AU5163398A

AU5163398A - Three-dimensional insert construction

Info

Publication number: AU5163398A
Application number: AU51633/98A
Authority: AU
Inventors: Anthony J. Nowakowski
Original assignee: Individual
Current assignee: Individual
Priority date: 1996-10-31
Filing date: 1997-10-30
Publication date: 1998-05-22
Anticipated expiration: 2017-10-30
Also published as: WO1998018693A1; DE69703848T2; ES2154911T3; BR9712712A; DE69703848D1; EP0935569A1; EP0935569B1; IL129708A; CA2273966A1; TR199900961T2; JP2002500598A; IL129708A0; AU735100B2; USRE37910E1; ATE198458T1

Abstract

A three-dimensional insert for use in a handling system comprising a sheet of cardstock or the like defined by ends and first and second sides, a laminate applied to the top surface of the cardstock, and an overwrap material bonded to the laminate proximate to the first and second sides. This structure enables a three-dimensional object to be placed within the overwrap material without risk of movement to the peripheral sides.

Description

THREE-DIMENSIONAL INSERT CONSTRUCTION

Technical Field

The present invention generally relates to the packaging art, and more

particularly, to a three-dimensional insert construction provided in a continuous web

of inserts that may readily be handled by automated packaging equipment or the like.

Background Art

Packaging apparatus particularly adapted for handling inserts or

coupons provided in the continuous perforated web are known in the art from, for

example, U.S. Patent No. 5,079,901, assigned to the assignee of the present invention.

That patent describes an apparatus and system that receives a continuous perforated

web of coupons, provides a forwardmost coupon between pairs of feed rolls and burst

rolls, and at a desired time, separates the forwardmost coupon from the continuous

web by applying a bursting tension to a transverse perforation separating the

forwardmost coupon from the next succeeding coupon. The separated coupon is then

passed to a point of insertion at a desired time such as into a moving container based

on signals provided by timing circuitry.

Other insertion handling apparatus are known such as that described in

U.S. Patent No. 5,549,233. That patent describes an insert handling system that

processes three-dimensional piece inserts with the use of laterally-spaced pairs of

rolls. This configuration enables the three-dimensional aspect of the insert to be

"passed through" the handling apparatus intermediate to the spaced sets of rolls.

However, problems may occur with these equipment types where the projected piece insert requires a flat area to be used to drive the piece either for bursting or for

projection of an individual piece into a container or the like.

One attempt to overcome this problem has been to provide an insert

that utilizes a piece of rigid cardstock or the like together with a three-dimensional

item. The additional rigidity provided by the cardstock adds desired stiffness to the

insert or to use stiffer films. However, it does not overcome the problem of the packet

or prize being laterally displaced to the peripheral sides of the cardstock during

storage or handling and interfering with the rollers utilized in the burst operation.

This is particularly problematic when a relatively high throughput of inserts is

required, requiring frequent stoppages of the processing line. Other approaches have

included the use of glue applied to the cardstock to secure the object in a desired

location on the cardstock and/or the object. While this approach solves the problem

of lateral movement of the three-dimensional object, it dramatically increases the

manufacturing cost of the insert. In addition, proper alignment of the object with the

glued portion of the cardstock is often problematic. The residual glue on the object

may also be undesirable to the end user.

Yet another approach is referred to as "skin pack," in which plastic

film is attached to a porous paper backer material through which a vacuum is drawn to

conform the film to the item to be packaged. Although this method also solves the

problem of lateral movement, the porous paper backer is, inherently, not well suited

for most permeability requirements of food-contact inserts. Disclosure of Invention

Accordingly, it is a general object of the invention to overcome the

deficiencies of the prior art.

It is a further object of the present invention to provide a three-

dimensional insert which is easily fabricated at acceptable cost, while enabling ready

handling in a coupon-handling system.

The present invention provides these and other additional objects with

a three-dimensional insert comprising a piece of cardstock or paperboard (hereinafter

referred to as cardstock) defined by first and second opposed ends and first and

second opposed sides. A thermosealable, olefm coating or film is applied to the top

surface of the cardstock. An overwrap material is contacted with the coating and is

bonded therewith to provide a seal between the overwrap material and the surface of

the cardstock. This arrangement presents relatively consistent surfaces that are readily

grasped by coupon processing equipment. In this way, a prize or other three-

dimensional object is retained in the overwrap without moving toward the peripheral

sides utilized in handling the insert.

Brief Description of Drawings

Fig. 1 is an isometric view of first and second inserts provided in a continuous

web of inserts according to the present invention.

Fig. 2 illustrates a piece of cardstock with an thermosealable coating on the

cardstock. Fig. 3 is a sectional view of the insert shown in Fig. 1 taken along the lines 3-3.

Modes for Carrying Out the Invention

Generally, the present invention relates to an insert used in a packaging

application. The insert is particularly suited for handling by automated processing

equipment such as that disclosed in U.S. Patent No. 5,549,233, the subject matter of

which is incorporated herein by reference. Such equipment is adapted to engage the

peripheral side edges of the insert while a three-dimensional object located in the

central portion of the insert passes between the sets of rolls to enable handling of

various types of three-dimensional objects. By way of example, the three-

dimensional object may be a premium, prize or a package component that is intended

to be inserted into a container such as a cereal box, bag or pouch. Alternatively, the

insert may be a packet of flavoring or seasoning that is intended to be placed into a

container, while remaining physically separated from the remaining contents of the

container.

Fig. 1 is an isometric view of first and second inserts or coupons 10, 12

provided in a continuous web or stream of inserts. In the preferred embodiment, each

of the inserts 10, 12 includes a three-dimensional piece or object lOp, 12p which will

ultimately be placed within a container or the like. By way of example, the objects

lOp, 12p may be prizes or the like provided in cereal boxes, bread wrappers or other

suitable containers. Alternatively, the pieces lOp, 12p may be small packages which

are utilized in food packaging or other similar applications. The inserts 10, 12 are preferably provided in a continuous perforated

web format and are separated from each other by a perforation 14 disposed to extend

transversely to the web which connects inserts 10, 12 together. The remaining inserts

in the web are similarly connected to each other.

Fig. 2 illustrates a relatively flat piece 20 of cardstock, paperboard or

other material having a suitable rigidity to withstand processing by automated

handling equipment. In this way, the cardstock piece provides structural support for

the insert. The cardstock piece is defined by a pair of opposed ends 20e, a pair of

opposed sides 20s, and a top surface. Fig. 2 also shows the cardstock piece 20 having

a thermosealable coating 22 applied to the entire top surface of the cardstock.

Preferably, the coating 22 is an olefm-based material or other material having suitable

thermo-sealing characteristics.

Alternatively, a pair of strips of coating or other adhesive (not shown)

may be applied to the peripheral edges of the cardstock piece 20, preferably proximate

to the sides 20s. In this embodiment, the surface of card 20 may be coated with heat

sealable olefm-based material strips that extend the lengthwise dimension of the piece

20 between ends 20e. It should also be understood that the coating may applied to the

top surface of the cardstock piece in other forms, such as in the form of spaced lands

or the like.

The cardstock piece 20 with thermo-sealable coating and object lOp

are surrounded by a plastic overwrap material such as overwrap material 26. For

example, the overwrap material may be utilized to circumscribe the object and

cardstock 20 to provide a barrier with the outside such as an aseptically packaged insert. Preferably, the overwrap material ends 26e are heat sealed together to provide

a transverse band which is then perforated or otherwise weakened proximate to the

ends 20e of the cardstock. The sides 26s of the overwrap material are also preferably

heat sealed or otherwise bonded or affixed to the lateral sides of the top surface of the

cardstock piece 20 to completely enclose the three-dimensional object. One

alternative method for engaging the overwrap material with the lateral sides of the top

surface of the cardstock 20 is with the use of rollers or the like which provides a

suitable compressive forces to the overwrap material and coating to provide a seal

therebetween. In any event, a seal is provided between the overwrap material and the

thermo-sealable coating on the surface of the cardstock at locations proximate to the

side edges of the cardstock piece. In the preferred embodiment, the overwrap material

is fabricated of the same material as the coating, for example an olefm-based material.

However, the overwrap may be fabricated of a different material so long as its

bonding characteristics are such that it will be readily secured with the coating on the

top surface of the cardstock upon the application of heat and/or compressive forces

applied to the lateral edges of the cardstock piece.

Accordingly, the three-dimensional object such as a promotional piece

or packet is prevented from being laterally moved or dislodged toward the peripheral

side edges of the insert and is kept away from the handling equipment. In addition,

this arrangement presents relatively flat, uniform side surfaces which are the portions

of the insert to be handled by the processing equipment.

As described in U.S. Patent No. 5,549,233, the web of inserts is

presented to handling apparatus which engages the sides of the insert. In this regard, spaced pairs of feed rolls engage the side edges of the forwardmost insert in the web

and pass the coupon downstream to a pre-dispense location, preferably such that the

forwardmost coupon is engaged by spaced pairs of burst rolls while the perforation

separating the forwardmost coupon is disposed between the pairs of feed rolls and the

burst rolls. At the desired time, the burst rolls are rotated at relative angular speed

greater than that of the feed rolls to apply a bursting tension to the perforation

between the forwardmost coupon and the next succeeding coupon to disengage the

forwardmost coupon from the remainder of the web and to position the coupon into a

container or the like. In this way, three-dimensional inserts of the type described

above may be readily placed into containers.

Accordingly, a three-dimensional insert meeting the aforestated

objectives has been described. The insert provides improved structural integrity as

well as improved handleability. While the invention has been described in terms of

the best mode currently contemplated, those skilled in the art will appreciate that

various modifications may be made without departing from the spirit and scope of the

invention, as defined by the appended claims.

Claims

1. An insert adapted for use in conjunction with packaging apparatus

comprising:

a three-dimensional object;

a piece of cardstock including a top surface defined by first and second ends

and first and second side edges;

a thermo-sealable coating applied to at least a portion of the top surface of the

piece of cardstock; and

an overwrap material circumscribing the three-dimensional object and the

cardstock, the overwrap material being in sealing relation with the coating proximate

to the first and second side edges to prevent lateral movement of the three-

dimensional object toward the side edges of the cardstock.

2. The insert as in claim 1 wherein the coating extends the lengthwise

dimension of the cardstock.

3. The insert as in claim 1 or 2 wherein the overwrap material is heat-

applied to the coating.

4. The insert as in claim 1, 2 or 3 wherein the overwrap material is heat-

sealed proximate the ends of the cardstock to provide a relatively flat transverse band

surface.

5. The insert as in claim 4 wherein the relatively flat transverse band

surface interconnects the insert with a second insert provided in a continuous web, the

transverse band including a perforation formed therein.

6. The insert as in claim 1, 2, 3, 4 or 5 wherein the coating comprises an

olefm-based thermo-sealable material.

7. The insert of claims 1, 2, 3, 4, 5 or 6 wherein the coating is applied

only to the periphery of the cardstock.

8. The insert of claim 7 wherein the coating is applied only proximate the

side edges.

9. The insert of claims 1 , 2, 3, 4, 5 or 6 wherein the coating is applied to

substantially all of the top surface.

10. A continuous web of a plurality of three-dimensional inserts adapted

for handling by automated packaging apparatus, each insert in the web comprising:

a three-dimensional object;

a piece of cardstock including a top surface, first and second ends, and first

and second side edges; a coating applied to at least a portion of the top surface of the cardstock; and

an overwrap material in surrounding relation to the three-dimensional object

and to the cardstock, the overwrap material being in heat-sealing engagement with the

coating proximate to the first and second side edges to present opposed, relatively flat

side surfaces engageable with the packaging apparatus.

11. The continuous web as in claim 10 wherein the coating comprises a

thermo-sealable olefm-based material.

12. The continuous web as in claim 11 wherein the overwrap material is

heat-sealed proximate to the ends of the cardstock to provide a relatively flat

transverse band connecting one insert in the web with a succeeding insert in the web.

13. The continuous web as in claim 12 wherein the transverse band has a

weakened portion formed therein.

14. The continuous web as in claim 13 wherein the weakened portion is a

perforation.

15. The continuous web of claims 10, 11, 12, 13 or 14 wherein the coating

is applied only to the periphery of the cardstock.

16. The continuous web of claim 15 wherein the coating is applied only

proximate the side edges.

17. The continuous web of claims 10, 11, 12, 13 or 14 wherein the coating

is applied to substantially all of the top surface.