Abstract:
The present invention is generally directed to methods of manufacturing data card assemblies. These methods generally comprise manufacturing or purchasing a data card comprising a special number, wherein the special number is associated with a particular data card account; packaging the data cards in a package such that the special number is visible; generating activation information; reading the special number on the data card; recording the activation information on the package; and associating the special number with the particular activation information recorded on the package. Some embodiments of the present invention may further comprise conveying the association between the activation information and the special number to an intermediary managing the data card accounts. Some embodiments of the present invention may further comprise generating a special number associated with a particular data card account; and generating activation information associated with a particular special number.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of, and claims priority to, U.S. patent application Ser. No. 11/232,573, filed on Sep. 22, 2005, which is incorporated by reference in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     Data cards such as gift cards and telephone calling cards permit consumers to prepay for goods or services. An account associated with the data card is debited as goods and services are purchased using the card. 
     Data cards typically include raised or protruding numbers which are a personal account number (PAN), and identify the account associated with the card. Data cards further typically contain a magnetic strip which contains all the data needed for commercial transactions: the PAN, the expiration date, and sometimes the name of the user. These magnetic strips must comply with commercial standards in order to be useful at most stores. 
     In many instances, the data cards are available for purchase directly from large retail displays. For security purposes, the data cards may be un-activated or have no value associated with them until a purchaser pays a retailer to activate the card or to associate a certain value with the card. Despite these security features to discourage theft, many criminals still steal the data cards, often by removing the card from its packaging. 
     Additionally, criminals may attempt to steal information by copying the raised numbers that press through the package. Copying these raised numbers (possibly by etching) is a substantial first step towards penetrating the security procedures of the data card system. The criminal would then wait until the customer purchased and activated the card, and then attempt to obtain additional security information (such as a Personal Identification Number) from the customer through theft or trickery. 
     Accordingly, it may be desirable to provide a data card which is concealed within its packaging to discourage theft of the cards. 
     Generally, during manufacturing the individual unique data card is physically matched to an individual unique package. For example, U.S. Pat. No. 6,439,613 to Klure addresses this matching, and discloses a procedure to confirm “that no mismatching of the separately manufactured card” has occurred during packaging. See, e.g., U.S. Pat. No. 6,439,613 at column 4, line 2. The disclosure of these patents are incorporated herein by reference. 
     SUMMARY OF THE INVENTION 
     Aspects of the invention include methods of manufacturing data card assemblies. These methods generally comprise manufacturing or purchasing a data card comprising a special number, wherein the special number is associated with a particular data card account; packaging the data cards in a package such that the special number is visible; generating activation information; reading the special number on the data card; recording the activation information on the package; and associating the special number with the particular activation information recorded on the package. Some embodiments of the present invention may further comprise conveying the association between the activation information and the special number to an intermediary managing the data card accounts. Some embodiments of the present invention may further comprise generating a special number associated with a particular data card account; and generating activation information associated with a particular special number. 
     It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only, and are not restrictive of the invention as claimed. The accompanying drawings constitute a part of the specification, illustrate certain embodiments of the invention and, together with the detailed description, serve to explain the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In order to assist in the understanding of the invention, reference will now be made to the appended drawings, in which like reference characters refer to like elements. The drawings are exemplary only, and should not be construed as limiting the invention. 
         FIG. 1  displays a foldable base assembly, in an exemplary embodiment of the invention. 
         FIG. 2  displays a data card properly positioned on the base assembly, in an exemplary embodiment of the invention. 
         FIG. 3  displays the right portion of the base assembly folded over the data card in a stowed position, in an exemplary embodiment of the invention. 
         FIG. 4  displays the left portion of the assembly folded over the data card in a covering position, in an exemplary embodiment of the invention. 
         FIG. 5  displays a bar code and a magnetic strip on the base assembly, in an exemplary embodiment of the invention. 
         FIG. 6  displays a security barrier, properly positioned on the base assembly, in an exemplary embodiment of the invention. 
         FIG. 7A  displays a method of manufacture of stored value cards, in an exemplary embodiment of the invention. 
         FIG. 7B  displays a method of manufacture of stored value cards, in an exemplary embodiment of the invention. 
         FIG. 8  displays two data cards positioned in a base assembly with two apertures, in an exemplary embodiment of the invention. 
         FIG. 9  displays two data cards in a horizontal overlapping position, in an exemplary embodiment of the invention. 
         FIG. 10  displays two data cards in a vertical overlapping position, in an exemplary embodiment of the invention. 
         FIG. 11  displays a data card package with a data card therein, in an exemplary embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
     Various card packages according to the present invention provide various benefits. For instance, a card may be contained in the package and may not be visible from the outside. The card package itself may have an indicia of an identifier associated with the card number. The indicia of the card package may be used to activate the card without ever exposing the card number on the card. Thus, criminals may be unable to obtain a card number printed or embossed on the card. In some embodiments, an aperture may expose a portion of the card, such as an indicia of an identifier of the card. 
     According to some embodiments, a method of manufacturing a card and card package comprises inserting a unique data card into a standard card package, and then modifying the package so that it becomes uniquely matched to the unique data card. An advantage of this manufacturing method is that there is no risk of mismatching a card to the wrong package. 
     According to some embodiments, a data card is concealed within its packaging to discourage theft of the cards. In some embodiments, a security barrier is enclosed within the package to prevent the raised numbers of the data card from pressing into the package and becoming susceptible to copying by etching. 
     According to some embodiments, multiple data cards are placed within a single package. For example, four cards each worth $20 may be sold simultaneously in a single package for $80, and may be simultaneously activated. Similarly, a single $50 card and three $10 cards could be sold simultaneously in a single package for $80, and may be simultaneously activated. 
     The present invention, as defined in the claims, can be better understood with reference to the following drawings. The drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present invention. Throughout the figures, like reference numerals designate corresponding parts throughout the several views. 
       FIG. 1  displays a foldable base assembly  10 , in an exemplary embodiment of the invention. The base assembly  10  may be constructed of a suitable packaging material that is relatively thin and relatively rigid, for example cardboard or plastic. The base assembly  10  may comprise three major portions: the left portion  20 , the middle portion  30 , and the right portion  40 . 
     The left portion  20  may comprise an aperture  25 , notches  50 , perforations  52 , and/or a hanging hole  53 . A folding line  54  may separate the left portion  20  from the right portion  30 . The folding line  54  may comprise a line of weakness created by perforations, by scoring, or by other means (e.g., grooving, scratching, or notching). The aperture  25  may be covered by a transparent film such as cellophane. 
     The middle portion  30  may comprise a hanging hole  53  and/or folding lines  54 . A first folding line  54  may separate the left portion  20  from the middle portion  30 . In some embodiments, a second folding line  54  may separate the middle portion  30  from the right portion  40 . 
     The right portion  40  may be relatively smaller than (or bigger than or equal in size to) the middle portion  30 . The right portion  40  may be separated from the middle portion  30 , e.g., by a folding line  54 . 
     In some embodiments, the base assembly  10  may be folded to enclose a card. The card may be placed flat across the face of the middle portion  30 . For instance, the card may be placed in approximately the center of the package, and the length of the card may be parallel or perpendicular to the line of weakness  54 . As viewed from the top-down view of  FIG. 1 , the right portion  40  may be folded along line of weakness  54  in an upward direction and onto the front of middle portion  30  (e.g., and onto the top of the card). The left portion may also be folded along its line of weakness  54  in an upward direction so that it is also laying across the face of middle portion  30  (e.g., and also laying across the folded left portion  20 ). Adhesive and/or tabs or other folds may be used to cause the folded assembly  10  to remain in its folded position, thereby enclosing the card. The card may then be displayed and sold in a merchant store. After activation and distribution to a customer, the customer may open the card package by tearing at the perforations  52  to expose the card. 
       FIG. 2  displays a data card  60  positioned on the base assembly  10 , in an exemplary embodiment of the invention. Data card  60  is shown positioned on the middle portion  30 . Data card  60  may be affixed in its location on the assembly  10 , e.g., via adhesive such as glue or tape or other coupling mechanism (e.g., adhesive between the card  60  and middle portion  30 ). Data card  60  may comprise any transaction card as known in the art, such as a prepaid card (e.g., for use related to telecommunications service). Data card may have a barcode, magnetic stripe, or any other features of well-known transaction cards. 
     Data card  60  may comprise a relatively thin and relatively rigid material such as cardboard or plastic. Data card  60  may have a special number  65 . The special number may be any number, code, or symbol. The special number  65  may be associated with the personal account number (PAN) of the data card. In some embodiments, the special number  65  may be generated at the same time as the PAN, but might not be the same number as the PAN. Special number  65  may be a 9 digit number (or have any other number of alpha-numeric symbols), or may be any optically recognizable image. For instance, the special number may be adapted to be read by an optical reader device, such as an OCR (optical character recognition) device. Special number  65  may be located on the bottom left of the data card. Special number  65  may be sized smaller than the aperture  25 , so that the entire special number  65  will be visible through aperture  25  after assembly is completed. 
       FIG. 3  displays the base assembly  10  wherein the back of the right portion  41  is folded over the data card  60  in a stowed position, in an exemplary embodiment of the invention. The special number  65  is not covered. (In other embodiments, the special number  65  may be covered or may not exist.) 
       FIG. 4  displays the back of the left portion  21  of the base assembly  10  folded over the data card in a covering position, in an exemplary embodiment of the invention. The special number  65  is visible through the aperture  25 . The base assembly  10  may be fixed in this folded position by adhesive along the edges, or by staples along the edges, or by heat treatment along the edges, or by shrink wrapped cellophane, or by any of numerous methods known in the art. 
       FIG. 5  displays a bar code  70  and a magnetic strip  72  on the base assembly, in an exemplary embodiment of the invention. The bar code  70  may be a bar code, or may be any optically readable image containing information. The total thickness of the assembled package where the magnetic strip  72  is located may be between 24 mils and 30 mils so that it is readable through most commercial magnetic strip readers. 
     The bar code  70  and/or magnetic strip  72  may comprise information identifying and/or associated with a card package and/or a card (e.g., a card inside a card package). For instance, such information may be used at a point of sale to activate the card, e.g., as described in U.S. Pat. No. 5,777,305 to Smith et al. Such information may be stored in a database record that stored other information about an associated card, such as a card number, special number, and/or PAN. 
       FIG. 6  displays a security barrier  80  positioned on the base assembly  10  in an exemplary embodiment of the invention. Security barrier  80  may be securely fastened to the middle portion  30  by adhesive or other methods. The data card  60  may be positioned on top of the security barrier  80  in such a way that the protruding digits (e.g., Personal Account Number) of the data card are adjacent to the security barrier  80 . When the security barrier  80  is positioned adjacent to protruding digits (such as an embossed card number) so that it “covers” the digits, it may prevent unauthorized users from attempting to determine the digits without opening the card package (e.g., by viewing any deformations in the surface of the card package caused by embossed numbers, or by detecting any magnetic information stored on the card. Accordingly, the security barrier may comprise a hard surface and a dark shape. In some embodiments, the security barrier may have electromagnetic properties that prevent unauthorized users from determining any electromagnetic information stored on the card (e.g., in a magnetic stripe of the card). 
     In some embodiments, the security barrier  80  may be at least as large as the area of the protruding digits, and in some embodiments it may be larger than the entire data card  60 . The security barrier  80  may consist of a single unfolded sheet of material, or may be a folded sheet of material, or may be multiple sheets of material. The security barrier  80  may include printed terms and conditions regarding the data card. 
     In an alternate embodiment (not shown), the security barrier  80  may be positioned and fastened to the left portion  20  in such a way as to not cover the aperture  25 . The data card  60  may be positioned such that the protruding digits are adjacent to the security barrier after assembly. 
     In an alternative embodiment (not shown), the aperture  25  may be in the middle portion  30 , e.g., instead of in the left portion  20 . The data card  60  may be positioned such that the special number  65  is aligned with the aperture  25  after assembly. The security barrier  80  may be positioned adjacent to the protruding digits of the data card, e.g., but not blocking the aperture  25 . 
       FIG. 7A  displays the manufacturing steps; in an exemplary embodiment of the invention. In block  102 , manufacture or purchase a data card comprising an indicia of a personal account number (PAN) is purchased or manufactured. In block  104 , create a special number associated with the PAN, but not equivalent to the PAN. In block  106 , print the special number on the data card. In block  108 , wrap or fold the data card inside of a package that has an aperture adapted to view the special number through the aperture. In block  110 , generate activation information associated with the special number. Block  112 , print the activation information on the package. 
       FIG. 7B  displays a method  70  that may be followed in producing a stored value card in accordance with some embodiments of the present invention. The method  70  provides a manner in which associations between activation indicia and particular card accounts are not created until the card production is nearly complete. In such a manner, greater efficiencies may be achieved, and production line problems or difficulties may have minimal impact on the intermediary that may be managing the stored value card accounts. 
     At step  710  a stored value card may be manufactured, printed, produced, purchased, or otherwise obtained. The stored value card may be manufactured, printed, produced, purchased or otherwise obtained with a special number  65  previously established thereon. Alternatively, at optional step  720 , a special number  65  may be printed, embossed, labeled, or otherwise recorded on the stored value card. 
     At step  720  the special number  65  is recorded in a database. Each special number is associated with a particular stored value card record. Please note that it is contemplated that the database recordation and association with a particular stored value card record may be accomplished prior to, during, or after the special number is printed, embossed, labeled, or otherwise recorded on the stored value card. At this point during the method, the association between each special number and each stored value card record and account is known. 
     At step  730 , a plurality of activation indicia are generated. These activation indicia may be a sequential series, may be selected randomly, or my be selected according to some algorithm. At this point during the method, there is no association between any stored value card record and special number, and any activation indicia. The activation indicia may be a series of numbers, letters, symbols, or any combination thereof. It is also contemplated that such activation indicia may contain radio frequency identification (RFID) tags, and/or any other such wireless communication capabilities. 
     At step  740 , packaging of the manufactured, printed, produced, purchased, or otherwise obtained stored value cards may be initiated. This packaging may be done by a separate entity from the manufacturer, printer, producer, or purchaser. Alternatively, the same party may package the stored value cards. At step  750 , the stored value cards may be inserted into a package such that the special number  65  remains readable (i.e., the view of the special number  65  is not obstructed by packaging. The special number  65  may protrude out of the packaging, may be readable through an aperture in the packaging, or the card may not be packaged inside anything at all (e.g., the stored value card may be attached (e.g., adhered) to a “carrier” in such a manner that an entire side of the stored value card may be visible). It is also contemplated that the stored value card may be integrally formed with a carrier, such that the special number  65  of the card may be visible. If the stored value card is integrally formed with the packaging, step  750  may be omitted, and the method may continue directly to step  760 . 
     At step  760 , an activation indicia may be selected from the plurality of activation indicia that were generated at step  730 . This activation indicia may be printed, embossed, recorded, or otherwise labeled on a stored value card. 
     Prior to, during, or after the selection and printing of the activation indicia, the special number  65  may be recorded at step  770 . The special number  65  may be recorded by optical character recognition abilities, by machine readable data (e.g., magnetic stripes, bar codes, RFID, etc.). 
     At step  780 , an association between the activation indicia selected and labeled on the stored value card and the stored value card&#39;s special number may be recorded. This association may be recorded in a local or remote database. 
     At step  790 , the association between the special number and the activation indicia may be conveyed or otherwise provided to the intermediary that may be managing the stored value card accounts. The association may be conveyed over a network, or may be conveyed by storing the associations on a data storage device and physically delivering the data storage device to the stored value card account managing intermediary. 
     Multiple variations in the above described method are possible and are contemplated. For example, step  730  (generation of activation indicia) and step  760  (selection of activation indicia) may be combined, such that, for example, the entity that prints, embosses, or otherwise labels the stored value card packaging with the activation indicia may generate the activation indicia itself. Alternatively, the special number  65  and the activation indicia may be pre-associated before the step of printing, embossing, or otherwise labeling. Here, at step  770  the special number may be captured, and the associated activation indicia may be retrieved and then printed on the appropriate packaging. 
     Note that other manufacturing embodiments of the invention may include some, all, or none of the actions mentioned in the blocks, and the actions may occur in other orders. For example, a security barrier may be inserted or attached adjacent to the PAN before wrapping or folding the package. Specifically, a security barrier such as a folded security paper may be placed in front of the card before the card is tipped into position in the package. 
       FIG. 8  displays two data cards positioned in a base assembly with two apertures, in an exemplary embodiment of the invention. Note that the base assembly  10  previously shown in  FIG. 1  has been substantially modified to enclose multiple data cards. Specifically, the left portion  20  now has two apertures: first aperture  25   a  and second aperture  25   b . First aperture  25   a  is positioned so as to align with the special number  65   a  of first data card  60   a  after folding. Second aperture  25   b  is positioned so as to align with the special number  65   b  of second data card  60   b  after folding. Note that the notches, perforations, and right portion  40  of base assembly  10  have been modified slightly (in comparison to base assembly  10  as shown in  FIG. 1 ) to accommodate the two data cards. Although there are two aperture areas it is not necessary it can be done with one aperture. The cards can be optically read before inserting the cards into the packaging. The packaging displayed is merely examples of the type of packaging it can be in the form of a box, a sleeve or other types of containers. The key is that one scan at a retail POS system activates all cards contained within the package. 
     In an alternative embodiment (not shown), the base assembly shown in  FIG. 8  may be elongated in a horizontal direction to accommodate the two data cards  60   a  and  60   b  placed adjacent to each other in a horizontal fashion, rather than placed adjacent in a vertical fashion as shown as shown in  FIG. 8 . 
     In an alternative embodiment (not shown), additional cards may be accommodated by placing apertures in the middle portion of the base assembly. For example, in  FIG. 8 , a third card (not shown) may be placed adjacent to and directly below card  60   a , so that the special number of the third card may face downward and may be visible through a third aperture (not shown) in the middle portion  30 . Similarly, a fourth card (not shown) may be placed adjacent to and directly below the second card  60   b , so that the special number of the fourth card may be visible through a fourth aperture (not shown) in the middle portion  30 . 
     Thus, a total of four cards could easily be accommodated inside of a base assembly with four apertures (two apertures in the left portion, and two apertures in the middle portion), but with the same maximum dimensions as the base assembly shown in  FIG. 1 . All of the special numbers of the cards may be visible through their respective apertures. Alternately, a single special number readable through a single aperture may be associated with all four cards. 
     The multiple special numbers may be read during the packaging process, and may be used to generate and print one or more bar codes or magnetic strips or readable data sets on the package. During a sale, said one or more bar codes or magnetic strips or readable data sets may be read, and may be used to activate the multiple cards contained within the package. 
       FIG. 9  displays two data cards in a horizontal overlapping position, in an exemplary embodiment of the invention. Two or more data cards may be placed in a horizontal overlapping position such that all of the special numbers remain visible. 
       FIG. 10  displays two data cards in a vertical overlapping position, in an exemplary embodiment of the invention. Two or more data cards may be placed in a vertical overlapping position such that all of the special numbers remain visible. 
     In an alternative embodiment (not shown), multiple data cards may be stacked like a deck of cards so that only one special number may be visible through one aperture. In this embodiment, said only one visible special number may be associated with the special numbers that are not visible. The visible special number may be used to generate one or more bar codes or magnetic strips or other readable data sets on the package. During a sale, said one or more bar codes or magnetic strips or readable data sets may be read, and may be used to activate the multiple cards contained within the package. 
     In an alternative embodiment (not shown), multiple data cards may be oriented in a strip, and then folded in an alternating fashion like an accordion or a street map so that at least one special number is visible. In this embodiment, said at least one visible special number may be associated with the special numbers that were not visible. The at least one visible special number may be used to generate one or more bar codes or magnetic strips or other readable data sets on the package. During a sale, said one or more bar codes or magnetic strips or readable data sets may be read, and may be used to activate the multiple cards contained within the package. 
     With reference to  FIG. 11 , it may be seen that more than one activation indicia may be printed, embossed, or otherwise labeled on a stored value card packaging  1100 . First activation indicia  1110  may be a series of numbers, letters, characters, symbols or any combination thereof. Alternatively, and as illustrated in  FIG. 11 , the first activation indicia  1110  may be machine readable (e.g., a barcode, magnetic stripe, or RFID tag)  1115 . A second activation indicia  1120  may optionally be included on the stored value card package  1100 . The second activation indicia  1120  may be optionally included on the stored value card package  1100  should any problems with the first activation indicia  1110  arise. 
     For example, if the first activation indicia  1110  is comprised of a magnetic stripe or a bar code, it may be damaged and rendered unreadable. In this situation, a second activation indicia  1120  may be utilized to activate the specific stored value card. 
     The second activation indicia  1120  may repeat the first activation indicia  1110 , in whole or in part, may be determinable based on the first activation indicia, or its indicia may be entirely unrelated to the first activation indicia  1110 . It is contemplated that for simplicity, the second activation indicia  1120  may comprise a portion of the first activation indicia  1110 . For example, in  FIG. 11  a first activation indicia reads “135798642975318642” may have a second activation indicia that reads “18642.” 
     A special number  1130  that is printed on the stored value card may also be readable through an aperture, as described above. 
     The present invention is not to be limited in scope by the specific exemplary embodiments described herein. Indeed, various modifications of the present invention, in addition to those described herein, will be apparent to those of ordinary skill in the art from the foregoing description and accompanying drawings. Thus, such modifications are intended to fall within the scope of the following appended claims. Accordingly, the claims set forth below should be construed in view of the full breath and spirit of the present invention as disclosed herein.