GB2288365A - A method of producing an envelope containing a separate composite card from a combined card sheet-integral envelope sheet - Google Patents

Description

1 - 2288365 ENVELOPE CONTAINING A SEPARATE PRINTED CARD FROM AN INTEGRAL

SHEET AND METHOD OF MANUFACTURE BACKGROUND OF THE INVENTION

(1) Field of the invention

This invention relates to articles and methods for their manufacture from an integral web or sheet of lightweight paper, comprising printed cards contained in a sealable envelope of approximately the size and appearance of a conventional plastic credit card. The method includes the use of high- speed printing equipment, including computer directed contact and electrostatic image transfer printers, for the large volume production of the finished articles.

Each of the envelopes, or cards, or both, can be printed with a unique indicia, such as names, alpha-numeric characters, bar codes, magnetic ink characters, symbols that can be read by optical character recognition ("OCR") systems, or the like. The indicia can be of the type that can be read with or without the assistance of optical or electronic readers or scanners for entry of information in a data storage and retrieval system. The cards are particularly adapted for use as fare cards in a transportation system and as disposable telephone cards.

(2) Description of the prior art

Methods have been developed for preparing printed direct mail articles and the like where an envelope and an enclosure are produced from an integral web or sheet. These methods include, for example, those of US,A-3,557,519 disclosing an envelope and single letter sheet enclosure which can be personalized.

Other methods have been developed for manufacturing printed direct mail articles comprising an envelope and various enclosures produced from two or more superposed webs or sheets that are brought into aligned relationship for finishing. These methods include, for example, US-A4,067,171 disclosing an envelope and multiple card sheets; US-A-4,437,852 disclosing an envelope, an card sheet and enclosed pre-formed return envelope; US-A-4,437,852 disclosing an envelope, a response device and an enclosed pre-formed return envelope; and US-11-4,912,909 disclosing an envelope, at least one card sheet and a reply card formed by adhesively joining two separate sheets of lightweight paper.

The use of special purpose debit cards, fare cards, and the like for charging telephone calls and for use in metropolitan transportation systems has become more prevalent in recent years. These cards can be fabricated from plastic or heavy paper stock, and often include a magnetic strip that can be encoded with appropriate electronic equipment to reflect the consumer's personal identity data, account information, and/or the "value, , or credit available for use in making telephone calls or utilizing the transportation system. Specialized equipment in the nature of automated vending machines has been developed for issuing fixed or variable value cards in -3 response to the insertion of coins, bills or a credit card in the dispensing machine.

Cards containing embedded magnetic strips have the disadvantage of requiring specialized equipment to encode data onto the cards at the time of their original purchase by the consumer, and also for the purposes of reading the card to deduct or debit the user's account by the value of the service provided. In the case of plastic cards, a disposal problem is also created since the materials are not biodegradable, and their incineration produces undesirable pollutants.

If cards bearing an access number are issued by individual vendors, there is the risk that third parties will note the number of the card prior to, or at the time of its sale, and make unauthorized use of it after it has been purchased.

It is therefore an object of the present invention to provide in combination, as an article of manufacture, a sealed envelope containing a separate card produced from an integral sheet or web of paper each of which is imprinted with an indicia that is unique to the card-envelope set.

It is another object of the invention to provide an envelope containing a printed card with a unique indicia, and methods for production of a such card-envelope set, that provides security for the card indicia and which is tamperevident.

It is also an object of this invention to provide a method of manufacturing from an integral sheet or web, a plurality of sealed envelopes each containing a card, where each card and envelope set is provided with the same or a different unique indicia, and, in the case where the indicia are different, providing means for relating the indicia on the envelope to the corresponding indicia on the card in that envelope.

It is yet another object of the invention to provide an inexpensive paper card that can be purchased and sold for value and that can be discarded with minimal impact on the environment, where the card has a secure identification number that is known only to the user.

BRIEF DESCRIPTION OF THE INVENTION

The present invention contemplates an inexpensive method for the manufacture of a paper card contained in an envelope, both of which are produced from an integral sheet or web. In accordance with the method, a unique indicia can be printed on one or both of the card and the envelope comprising the set. The invention contemplates the production of a large number of such envelope-card sets quickly and inexpensively by employing electronic data storage and processing means. The indicia can include names, numerical bar codes, machine readable data grids, magnetic ink characters, OCR symbols or alpha-numeric characters that can be read by bar code readers, optical 11 -5 k character readers and like means, where the indicia can serve as a unique account identifier.

As will be described in more detail below, in a preferred embodiment the card can be produced in either a conventional two-sided configuration, or as a folded sheet having four panels, each suitable for carrying a printed field. The card is securely contained in an envelope of any convenient size, and the card and the envelope are produced from an integral sheet or web.

As a preliminary step in the manufacturing method, the web or sheets can be appropriately printed with the unique identifying indicia, and/or other fixed and variable information, as well as other information concerning the use of the card, its issuer, or the vendor of the card. The method of the invention also permits the printing of the identical or different unique indicia on the exterior of the envelope and on the card. Since the card and the envelope are assembled from an integral sheet, and not separated until the card is positioned in the interior of the envelope, there is no possibility of mismatching.

The invention is particularly adapted, for example, for use in purchasing a specified amount of credit to be used with a telephone system. At the time of purchase of the card from a vending machine or from any of a variety of commercial vendors, including newsstands, retail stores, restaurants and the like, the value associated with the purchase and the account number associated with.the unique indicia printed on the card and/or envelope is communicated to the issuing telephone company to establish a temporary account. Thereafter, at the time of making the telephone call, the card holder enters the unique identifying account number appearing on the card in lieu of depositing coins or charging to an otherwise established permanent billing account number. Upon termination of the call, the prepaid account is debited with the amount of the telephone charge, and the value of the credit remaining in this prepaid account is communicated to the card holder. When the value of the prepaid credit has been depleted, the temporary account is terminated by the telephone company and the card can be discarded.

In another preferred embodiment, the envelope containing a card is itself the size of a conventional credit card and is adapted for use in existing dispensing machines in place of the cards now in use. At the time of dispensing the envelope and card, a reader records the unique indicia on the envelope and the value or amount paid by the purchaser, which data is transmitted electronically to appropriate data storage means associated with the system.

The method of the invention permits the production of large volumes of inexpensive paper cards that can be disposed of with a lesser burden on the environment than plastic cards, or even paper cards containing electronically or magnetically encodable polymer strips.

1 1 In another embodiment of the invention, the envelope contains a first card of either two-sided or four panel configuration as described above, and also contains one or more folded and optionally, glued inserts of the same size as the first card. The inserts are separated from the first card, and can be joined to, or separated from each other.

As previously noted, unique indica are printed on the envelope. Where the card and envelope are printed with different unique indicia, the data relating to the correspondence between these two indicia will also be retrievable from appropriate data storage means. In a typical preferred embodiment, the correlation between the unique indicia on the respective envelope and card sets will be random, and selected for printing using standard encryption methods known in the art. The program or encryption scheme for generating these pairs of unique indicia can be stored in a secure central processing unit and then transmitted to a computer-directed printer via a magnetic tape or disk or modem for printing the web. The printer can be of the impact or electrostatic image transfer type.

During the printing of the web, in one preferred embodiment that is adapted to the production of telephone cards, each envelope section is provided with a unique bar code, or other optically scannable symbol, and each associated card blank is provided with a unique sequence of numbers, and/or alphabetic characters that correspond to those found on the telephone keypad or dial.

For example, a continuous paper web is provided with a plurality of printed fields corresponding to the envelope and card sections as described above. A web of paper in the form of a standard roll measuring approximately 18,000 feet in length can be printed to produce approximately 140,000 finished envelopes containing cards, each envelope measuring approximately 4.5 inches by 2.25 inches, or approximately

11.34 cm, by 5.67 cm.

The process of preparing the printed web with these indicia can advantageously be accomplished using an appropriate computer program and a high-speed, computer directed electro-static image transfer means. Commercial electro-static image transfer equipment, such as that sold under the trademark ELECTROPRESS@, is well known in the art.

Conventional high speed, multi-color lithographic web printing equipment can also be used to print any desired information, instructions, logos and the unique identifying indicia that will appear on the finished card and envelope. Typically, the printed web is separated into sheets for ease of handling and feeding into conventional die-cut, folding and trimming equipment known to those skilled in the art. Following separation of the composite card device from the envelope rear panel, the flap may either be sealed or left open for the insertion of additional enclosures.

The envelope can be of conventional construction and opened by lifting or tearing along the sealed flap. Alternatively, the envelope can be provided with lines of perforations adjacent one or both of the sealed side edges of the envelope, whereby the edge can be torn off to remove the card. Lines of perforations can also be provided in one panel of the envelope to permit it to be torn open for removal of the card. Other configurations known in the art can be employed to facilitate convenient opening and removal of the card from the envelope.

The method of the invention utilizes a combination card sheet and integral envelope sheet, and comprises forming the enclosure card sheet into a composite card device, folding the composite card device first along a transverse line, which can be scored or perforated for ease of folding, and thereafter folding and gluing said envelope sheet to form an envelope containing the composite card device. The envelope sheet has a second transverse line defining front and rear envelope panels which, after the card device has been folded, are adapted to fold around the composite card device to form an envelope pocket which is sealed along the longitudinal edges of said panels. The envelope sheet is further characterized as containing a top panel which is adapted to fold along a third transverse line and thereby form an envelope flap. The composite card device of said combination is folded in such manner as to position the perforated line joining the enclosure card sheet, which has been formed into a composite card device, and the envelope portions so that the card device portion can be separated, preferably in the same operation, from the envelope portion after folding and prior to sealing.

In a preferred embodiment, the invention comprehends a method for producing an envelope containing a separate composite card device from a combined card sheet-integral envelope sheet in which said combined card sheet-integral envelope sheet comprises a card sheet comprising a first card panel and a second card panel joined along an intermediate transverse line, said envelope sheet being joined to the card sheet along a first transverse line, the opposite longitudinal edges of said card sheet being positioned inside those of the envelope sheet, said envelope sheet having a second transverse line defining front and rear envelope panels and a third transverse line in said front panel defining an envelope flap, which method comprises (a) applying adhesive to the first card panel, or the second card panel, or both, (b) folding the card sheet along the intermediate transverse line to adhesively bond the first and second card panels to form a composite card device, (c) folding said composite card device along said first transverse line in the direction of the envelope sheet, and 1 (d) folding said envelope sheet along said second transverse line about said composite card device and sealing the overlapping edge portions of said envelope sheet together, thereby forming said envelope sheet into an envelope containing said composite card device with said first transverse line located at the opening of said envelope adjacent said rear envelope panel, (e) thereafter, while said envelope flap is open, separating said envelope sheet from said composite card device along said first transverse line, to thereby produce a separate composite card device contained in an envelope, and thereafter closing the envelope flap.

For adaptation to continuous high-speed web lithographic printing techniques and computer directed printing techniques, the combined card sheet and integral envelope sheet is printed on a continuous web. The opposite longitudinal edges of the web can optionally be punched with line holes that engage sprocket feeding rollers on the computer directed printing system used to print the indicia and other information that appears on the cards and envelopes, and to facilitate continuous high-speed feeding during the subsequent cutting, folding, gluing and other processing steps to which the web is subjected.

is In connection with such high-speed feeding an embodiment of the method of the invention comprises, in combination, a plurality of the card sheetintegral envelope sheet combinations as described above, sequentially joined one to the other along a transverse line common to the end of the card sheet, remote from said intermediate transverse line and the end of the envelope sheet that is remote from said third transverse line. In a further preferred embodiment of the invention for the manufacture of envelope-card sets where the envelope and card in each set have unique identifying indicia, the method comprises:

(a) generating a first unique series of machine readable indicia from electronic data storage means; (b) generating a second series of indicia from the electronic data storage means, where each indicia in the second series corresponds to only one of the indicia in the first series; (c) printing a first unique indicia selected from the first series of indicia on a first section of a moving printable web; (d) printing the corresponding indicia from the second series on a second section of the printable web that is proximate the first section; (e) separating the first and second sections from the printable web to form an integral sheet containing the first indicia and corresponding indicia; (f) forming the separated first section bearing the first indicia into an envelop and the second section bearing the corresponding indicia into a card device contained in the envelope; and (g) separating the card device from the envelope.

The method avoids potential problems of mismatching of uniquely encoded cards and envelopes that is attendant to continuous envelope systems where the separated cards and envelopes are printed with unique indicia and the card thereafter inserted in the envelope, since in the method of the invention both elements are part of an integral preprinted sheet. The composite card device of the finished article is separate in the envelope and is ready for use by the recipient or purchaser. In addition, personalization used in connection with presently available computerized printing techniques can also be utilized. For example, if the cards are to be used for advertising or promotional purposes individual recipients' names and addresses can be printed on the envelope sheet and/or on the composite card device.

The folding of the paper stock and bonding the card panels with an intermediate layer of adhesive produces a finished composite card device having the feel and appearance of heavier card stock. Additional steps of folding the card sheet and the application of intermediate layers of adhesive can be employed to produce a finished composite card device of more than two layers having an even heavier feel and greater stiffness.

The printing of different indicia on the card and the exterior of the sealed envelope provides a number of advantages and permits the combination card and envelope to be used in a variety of commercial and promotional applications. One important advantage to the use of a sealed paper envelope is that it provides a tamper-evident wrapper for the card. The sealed envelope bearing a unique indicia provides a secure means for transmitting and recording the value paid at the time of the purchase of the card so that the individual vendor or a bystander cannot determine the numerical sequence printed on the card.

The combination card and sealed envelope can also be used in a variety of gaming schemes and games of chance in the nature of lotteries. So-called "winning cards" are associated with a unique indicia on the outside of the sealed envelope by the central data processing unit. The time, place and location of the distribution of the card- containing envelopes can also be entered in the central data-storage means. Since each sales transaction is electronically transmitted to, and stored in the central data storage means, the time and/or place of sale of winning cards can be determined, or estimated based on its relation to cards previously sold. These records can also be used to insure that winning cards are uniformly distributed with respect to geographical or other desired criteria, while at -Is- the same time insuring that those involved in the distribution and sales are unaware of the identification associated with the winning card(s).

A method similar to that described above can be employed, for example, by retailers with the distribution of envelopes, each containing a coupon of predetermined value. The value of the coupon can be indicated as a specified number of dollars or as a percentage off the regular or list price of the goods or services. The recipient of the sealed envelope containing a coupon does not know the value of the coupon, which can only be determined by the user by opening the envelope after the sale transaction has been completed. The use of a traceable coupon permits the issuer to determine the location and distribution of valuable coupons, while at the same time ensuring the security and integrity of their use.

DETAILED DESCRIPTION OF THE INVENTION

In the drawings accompanying and forming part of this specification:

FIG. 1 is a plan view showing a section of the continuous web containing the card sheet and integral envelope sheet of the present invention; FIG. 2 is a front perspective view of the card sheet that has been formed into a composite card device and integral envelope, partially folded, showing the envelope in a folded position prior to separation from the envelope portion; FIG. 3 is a front perspective view of the sheet and integral envelope in nearly completed form ready for edge sealing to form the envelope and separation of the letter from the envelope as described hereafter; FIG. 4 is a schematic cross-sectional side view of the completed envelope containing the card sheet formed into a composite card device being separated along the fold line by 10 cutting means; FIG. 5 is a fragmentary perspective view of the sealed envelope and composite card device ready for use; FIG. 6 is a plan view similar to FIG. 1 showing a modified embodiment of this invention; and is FIG. 7 is a plan view showing a section of the con- tinuous web containing two combined card sheet-integral envelope sheets in a parallel configuration.

FIG. 8A and 8B are perspective views of the finished envelope-card sets illustrating alternative embodiments for 20 opening the envelope along perforation lines.

FIG. 9 is a plan view showing a section of continuous web and a further embodiment of a card sheet for producing multiple cards j oined to the integral envelope sheet.

FIG. 10 is schematic block diagram illustrating one embodiment for practicing the method of the invention in a typical commercial application.

f DETAILED DESCRIPTION OF THE INVENTION

Referring to the drawings, wherein like reference characters designate corresponding parts throughout the several figures, and particularly to FIG. 1, there is shown a composite sheet 10 that is divided by a perforated line 22 into a card sheet 11 and an integral envelope sheet 13.

Composite sheet 10 is a continuous form, preferably a section of a lithographic web 9, having a plurality of sheets 10 interconnected by cutting lines 4. This web is adapted to be used with a machine such as a high-speed computerized printing machine, that utilizes the continuous sheet forms and is therefore provided with a sprocket for high speed feeding of the composite sheet 10 into the machine utilizing said sheets. The composite sheet 10 has longitudinal perforations 12 inside of and generally parallel to punched line holes 24 suitable for engaging sprocket feeding rollers. The method of the invention is equally applicable to sheets and webs that do not have punched line holes, such as those employing image transfer technology.

The card sheet 11 is joined to the envelope sheet 13 along first transverse perforation line 22. Envelope sheet 13 has opposite longitudinal perforations 6 positioned inside of punched line holes 24, but outside of perforations 12. Indentation 8 defines this positioning. Envelope sheet 13 contains a third transverse score line 18, which defines the envelope flap portion 2 of said envelope sheet 13, and a second transverse score line 20, which defines the front and back panels of the envelope sheet 13. Area 16 defines that part of the envelope flap to which adhesive is applied.

Sheet 11 is comprised of first card panel 25 and second card panel 27. Rounded corners 29 are die-cut in sheet 11 in a preferred embodiment to enhance the appearance and to simulate a conventional card. The card sheet 11 is also provided with intermediate transverse score line 23 that defines the first card panel 25 and a second card panel 27, the latter positioned adjacent the first transverse line 22.

The composite sheet 10 can be a printed lithographic web containing the graphic features previously described, including the unique indicia on the envelope and card sheets. The punched line holes 24 along the outer edge can be die-cut, as can be the envelope flap side edges 2 and the perforated lines 6, 12 and 22. Such die-cutting facilitates the removal of these parts after the computer printing and/or personalization process; however, it should be noted that any of lines 2, 6 and 12, in addition to die-cutting, can be guillotine cut or slit after bursting. The perforated line 22 also facilitates fan folding of the composite sheets so that the printed continuous web can be transferred for subsequent processing steps in the method of the invention. Line 22 also serves as a guide in the second fold of the card sheet 11. As will be discussed below, in a x k preferred embodiment, fold line 22 is skin-trimmed away after folding and assembly into the envelope.

The score line 18 facilitates folding of the envelope flap. The area identified by 16 is preferably covered with a rewettable gum adhesive, and it is an optional feature depending on the type of envelope sealing equipment to be used in the final flap closure of the envelope and whether or not additional material is to be added to the finished envelopes. This scoring and application of adhesive can be accomplished on the web press during printing.

Folding the enclosure and envelope sheets after the web has been printed and die-cut, and after the web edges 2, 6 and 12 have been mechanically stripped away, is preferably accomplished by first separating the sheets of the web into multiples of the desired length, and guillotine cutting at lines 4.

An adhesive is applied to first card panel 25, or second card panel 27, or both, as indicated at shaded areas 26. Referring to FIG. 2, the trimmed sheets 10 are then fed through a conventional folding machine which folds the card sheet 11 along line 23 to bond the first and second card panels to form a composite card device. The envelope 13 is folded around the already folded and glued composite card device.

As will be understood by one skilled in the art, the card sheet 11 can be lengthened to accommodate one or more additional card panels, and additional gluing and folding steps can be incorporated into the method of the invention to produce a finished composite card comprised of three or more layers of lightweight paper.

Referring to FIG. 3, a bead of adhesive 3 is placed along the edges 6 of sheet 13 so that when the envelope is folded around the folded card sheet 11, edges 6 are joined. These edges can then be skin-trimmed. The folded composite card device 11 is then separated from the envelope body 13 along line 22 with a special slitting device comprising an anvil 50 and slitting blade 55 which is adjusted to the thickness of the paper stock so that the top layers are trimmed clean leaving the third layer or envelope flap 16 untouched. As shown schematically in FIG. 4, anvil device 50 directs flap 16 away from scissor wheels 55 to permit the separation of the composite card device from envelope rear panel 15. In this manner, all the envelope edges are trimmed clean including the inside edge underneath the flap, as are the leading and bottom edges of the card, so that they are free of ragged machine perforation marks.

As shown in FIG. 5, the final closure of the envelope flap can be accomplished as an integral part of the separation of the composite card device from the envelope or by the use of conventional envelope sealing equipment if additional material is to be added to the envelope.

Referring to FIG. 6, inclusion of flaps 7 as an adjunct to edges 6 between lines 18 and 20, which can be folded over and affixed to the reverse side 15 of envelope 13 during the i folding operation, thereby eliminates the necessity of edge trimming the two side edges 6 of the envelope 13. In actual operation, it is preferred to use a plurality of composite

sheets in parallel configuration. FIG. 7 shows a typical composite sheet comprising a lithographic web containing two card-integral envelope sheets joined along line 9, which can be perforated for bursting. In all other respects the parts in FIG. 7 are identical to those in FIG. 1. Additional composite sheets 10 can be included in this parallel configuration to utilize the entire width of the web 9.

If desired, the card sheet 11 can be coated with varnish, a resin that is cured by exposure to UV radiation, or other coatings known in the art to give the finished composite card device additional body and or wear resistance.

As shown in FIG. 8A, finished envelope 13 is provided with lines of perforations 30 adjacent and parallel to sealed edges 6. The recipient can remove the sealed edge section 32 by tearing along one or both lines of perforations to remove card 11. FIG. 8B illustrates another embodiment in which the front panel of the finished envelope is provided with a plurality of intersecting perforation lines 36 that permit the easy separation of section 38 by the recipient and removal of the card 11.

A further embodiment of the invention is illustrated in Fig. 9 for the manufacture of an envelope containing two separate cards. As is shown, third card panel 31 is joined to card panel 25 along score or perforation line 42 and the fourth card panel 33 is joined to panel 31 along line 43. Glue is applied to one or both of the panels in each set of 25-27 and 31-33. After separation of section 10 from the web 9, the third and fourth panels are folded into a superposed position along line 43 and bonded together. Panel 25 is then folded along line 23 to position the side containing adhesive in contact with panel 27 for bonding and the bonded panels 31-33 are folded along line 29 into a superposed position above panel 25. The bonded panel sets are then folded along line 22 to position them above the interior of rear envelope panel 15. The remaining manufacturing steps are the same as those described above in connection with Figs. 1-4. It will be understood that fold line 42 will be positioned adjacent fold line 22, and that upon trimming as shown in Fig. 4, the cards will be separated from each other while positioned inside of the envelope.

The card section 11 can be made longer to provide addition pairs of card panels that are adhesively bonded to make cards that are separated using the same method. In addition, multiple finished cards can comprise three panels each that are adhesively bonded, folded into superposed relation and then trimmed as previously described to produce an envelope containing two or more cards.

i S 1? one preferred embodiment for a typical commercial use of the method of the invention is illustrated in the schematic block diagram of Fig. 10. Data relating to the identification of the first and corresponding second series of unique indicia is transmitted to the central processing unit (,,CPW) of the computer that directs and controls the printer. The data relating to these indicia, and any other constant and/or variable information is transmitted to the printer for reproduction on the printable web. It will be understood that the web can be partially pre-printed and indexed for printing only of the unique indicia.

After printing, the web is finished into envelope-card sets, each set bearing a unique indicia on the exterior of the envelope. The finished, sealed envelopes are distributed for sale, as for example, by vending machines, or individual vendors, and at the time of the sale data relating to the value paid for the envelope-card set and the indicia on the envelope is transmitted to a central computer for processing. The computer can be the same computer that provided the data to the printer for printing of the indicia on the web comprising the card-envelope sheets, or a computer maintained by the service provider, such as a telephone company.

As further illustrated in Fig. 10, when the indicia on the card is transmitted at the time of the service transaction, information from the electronic database or memory concerning the indicia relating to the cardenvelope set is retrieved and processed with information relating to the user's service transaction. For example, if the invention is used in a telephone system, the user of the card enters the unique indicia, e.g., numerals, printed on the card, via the keypad on the pay telephone.

The computer system's CPU retrieves the account information that was entered when the envelope-card set was originally purchased and determines that a credit sufficient to cover some established minimum time charge for the proposed call remains in the account balance. If the account balance is insufficient, the caller is so advised and the transaction can be terminated. If the account balance is sufficient, the call is processed, the account reduced by the appropriate charge, and in a preferred embodiment, the user is informed of the remaining account balance before the user's call is terminated.

In order to further enhance the security of the method and to avoid the possibility that unauthorized use of account balances could be used by the random entry of a series of numbers on the keypad, the user can be required to enter the indicia printed on both the envelope and the card. The possibility of an unauthorized caller being able to enter an active account and also enter the different set of numeric or alpha-numeric indicia corresponding to the characters printed on the envelope in the set can be reduced to acceptable limits by increasing the number of characters that must be entered by the card user.

Claims (39)

CLAIMS:

1. A method for producing an envelope containing a separate composite card device from a combined card sheetintegral envelope sheet in which said combined card sheetintegral envelope sheet comprises a card sheet comprising a first card panel and a second card panel joined along an intermediate transverse line, said envelope sheet being joined to the card sheet along a first transverse line, the opposite longitudinal edges of said card sheet being positioned inside those of the envelope sheet, said envelope sheet having a second transverse line defining front and rear envelope panels and a third transverse line in said front panel defining an envelope flap, which method comprises:

(a) applying adhesive to the first card panel, or the second card panel, or both, (b) folding the card sheet along the intermediate transverse line to adhesively bond the first and second card panels to form a composite card device, folding said composite card device along said first transverse line in the direction of the envelope sheet, and (d) folding said envelope sheet along said second transverse line about said composite card device and sealing the overlapping edge portions of said envelope sheet together, thereby to form said envelope sheet into an envelope containing said composite card device with said first transverse line located at the opening of said envelope adjacent said rear envelope panel, and (e) thereafter, while said envelope flap is open, separating said envelope sheet from said composite card device along said first transverse line, to produce a separate composite card device contained in an envelope, and thereafter closing the envelope flap.

2. The method of claim 1 where the height and width of the composite card device are approximately the same as those of a conventional credit card.

3. The method of claim 2 where the composite card device is about 3.375 inches wide and 2.125 inches high.

4. The method of claim 1 which comprises the further step of printing the envelope sheet with a unique indicia.

5. The method of claim 4 where the unique indicia is adapted for recognition by optical character recognition and transmittal means.

6. The method of claim 4 where the indicia is a bar code.

7. The method of claim 4 where the indicia is a series of characters printed in magnetic ink.

8. The method of claim 4 which comprises the further step of imprinting the card sheet with the same indicia as the envelope sheet.

9. The method of claim 4 where the card sheet is printed with a unique indicia that is different than the indicia on the envelope sheet.

10. The method of claim 1 where a plurality of card sheet-integral envelope sheets are positioned in adjacent lateral and longitudinal relation on a web to produce a plurality of finished envelope-card sets.

11. The method of claim 1 where the combined card sheet-integral envelope sheet is printable paper.

12. The method of claim 1 where the combined card sheet-integral envelope sheet is a printable synthetic paper substitute.

13. The method of claim 1 which comprises the further step of sealing the envelope flap.

14. A method for producing an envelope bearing a unique identifying indicia on its exterior and containing a separate composite card device bearing the same or a different identifying indicia from a combined card sheet integral envelope sheet in which said combined card sheet- integral envelope sheet comprises a card sheet defining a plurality of card panels joined along one or more intermediate transverse lines, said envelope sheet joined to the card sheet along a first transverse line, the opposite longitudinal edges of said card sheet being positioned inside those of the envelope sheet, said envelope sheet having a second transverse line defining front and rear envelope panels and a third transverse line in said front panel defining an envelope flap, which method comprises:

(a) providing the card sheet and the envelope sheet with unique identifying indicia, (b) applying adhesive to at least one card panel, (c) folding the card sheet along one or more intermediate transverse lines to adhesively bond the card panels to form a composite card device, (d) folding said composite card device along said first transverse line in the direction of the envelope sheet, and folding said envelope sheet along said second transverse line about said composite card device and sealing the overlapping edge portions of said envelope sheet together, thereby forming said envelope sheet into an envelope containing said composite card device with said first transverse line located at the opening of said envelope adjacent said rear envelope panel, (f) thereafter, while said envelope flap is open, separating said envelope sheet from said composite card device along said first transverse line, to produce a separate is (e) 1 1 29- composite card device contained in an envelope, and (g) closing the envelope flap.

15. The method of claim 14 which further includes trimming the opposite longitudinal edges of said envelope sheet after folding along said second transverse line.

16. The method of claim 14 where the height and width of the composite card device are approximately the same as those of a conventional credit card.

17. The method of claim 16 where the composite card (8.57 cm) (5.40 cm) device is about 3.375 inches/wide and 2.125 inches/high.

18. The method of claim 14 which the card sheet and the envelope sheet are printed with different unique indicia.

19. The method of claim 14 where the unique indicia is adapted for recognition by electronic data recording and transmittal means.

20. The method of claim 18 where the indicia on the envelope is a bar code.

21. The method of claim 18 where the indicia comprises characters printed in magnetic ink.

22. The method of claim 14 in which the envelope sheet and the card sheet are provided with different unique indicia that are adapted for recognition by optical character recognition and transmittal means.

23. A method of producing an envelope having a unique indicia printed on its exterior, the envelope containing a is card on which is printed a different unique indicia, comprising the steps of:

(a) generating a first series of unique machine readable indicia from electronic data storage means; (b) generating a second series of indicia from the electronic data storage means, where each indicia in the second series corresponds to only one of the indicia in the first series; (c) printing a first unique indicia selected from the first series of indicia on a first section of a moving printable web; (d) printing the corresponding indicia from the second series on a second section of the printable web that is proximate the first section; (e) separating the first and second sections from the printable web to form an integral sheet containing the first indicia and corresponding indicia; (f) forming the separated first section bearing the first indicia into an envelop and the second section bearing the corresponding indicia into a card device contained in the envelope; and (g) separating the card device from the envelope.

24. The method of claim 23 where the indicia of the first and second series are different.

25. The method of claim 24 where indicia of the second series are selected from the group consisting of alphabetic characters, numerals and alpha-numeric characters.

26. The method of claim 23 where the first series and the second series of indicia are maintained in electronic data storage means.

27. The method of claim 25 where the first and second sections of the web are joined along a transverse fold line.

28. The method of claim 23 comprising the further step of sealing the envelope.

29. The method of claim 23 where the indicia of the first series are different than the indicia of the second series.

30. The method of claim 23 where the indicia of the first series are bar codes.

31. The method of claim 25 where the indicia of the first series are bar codes.

32. The method of claim 25 which comprises the further step of transmitting the indicia on the envelope by electronic data transmission means for comparison with data in the data storage means relating to the indicia on the envelope.

33. The method of claim 32 which comprises the further step of transmitting the indicia on the card device by electronic data transmission means for comparison with data in the data storage means relating to the indicia on the card device.

34. An article of manufacture comprising a sealed envelope containing a card having at least two card panels where the card and envelope are provided with unique identifying indicia and the card and envelope are produced from an integral printable web.

35. The article of claim 34 where the indicia on the card and envelope are different.

36. The article of claim 34 where the card comprises two panels.

37. The article of claim 34 where the card panels are adhesively bonded.

38. The article of claim 34 where the height and width of the composite card device are those of a conventional credit card.

39. The article of claim 34 where the height and width of the finished envelope are those of a conventional credit card.

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