Not my area of knowledge.
But there is info on Moneysupermarket about this. http://www.moneysupermarket.com/prepaidcards
If you are not married or legally joined, I think you can only have separate cards. I don't think you can set up a joint bank account for the savings for the trip to go into and be withdrawn from.
I think you just transfer the money to the relevant account like any other transfer. When you pay a current credit card or move money to a different bank do they charge for that, as if they don't I can't see why they would charge. The Dollar card provider may make some charges but from what I have heard they give a better exchange rate, so you might get back anything you have paid in charges.
Perhaps add your query to a holiday related forum and you might get some feedback from people who have used the cards on a US trip. I have never used them and have taken cash, travellers cheques and normal cards. The prepaid cards are relatively new I suppose.