Abstract:
Described is an integrated transaction card and packaging assembly, such as for telephone cards. The packaging may be a co-op type packaging in that it includes promotional material, such as coupons, in addition to the transaction card.

Description:
BACKGROUND OF THE INVENTION 
     This invention pertains to an integrated transaction card and packaging assembly, such as for telephone cards. The packaging may be a co-op type packaging in that it includes promotional material, such as coupons, in addition to the transaction card. The packaging may be adapted for use in stores, as magazine inserts, direct mail items, etc. 
     A substantial market has developed in recent years for inexpensively manufactured, individually encoded transaction cards such a telephone cards, credit cards, membership cards and I.D. cards. While the manufacture and coding of the individual cards may be simple, distribution of the cards required individual packaging which was a multistep, labor intensive process. 
     The packaging of transaction cards required several labor intensive steps and coordination of several independent processes. For example, the card was produced by on printer while the package was produced by another printer, often at different geographic locations. Some types of packaging consist of multiple elements, which may need to be independently produced, thus adding to the number of total steps. Then the card and packaging was brought together, often at a third location, where insertion of the card into the packaging took place. 
     The problems of the prior art transaction card packaging are evident. Because the transaction cards and their packaging must be printed separately, more time is needed to complete production if the same printer is used to print both the card and the packaging. Alternatively, several printers must be used to simultaneously print the cards and the packaging. In addition, both methods require the extra step of insertion of the card into the packaging. 
     Sometimes, companies wish to provide incentives for transaction card purchasers, such as additional cards or coupons from a different company. Where products of more than one company are involved, the practice is referred to as co-op packaging. In such a case, insertion of the coupon or second card adds a further step to the total process. Moreover, insertion of the coupon or second card requires a level of coordination that is difficult to achieve with automated means. Thus, assembly by hand may be required in some cases. 
     The present invention provides an integrated transaction card and packaging system which overcomes the problems of prior art transaction card packaging methods. In addition, the inventive packaging system design lends itself well to multiple card and co-op type packaging. 
     SUMMARY OF THE INVENTION 
     The integrated card and packaging assembly of this invention comprises a contiguous sheet of material having at least one integrally formed manually detachable card. The contiguous sheet is folded thus forming a package for the card. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIGS. 1 a - 1   d  are schematic illustration of one embodiment of the integrated card and packaging according to this invention, and a line diagram for its fabrication. 
     FIGS. 2 a - 2   f  are schematic illustration of a second embodiment of the integrated card and packaging according to this invention, and line diagrams for its fabrication. 
     FIGS. 3 a - 3   f  are schematic illustration of a third embodiment of the integrated card and packaging according to this invention, and line diagrams for its fabrication. 
     FIGS. 4 a - 4   e  are schematic illustration of a fourth embodiment of the integrated card and packaging according to this invention, and line diagrams for its fabrication. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     In the first three embodiments of this invention, the integrated card and packaging assembly comprises a contiguous sheet of material having at least one integrally formed manually detachable card. The contiguous sheet is folded to form a package for the card. 
     The contiguous sheet may have an opening through which one side of the card is visible when the contiguous sheet is folded. The opening may be covered by a patch of transparent material such as polyvinyl, for example. 
     For co-op packaging designs, the contiguous sheet may also have perforated sections defining integrally formed coupon panels. The perforations make the coupons manually detachable by the customer. 
     The card section of these designs may be made of more than one layer of the material of the contiguous sheet, thus being stiffer than the contiguous sheet. The card section is formed from the contiguous sheet and remains attached to the contiguous sheet at least on one of its four edges. Perforations at the edge of attachment hold the card attached to the contiguous sheet, while allowing the customer to easily and cleanly detach the card from the contiguous sheet. 
     In the fourth embodiment the integrated card and packaging assembly comprises a back panel having a front side and a back side; a card panel attached to the front side of the back panel and having a front side, a back side and a card section; a cover panel attached to the front side of the card panel and having a section outlined by perforation to constitute a flap larger in area than the area of the card. 
     The flap in the cover panel may have a window die cut within it and disposed to make the card section of the card panel visible. 
     This embodiment may comprise a second card panel disposed between the card panel and the cover panel. The second card panel may be used to enhance the stiffness of the card section of this assembly. 
     Each card panel of this embodiment may also have a coupon section formed therein. Where more than one card panel is used and each has a coupon section, numerous coupons may be packaged in a booklet type format, i.e. one coupon on a first page, a second coupon on a second page, etc., each page being the coupon section of each card panel. 
     In all embodiments, the card or the coupons or both may be coded during processing. For example, the card may have a unique number imaged on it during processing, then a barrier coating may be formed over the imaged number, and a scratch-off panel may be formed over the barrier coating. 
     The materials used in this invention are widely know in the art and available to the skilled artisan. The material of the contiguous sheet or each individual panel can be selected according to the final use of the packaging. For most applications, 80 pound matte coated text can be used as the substrate. 
     The fabrication of the integrated card and packaging of this invention may be performed by conventional equipment, configured, of course, to fabricate the inventive assemblies. It is preferred to use a web roll printer with the appropriate number and the appropriate configuration of plow folding units, die cutting units, pattern gluers and bead-line gluers. 
     DETAILED DESCRIPTION OF THE DRAWINGS 
     FIG. 1 a  is the front face view of the final form of the first embodiment of this invention. The package  100  has a window opening  120  through which the card  110  is visible, a hanger hole  105 , and a perforation  130  for opening the package and accessing the card. 
     FIG. 1 b  is the rear view of the same package having two coupon sections  140  and  145 , and perforations  130 ,  131  and  132  for detaching the coupons. More than two coupons sections may be present or only one or none at all, as required by the specific application. 
     FIG. 1 c  is an exaggerated side view showing the card  110  disposed in between the back panel  141 , which may have the coupon sections  140  and  145 , and the front panel  101  which has the window  120 . This depiction is exaggerated because in section  102  the panels are not shown as being attached for clarity of the design using a contiguous sheet. However, the panels would be attached, for example by glue, in section  102 . 
     FIG. 1 d  is a line diagram for manufacturing the first embodiment of the invention from one contiguous sheet. Three sections of the contiguous sheet are folded over each other along plow lines  150  and  151  to form a section of triple thickness. Sections  170  are die cut and removed thus forming a card section  110  having a stiffness greater than the rest of the sheet because of its triple thickness. The edge attaching the card to the contiguous sheet has a perforation  133  to facilitate removal of the card by the customer. The contiguous sheet is folded along plow lines  152  and  153  then glued at areas  160 ,  161  and  162  to form the final package. 
     FIG. 2 a  is the front face view of the final form of the second embodiment of this invention. The package  200  has a window opening  220  through which the card  210  is visible and a hanger hole  205 . 
     FIG. 2 b  is the rear view of the same package having a coupon section  240  attached to back panel  231 . The coupon section may be divided into numerous smaller coupon section or none at all, as required by the specific application. 
     FIG. 2 c  is an exaggerated side view showing the card  210  disposed in between the back panel  231  of the front of the package and the second coupon panel  241 . No points of attachments are shown in this figure for clarity of the design using a contiguous sheet. However, the panels would be attached, for example by clean release glue, in section  202 . 
     FIGS. 2 d - 2   f  are line diagrams for fabricating the second embodiment of the invention from one contiguous sheet. Three sections  211 ,  212  and  213  of the contiguous sheet are folded over each other along plow lines  250  and  251  to form a section of triple thickness. More or less sections may be folded over depending on the thickness desired. Section  270  is die cut and removed thus forming a card section  210  having a stiffness greater than the rest of the sheet because of its triple thickness. The edge attaching the card to the contiguous sheet has a perforation  233  to facilitate removal of the card by the customer. 
     The contiguous sheet is folded along plow lines  252 ,  253  and  254 . The front of the package is formed from a cover panel  230  and a back panel  231  folded over each other along plow line  255 . Plow lines  252 ,  253  and  254  may be perforated if panels  240  and  241  are coupons to allow for easy separation of the coupons. The package is sealed by a line of clean release glue  280 . 
     FIG. 3 a  is the front face view of the final form of the third embodiment of this invention. The package  300  has a window opening  320  through which the card  310  is visible and a hanger hole  305 . 
     FIG. 3 b  is the rear view of the same package. The back panel  330  is the only panel visible in this design. The back panel may have coupons and the corresponding perforations. 
     FIG. 3 c  is an exaggerated side view showing the card  310  disposed in between the optional coupon panels  340  and  341 . No points of attachments are shown in this figure for clarity of the design using a contiguous sheet. However, the panels would be attached, for example by clean release glue, in section  302 . 
     FIGS. 3 d - 3   f  are line diagrams for fabricating the third embodiment of the invention from one contiguous sheet. Two sections  311  and  312  of the contiguous sheet are folded over each other along plow line  250  to form a section of double thickness. More or less sections may be folded over depending on the thickness desired. Section  370  is die cut and removed thus forming a card section  310  having a stiffness greater than the rest of the sheet because of its double thickness. The edge attaching the card to the contiguous sheet has a perforation  333  to facilitate removal of the card by the customer. 
     The contiguous sheet is folded along plow lines  352 ,  353  and  354 . The front of the package is formed from a cover panel  331  and a back panel  330  folded over each other along plow line  355 . Plow lines  351 ,  352  and  353  may be perforated if panels  340  and  341  are coupons to allow for easy separation of the coupons. The package is sealed by a line of clean release glue  380 . 
     FIG. 4 a  is the front face view of the final form of the fourth embodiment of this invention an open position. The package  400  has flap  460  covering a card  410  and optional coupons  440  and  441 . The flap has an window opening  420  through which the card is visible. The card  410  and coupons are attached to the package at least one edge; the point of attachment having perforations  430  and  431  to facilitate removal of the card and coupon by the customer. 
     FIG. 4 b  is the front face of the fourth embodiment in a closed position. The front cover panel  490  has perforations  432  which define the flap  460 . In the closed position only the flap  460  is visible and the card  410  is visible through the die cut window opening  420  in the flap. The window opening may have a transparent material covering it. A hanger hole  405  may also be die cut. 
     FIG. 4 c  shows the card and coupon panel  491  behind the front cover panel  490 . The card and coupon panel  491  may be attached to the back of the front cover panel by glue. The glue, however, is only deposited outside the flap indicator line  461 . The card and any coupons are die cut from this panel. 
     FIG. 4 d  shows the optional second card and coupon panel attached to the back of the card and coupon panel of FIG. 4 c.  If attachment is by means of glue, the glue is deposited outside the coupon area  462 . This second card and coupon panel may be used to enhance the thickness and stiffness of the card. In addition, but not necessarily, the second card and coupon panel  492  may be used if more than one coupon is desired in the package. That is, if the first card and coupon panel  491  gives coupon  440  in FIG. 4 a,  the second card and coupon panel  492  gives coupon  441  in FIG. 4 a.  It is thus evident to a skilled artisan that more that the described two card and coupon panels may be used to present a card of desired thickness and/or to present more coupons. 
     FIG. 4 e  shows the back panel  493  of the fourth embodiment of this invention. The back panel  493  is attached to the back of last card and coupon panel. If the attachment is by means of glue, the points of attachment are outside the coupon area  463  and outside card area  464 . 
     While the invention has been described and shown herein in what is presently conceived to be the most practical and preferred embodiments thereof, it will be readily apparent to those of ordinary skill in the art that many modifications may be made within the spirit and scope of the invention, which scope is to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent assemblies.