MXPA99004058A - Three-dimensional insert construction - Google Patents

Abstract

A three-dimensional insert for use in a handling system comprising a sheet of cardstock or the like defined by first and second ends (20e) and first and second sides (20s), a coating (22) applied to at least a portion of the top surface of the cardstock, and an overwrap (26) material bonded to the coating, preferably proximate to the first and second sides. This structure enables a three-dimensional object (10p, 12p) to be placed within the overwrap material without risk of movement to the peripheral sides thereby eliminating the possibility of interference with the apparatus for handling the insert.

Description

CONSTRUCTION OF TRIDIMENSIONAL INSERT TECHNICAL FIELD The present invention generally relates to the packaging technique and more particularly to a three-dimensional insert construction, which is provided in a continuous web of inserts that can be easily handled by automated packaging equipment or the like. PREVIOUS TECHNIQUE Packing apparatuses particularly adapted to handle inserts or coupons that are provided in the continuous perforated web are known in the art, for example from U.S. Pat. No. 5,079,901, granted to the assignee of the present invention. This patent discloses an apparatus and system that receives a continuous perforated web of coupons, provides a more forward coupon between pairs of feed rollers and release rolls and at a desired time, separates the forwardmost coupon from the continuous web by applying a voltage of detachment to a transverse perforation separating the leading coupon from the next successive coupon. The separate coupon is then passed to an insertion point at a desired time such as in a moving container, based on signals that are provided by synchronization circuits. Another insertion handling apparatus is known such as that described in U.S. Pat. No. 5,549,233. This patent describes an inserts handling system, which processes inserts of three-dimensional pieces with the use of laterally spaced pairs of rolls. This configuration allows the three-dimensional aspect of inserts to be "passed through" the intermediate handling apparatus to the spaced sets of rollers. However, problems can occur with these types of equipment where the projected part insert requires a flat area to be used in moving the part, either to detach or project an individual piece in a container or the like. An attempt to overcome this problem has been to provide an insert that uses a piece of rigid cardboard or the like along with a three-dimensional item. The additional rigidity that is provided by the cardboard contributes with desired rigidity to the insert or use more rigid films. However, it does not overcome the problem that the package, gift or prize moves laterally to the peripheral sides of the cardboard during storage or handling and interferes with the rollers used in the peeling operation. This is particularly problematic when a relatively high performance of inserts is required, which requires frequent stops of the processing line. Other approaches have included the use of adhesive applied to the cardboard to hold the object at a desired location on the cardboard 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 cardboard is often problematic. The residual glue on the object may be undesirable to the end user. Yet another approach is referred to as "thin packaging", wherein plastic film is connected to a porous paper backing material through which a vacuum is applied to shape the film to the item to be packed. Although this method also solves the problem of lateral movement, the porous paper backing inherently is not well suited for most of the permeability requirements of food contact inserts. DESCRIPTION OF THE INVENTION According to this, a general objective of the invention is to overcome the deficiencies of the prior art.

A further object * of the present invention is to provide a three-dimensional insert that is easily manufactured at an acceptable cost, while allowing easy handling in a coupon management system. The present invention provides these and other additional objectives with a three-dimensional insert comprising a stub of cardboard or paperboard (hereinafter referred to as cardboard) defined by first and second opposite ends and first and second opposite sides. A heat-sealable olefin film or coating is applied to the top surface of the board. A wrapping material is contacted with the coating and is bonded or bonded thereto to provide a seal between the wrapping material and the surface of the paperboard. This structure has relatively consistent surfaces that are easily held by coupon processing equipment. In this way, a prize or other three-dimensional object is retained in the envelope without moving towards the peripheral sides used in the handling of the insert. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is an isometric view of the first and second inserts that are provided in a continuous frame of inserts according to the present invention. Figure 2 illustrates a piece of cardboard with a heat-sealable coating on the cardboard.

Figure 3 is a sectional view of the insert shown in Figure 1 taken on lines 3-3. Ways to Carry Out the Invention In general, the present invention relates to an insert used in a packaging application. The insert is particularly suitable for handling by automated processing equipment such as that described in U.S. Pat. No. 5,549,233, the subject of which is incorporated herein by refererence. Said equipment is adapted to couple 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 rollers to allow handling of various types of three-dimensional objects. By way of example, the three-dimensional object may be a prize, gift or component of a package that is intended to be inserted in a container such as a cereal box, bag. Alternatively, the insert may be a package of flavoring or seasoning that is intended to be placed in a container, while remaining physically separate from the rest of the contents of the container. Figure 1 is an isometric view of first and second inserts or coupons 10, 12 that are provided in a continuous frame or stream of inserts. In the preferred embodiment, each of the inserts 10, 12 includes a three-dimensional object or part lOp, 12p, which will finally be placed inside a container or the like. By way of example, the lOp, 12p objects may be prizes or the like which are provided in cereal boxes, bread wraps or other convenient containers. Alternatively, the lOp, 12p pieces can be small packages that are used in food packaging or other similar applications. The inserts 10, 12 are preferably provided in a perforated continuous-frame format and are separated from each other by a perforation 14, arranged to project transversely which connects inserts 10, 12 to each other. The remaining inserts in the frame are similarly connected to each other. Figure 2 illustrates a relatively flat piece of cardboard, paperboard or other material having a suitable rigidity to withstand processing by automated handling equipment. In this way, the piece of cardboard provides structural support for the insert. The piece of cardboard is defined by a pair of opposite ends 20e, a pair of opposite sides 2Os and a top surface. Figure 2 also shows the piece of cardboard 20 having a heat-sealable coating 22 applied to the entire upper surface of the cardboard. Preferably, the coating 22 is an olefin-based material or other material having suitable heat-sealing characteristics. Alternatively, a pair of coating strips or other adhesive (not shown) may be applied to the peripheral edges of the cardboard part 20, preferably near the sides 20s. In this embodiment, the cardboard surface 20 can be coated with strips of heat-sealable olefin-based material extending the longitudinal dimension of the piece 20 between the ends 20e. It will also be understood that the coating can be applied to the upper surface of the piece of cardboard in other forms, such as in the form of spaced flat portions or the like. The piece of cardboard 20 with the heat-sealable coating and the object lOp are surrounded by a plastic wrapping material such as a coating material 26. For example, the coating material can be used to circumscribe the object and the cardboard 20, to provide a barrier with the outside such as an aseptically packed insert. Preferably, the ends of wrapping material 26e are heat sealed together to provide a transverse band which is then punctured or otherwise weakened proximate the ends 20e of the paperboard. The sides 20 of the wrapping material are also preferably heat sealed or otherwise joined or fixed to the sides of the upper surface of the piece of cardboard 20 to completely circumscribe the three-dimensional object. An alternate method for coupling the wrapping material with the sides of the upper surface of the carton 20 is with the use of rollers or the like which provide convenient compression forces to the wrapping and coating material., to provide a seal between them. In any case, a seal is provided between the wrapping material and the heat-sealable coating on the surface of the board, at sites near the side edges of the piece of cardboard. In the preferred embodiment, the wrapping material is made of the same material as the coating. For example, an olefin-based material. However, the wrapping can be made of a different material, provided that its binding characteristics are such that it is easily fastened with the coating on the upper surface of the cardboard before the application of heat and / or compression forces applied to the side edges. of the piece of cardboard. Accordingly, the three-dimensional object such as a package or promotional piece is prevented from moving or detaching laterally towards the peripheral side edges of the insert and is kept away from the handling equipment. In addition, this structure allows uniform, relatively flat side surfaces which are the portions of the insert to be handled by the processing equipment. As described in U.S. Pat. Do not. ,549,233, the insert frame is presented to handling apparatuses that engage the sides of the insert. In this regard, spaced pairs of feed rollers couple the side edges of the forwardmost insert into the web and pass the downstream coupon to a pre-supply site preferably in such a way that the forwardmost coupon is engaged in spaced pairs of release rolls, while the perforation separating the frontmost coupon is arranged between the pairs of feed rollers and the release rolls. At the desired time, the release rollers are rotated at a relative angular velocity greater than that of the feed rollers to apply a release tension to the perforation between the leading forward coupon and the next successive coupon to release the leading forward coupon from the rest of the plot and place the coupon in a container or similar. In this way, they can be easily placed in three-dimensional insert containers of the type described above.

Accordingly, a three-dimensional insert that complies with the above-stated objectives has been described. The insert provides improved structural integrity as well as improved manageability. 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 practiced without departing from the spirit and scope of the invention as defined by the appended claims.

Claims (17)

1. An insert adapted to be used in conjunction with a packaging apparatus, characterized in that it comprises: a three-dimensional object; a piece of cardboard including an upper surface defined by first and second ends and first and second side edges; a heat-sealable coating applied at least to a portion of the upper surface of the piece of cardboard; and a wrapping material circumscribing the three-dimensional object and the cardboard, the wrapping material is in seal relation with the coating next to the first and second side edges, to avoid lateral movement of the three-dimensional object towards the side edges of the cardboard.

The insert according to claim 1, characterized in that the coating extends over the longitudinal dimension of the cardboard.

The insert according to claim 1 or 2, characterized in that the wrapping material is applied with heat to the coating.

The insert according to claim 1, 2 or 3, characterized in that the wrapping material is heat sealed next to the cardboard ends to provide a relatively flat transverse band surface.

5. The insert according to claim 4, characterized in that the relatively flat transverse band surface interconnects the insert with a second insert that is provided in a continuous frame, the transverse band includes a perforation therein formed.

The insert according to claim 1, 2, 3, 4 or 5, characterized in that the coating comprises a heat-sealable material based on olefin.

The insert according to claim 1, 2, 3, 4, 5 or 6, characterized in that the coating is applied only to the periphery of the cardboard.

The insert according to claim 7, characterized in that the coating is applied only close to the side edges.

The insert according to claim 1, 2, 3, 4, 5 or 6, characterized in that the coating is applied substantially to the entire upper surface.

10. A continuous pattern of a plurality of three-dimensional inserts adapted to be handled by an automated packaging apparatus, each insert in the pattern is characterized in that it comprises: a three-dimensional object; a piece of cardboard including a top surface, first and second ends and first and second side edges; a coating applied to at least a portion of the upper surface of the cardboard; and a wrapping material in relation to the three-dimensional object and the cardboard, the wrapping material is in heat-sealing coupling with the coating close to the first and second side edges, to present opposed relatively flat side surfaces that engage with the packaging apparatus.

11. The continuous web according to claim 10, characterized in that the coating comprises a heat-sealable olefin-based material.

The continuous web according to claim 11, characterized in that the wrapping material is heat sealed next to the cardboard ends to provide a relatively flat transverse web connecting an insert in the web with a successive insert in the web.

13. The continuous web according to claim 12, characterized in that the transverse web has a weakened portion therein formed.

The continuous web according to claim 13, characterized in that the weakened portion is a perforation.

15. The continuous web according to claim 10, 11, 12, 13 or 14, characterized in that the coating is applied only to the periphery of the cardboard.

16. The continuous web according to claim 15, characterized in that the coating is only applied next to the side edges.

17. The continuous web according to claim 11, 12, 13 or 14, characterized in that the coating is applied substantially to the entire upper surface.