooth™, WiFi, or near frequency communication (NFC) technology, the powered card would be activated by the appropriate wireless signal. With mechanical switches, the powered card can be, for example, activated by a user&#39;s pressing a button or multiple buttons, or by a sliding a switch. In some applications, a user-actuated mechanical switch may be preferred to save power and extend the shelf life of the powered card. 
         [0031]    In an embodiment of the present invention, the circuitry and battery of a powered card is capable of insertion into a substrate equal in size to a conventional credit card, and meets at least the flexibility requirements of ISO 7816. An appropriate flexible battery for such an apparatus is available from Solicore (Lakeland, Fla.), which produces batteries using polymer matrix electrolyte (PME). The batteries are ultra-thin, flexible, environmentally friendly, and safe, and preferably having the following characteristics:
       low profile design—approximately 0.3 mm thick; flexible and will not break or crack when bent or flexed;   conformable, in that the electrolyte can be a solid, non-compressible film, which can be shaped and formed into a variety of designs;   compatible with high speed printing and binding processes, and card manufacturing processes, and can survive hot lamination processes;   operable over a wide temperature range (−20° C. to +60° C.);   offer high ionic conductivity over a broad temperature range;   feature low self discharge rates (less than 1% per month);   provide high energy density (up to 300 Wh/l), thus offering maximum performance in smallest packages;   possess self connecting terminals;   are non-toxic, disposable, and environmentally friendly;   contain solid polymer electrolyte—no volatile liquids or gelling agents;   offer overall safety: with no out-gassing, swelling, or thermal runaway; no need for added safety devices; and pass UL requirements for crush test, drop test, and nail test; and   enjoy an inherently safe design, which reduces the need for additional battery safety circuitry.       
 
         [0044]    The circuitry of the powered card includes at least one electronic output device that provides the user with information, such as a token value necessary for authentication. For example, the electronic output device can display an encrypted light array, alphanumeric characters, or a graphic, or can play a voice message. The user would then use the information for the purpose of authentication to obtain access to an associated system, such as a banking system or online game system. 
         [0045]      FIG. 1  illustrates a powered card  100  according to an embodiment of the present invention. As shown, card  100  comprises a substrate  104 , a battery  106 , and circuitry  108 . Substrate  104  can be paper or any other thin flexible material. Battery  106  and circuitry  108  are embedded in substrate  104  (e.g., sandwiched between a front and back face of substrate  104 ), as represented by the dashed lines. Circuitry  108  includes a controller  102 , which may include, for example, a token value generator, a microprocessor, memory, clock, and any other necessary circuitry or devices. Circuitry  108  is controlled by a switch  110 , such as a press button. Alternatively, circuitry  108  could be controlled by a light, audio, or motion sensor. Circuitry  108  also includes one or more electronic output devices that are activated when circuitry  108  is powered. For example, circuitry  108  can include an illumination device  114 , a display  16 , a speaker  118 , and/or a vibrator  120 . 
         [0046]    As one of ordinary skill in the art would appreciate, circuitry  108  is shown only for illustration purposes and could include differently configured wires or conductive traces. For example, conductors to the illumination device  114  could be individually connected to each of the illumination elements (e.g., each LED or each electroluminescent device), or connected collectively such that the elements could be illuminated in unison, or some combination thereof. Similarly, if an alphanumeric or graphic display is used, the circuitry can be configured to drive the individual elements thereof in accordance with any desired sequence or design. 
         [0047]    In one embodiment, substrate  104  comprises front and back faces made from cardstock and adhered together using adhesive. Battery  106 , circuitry  108 , and the other components are all sufficiently thin and flexible that the powered card has the same “feel” as a conventional cardstock playing card. 
         [0048]    In another embodiment, substrate  104  comprises front and back faces made from plastic sheeting, similar to that used for a credit card-sized ISO 7816 compliant card. Optionally, thinner layers of plastics can be used to allow for increased flexibility. 
         [0049]    In operation, powered card  100  activates in response to completion of circuitry  108 , which provides power from battery  106  to the electronic output devices. In this example, circuitry  108  is completed by pressing button  110 . Alternatively, another mechanical switch, such as a slide switch, could be used to activate card  100 . 
         [0050]    Once circuitry  108  is closed, controller  102  and circuitry  108  activate one or more electronic output devices  114 ,  116 ,  118 , and  120 . For example, controller  102  and circuitry  108  can light illumination device  114  in a particular pattern that reveals a code, can display an alphanumeric message or graphic  122  on display  116 , can play a sound, a message, or music through speaker  118  (e.g., a voice stating a code), or can activate vibrator  120  in a pattern that reveals a code. Illumination device  114  can comprise, for example, LED lights, incandescent lights, or electroluminescent devices. Display  116  can comprise, for example, an LCD screen, an electroluminescent display (such as those produced by Philips Electronics of Amsterdam; Sharp of Osaka, Japan; or Planar Systems, Inc. of Beaverton, Oreg.), or a printable electronic ink (such as those produced by E Ink of Cambridge, Mass., or Xerox of Palo Alto, Calif.). Speaker  118  can comprise, for example, a miniature speaker suitable for tight form factor applications. Vibrator  120  can comprise, for example, a miniature vibrator suitable for tight form factor applications, such as applications involving pagers and cellular telephones. 
         [0051]      FIGS. 2A-2D  illustrate a powered card  200  and mailing apparatus  202  according to an embodiment of the present invention. As shown, mailing apparatus  202  is a sleeve that includes a face panel  204  and two side panels  206 ,  208 . Side panels  206  have slots  210  into which the edges of the powered card  200  slide, thereby holding the front face of the card  200  at a fixed distance from the underside of face panel  204 . Mailing apparatus  202  is sufficiently rigid enough to retain card  200  within slots  210 , and can optionally include a second face panel  212  opposing face panel  204  to provide a desired rigidity, as is shown in  FIG. 2C . In addition, face panel  204  is itself sufficiently rigid enough to resist a force (especially a point force) in the general direction of arrow  214 , to prevent a switch on the face of card  200  from being activated. As one example,  FIG. 2D  illustrates face panel  204  yielding slightly to the force  214 , but not allowing contact with switch  216 . Although shown as not contacting switch  216 , the flexibility of face panel  204  could allow some degree of contact, as long as the force  214  is sufficiently dissipated or distributed to prevent actuation of switch  216 . The degree to which the face panel  204  can contact switch  216  or any other portion of the face of panel  204  would of course depend on, for example, the type and sensitivity of the switch. Mailing apparatus  202  could be made of plastic, such as ABS or PVC. 
         [0052]    Although  FIG. 2A  depicts the mailing apparatus  202  covering a majority of the card  200 , mailing apparatus  202  could cover any appropriate length of the card  200  depending on, for example, the location of switches or other electronic components that should not be activated or damaged during mailing. As an example, if only a small switch need be covered, then mailing apparatus  202  could be a narrow band spanning the width of card  202 , with the band just wide enough to cover the small switch. 
         [0053]      FIG. 3  illustrates a powered card  300  and mailing apparatus  302  according to another embodiment of the present invention. As shown, card  300  defines slots  310  in two of its opposing edges. Mailing apparatus  302  includes a face panel  304 , two opposing side panels  306 , and two opposing protrusions  307  protruding from side panels  306 . Protrusions  307  are adapted to slide within slots  310 . In this position, the face panel  304  of mailing apparatus  302  is disposed over and spaced apart from the front face of card  300  and its switch  316 . Face panel  304  resists forces applied in a direction generally perpendicular to the front face of card  300 , as described above with reference to  FIGS. 2A-2D . 
         [0054]      FIG. 4A  illustrates a powered card  400  and mailing apparatus  402  according to another embodiment of the present invention. As shown, mailing apparatus  402  is a sleeve that includes a face panel  404 , two side panels  406 , and a back panel  412 . The underside of face panel  404  has one or more protrusions  403  located and adapted to contact portions of the front face of card  400  that do not affect the operation of the card  400  (e.g., areas of the face away from switch  416 ). The card  400  is held in place in the interior of mailing apparatus  402 , with the face panel  404  disposed over and spaced apart from the front face of card  400  and its switch  416 . In this position, face panel  404  resists forces applied in a direction generally perpendicular to the front face of card  400 , as described above with reference to  FIGS. 2A-2D . 
         [0055]    Although  FIG. 4A  depicts the cross-sectional shape of protrusions  403  as round, protrusions  403  could have other cross-sectional shapes such as a rectangle, square, or triangle. In addition, protrusions  403  could be isolated protrusions on the underside of face panel  404 , or could be continuous rails along the length of mailing apparatus  402 . In one embodiment, mailing apparatus  402  has one isolated protrusion in each of the four corners of face panel  404 . In another embodiment, mailing apparatus  402  has two continuous rails, each having a rectangular cross-section, with one disposed proximate to a side panel  406  and the other disposed proximate to the opposite side panel  406 . In another embodiment, as shown in  FIG. 4B , a protrusion  403  protrudes from a side panel  406  of mailing apparatus  402 , holding an edge of card  400 . In another embodiment, as shown in  FIG. 4C , a protrusion  403  protrudes from both a side panel  406  and the face panel  404 , for example, filling the corner of mailing apparatus  402  and holding an edge of card  400 . 
         [0056]    Although  FIG. 4A  shows the use of multiple protrusions, an alternative embodiment of the present invention provides only one protrusion, an example of which is shown in  FIG. 4D . In this exemplary configuration, mailing apparatus  452  has a single protrusion  453 , which can be, for example, an isolated round protrusion in the center of the face panel  454  of mailing apparatus  452 . The mailing apparatus  452  has side panels  456  and back panel  462  having similar characteristics as previously described side panels  406  and back panel  412 . The protrusion  453  may alternatively be a continuous round protrusion (e.g., shaped like a road speed bump) extending the length of mailing apparatus  452  along the center of face panel  454 . The protrusion  453  is preferably located to contact the face of card  400  in an area apart from switch  466 . In this manner, protrusion  453  prevents a force  464  applied in a direction generally perpendicular to face panel  452  from deflecting face panel  452  against switch  466  and activating switch  466 . 
         [0057]    An alternative embodiment of the present invention provides a mailing apparatus, such as the mailing apparatus  402 , with a closed end. In other words, rather than having a sleeve with two open ends, this alternative embodiment provides a closed end to form a pocket. In this manner, a powered card can be inserted into the pocket sleeve, with the sleeve covering only a portion of the card (e.g., one-third of the card starting from an end). The pocket sleeve could have protrusions or slots as described above, to prevent activation of a switch or other electronic component. 
         [0058]      FIG. 5A  illustrates a cross-sectional view of a powered card  500  and mailing apparatus  502  according to another embodiment of the present invention. As shown, mailing apparatus  502  is attached to the face of card  500  oh which a switch  516  is disposed, providing a cover over the switch. In this manner, mailing apparatus  502  resists a force  514  applied in a direction generally perpendicular to the front face of card  500 , similar to the embodiments described above with reference to  FIGS. 2A-2D . In this example, mailing apparatus  502  is attached to card  500  by a layer of adhesive  517 , which is strong enough to hold the mailing apparatus  502  to the card  500  during mailing, but can be conveniently released by the user after mailing so that the card  500  can be used. Although  FIG. 5A  shows the mailing apparatus  502  covering a majority of the width of card  500 , mailing apparatus  502  could cover any portion of the width or length of card  500 , depending on the location of the components of card  500 . For example, as shown in  FIG. 5B , if a switch is located in only one small portion of the face of card  500 , mailing apparatus  502  could be placed over only the switch, leaving the remaining portion of the face of the card  500  uncovered. 
         [0059]      FIGS. 6A and 6B  illustrate a further embodiment of the present invention, in which the mailing apparatus  602  comprises one or more projections adhered to the face of card  600  proximate to the switch  616 . The projections  602  help prevent structures, such as the paper of the envelope in which card  600  is mailed, from contacting switch  616  and activating card  600 . Although shown as doughnut-shaped, mailing apparatus  602  could comprise other shaped projections, such as individual raised bumps placed around the switch. 
         [0060]      FIG. 7  illustrates a cross-sectional view of a powered card  700  and mailing apparatus  702  according to another embodiment of the present invention. In this configuration, mailing apparatus  702  comprises a compressible release liner that is adhered to the face of card  500  over the switch  716 . Mailing apparatus  702  is made of a material having properties (e.g., hardness, compressibility, and thickness) sufficient to resist the typical forces  714  encountered during mailing, applied generally in a direction perpendicular to the face of card  700 . For example, mailing apparatus  702  could be made of a compressible foam or a compressible gel. Alternatively, mailing apparatus  702  could comprise a chamber filled with a liquid or a gas. In this manner, mailing apparatus  702  can dissipate or distribute forces  714  so that switch  716  is not actuated. In one configuration, mailing apparatus  714  is attached to the face of card  700  by a layer of adhesive that is strong enough to hold the mailing apparatus  702  to the card  700  during mailing, but can be conveniently removed by the user after mailing so that the card  700  can be used. 
         [0061]    Embodiments of the present invention therefore provide mailing apparatus that prevent activation of a powered card during mailing, to comply with applicable postal regulations. The mailing apparatus can be temporarily applied to a powered card for mailing, and then conveniently removed by the user so that the powered card can be activated and used. In addition, embodiments of the present invention are inexpensive and conveniently incorporated into high volume printing, card-making, and mailing operations. 
         [0062]    Although embodiments of the present invention describe mailing apparatus with respect to powered cards having mechanical switches such as membrane switches, the mailing apparatus of the present invention are equally applicable to other switches, such as sound-activated or light-activated switches. For example, the mailing apparatus  702  of  FIG. 7  could be used to seal a light sensor, wireless sensor, or sound sensor that is used to activate a powered card. In this manner, when the user removes mailing apparatus  702  from card  700 , the card is activated, for example, illuminating lights and displays to convey a mailed advertisement. In the case of a wireless sensor, the mailing apparatus could be made of an electromagnetically opaque material to act as a shield, preventing wireless signals from activating the card during mailing. 
         [0063]    In one implementation, the powered card and the mailing apparatus are branded (e.g., with graphics, logos, colors, or holography) to associate the card and mailing apparatus with each other and/or with a system to which the card provides access. The powered cards and mailing apparatus may be disposable (in that they may have limited temporal use) or may be intended to be collectors&#39; items. 
         [0064]    The powered cards and mailing apparatus in accordance with the present invention may be given away free, given away as part of a related promotion, given as a gift with a purchase of an unrelated item, included in the packaging of a video game, or made available for purchase on their own as products in their own right. 
         [0065]    The foregoing disclosure of the preferred embodiments of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many variations and modifications of the embodiments described herein will be apparent to one of ordinary skill in the art in light of the above disclosure. The scope of the invention is to be defined only by the claims, and by their equivalents. 
         [0066]    Further, in describing representative embodiments of the present invention, the specification may have presented the method and/or process of the present invention as a particular sequence of steps. However, to the extent that the method or process does not rely on the particular order of steps set forth herein, the method or process should not be limited to the particular sequence of steps described. As one of ordinary skill in the art would appreciate, other sequences of steps may be possible. Therefore, the particular order of the steps set forth in the specification should not be construed as limitations on the claims. In addition, the claims directed to the method and/or process of the present invention should not be limited to the performance of their steps in the order written, and one skilled in the art can readily appreciate that the sequences may be varied and still remain within the spirit and scope of the present invention.