Three dimensional insert construction

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.

What is claimed is:  
     
       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;  
       thermo-sealable laminate applied to 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 laminate 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 invention as in  claim 1  wherein the laminate extends the lengthwise dimension of the cardstock. 
     
     
       3. The invention as in  claim 2  wherein the overwrap material is heat-applied to the laminate. 
     
     
       4. The invention as in  claim 1  wherein the overwrap material is heat-sealed proximate the ends of the cardstock to provide a relatively flat transverse band surface. 
     
     
       5. The invention 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 invention as in  claim 1  wherein the laminate is fabricated of an olefin-based thermo-sealable material. 
     
     
       7. The 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 laminate applied to 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 laminate proximate to the first and second side edges to present opposed, relatively flat side surface engage-able with the packaging apparatus.  
     
     
       8. The invention as in  claim 7  wherein the laminate is a thermo-sealable olefin-based material. 
     
     
       9. The invention as in  claim 8  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. 
     
     
       10. The invention as in  claim 9  wherein the transverse band has a weakened portion formed therein. 
     
     
       11. The invention as in  claim 10  wherein the weakened portion is a perforation. 
     
     
       12. An insert comprising: 
         a three - dimensional object;    
       
         a support piece having a top surface, first and second ends, and first and second side edges; and  
       
         a flexible overwrap material surrounding and enclosing the three - dimensional object and the support piece, the overwrap material being sealed to the top surface of the support piece proximate to the first and second side edges; and    
       
         a sealable coating applied to at least a portion of the top surface of the support piece. 
       
     
     
       13. The insert as in  claim 12  wherein the coating is applied to at least the portion of the top surface proximate the first and second side edges. 
     
     
       14. The insert as in  claim 13  wherein the coating is applied only proximate the side edges. 
     
     
       15. The insert as in  claim 14  wherein the coating extends the lengthwise dimension of the support piece. 
     
     
       16. The insert as in  claim 12  wherein the coating is applied to only the periphery of the top surface of the support piece. 
     
     
       17. The insert as in  claim 12  wherein the coating is applied to substantially all of the top surface of the support piece. 
     
     
       18. The insert as in  claim 12  wherein the coating comprises an olefin- based thermosealable material.   
     
     
       19. The insert as in  claim 12  wherein the support piece is chosen from the group consisting of cardboard and cardstock. 
     
     
       20. The insert as in  claim 12  wherein the flexible overwrap material is heat- sealed to the support piece via the coating.   
     
     
       21. The insert as in  claim 12  wherein the flexible overwrap material is sealed to itself so as to provide a relatively- flat, transverse band surface defining one end of the insert.   
     
     
       22. The insert as in any one of claims  12 - 21  wherein the flexible overwrap material is sealed to itself so as to provide two relatively- flat, transverse band surfaces defining each of the ends of the insert.   
     
     
       23. The insert as in  claim 22  wherein one of the relatively- flat, transverse band surfaces interconnects the insert with a second such insert by one of its relatively - flat, transverse band surfaces to form a connection band.   
     
     
       24. A plurality of inserts as in  claim 23  interconnected as a continuous web. 
     
     
       25. The insert as in  claim 23  wherein the connection band includes a weakened portion formed therein. 
     
     
       26. A plurality of inserts as in  claim 25  interconnected as a continuous web. 
     
     
       27. The insert as in  claim 25  wherein the weakened portion includes a perforation. 
     
     
       28. A plurality of inserts as in  claim 27  interconnected as a continuous web. 
     
     
       29. A continuous web of a plurality of inserts, each insert in the web comprising: 
         a three - dimensional object;    
       
         a support piece having a top surface, first and second ends, and first and second side edges; and  
       
         a flexible overwrap material surrounding and enclosing the three - dimensional object and the support piece, the overwrap material being sealed to the top surface of the support piece proximate to the first and second side edges; and    
       
         a sealable coating applied to at least a portion of the top surface of the support piece. 
       
     
     
       30. The continuous web as in  claim 29  wherein the coating is applied to at least the portion of the top surface proximate the first and second side edges. 
     
     
       31. The continuous web as in  claim 30  wherein the coating is applied only proximate the side edges. 
     
     
       32. The continuous web as in  claim 31  wherein the coating extends the lengthwise dimension of the support piece. 
     
     
       33. The continuous web as in  claim 29  wherein the coating is applied only to the periphery of the top surface of the support piece. 
     
     
       34. The continuous web as in  claim 29  wherein the coating is applied to substantially all of the top surface. 
     
     
       35. The continuous web as in  claim 29  wherein the coating comprises an olefin- based thermo - sealable material.   
     
     
       36. The continuous web as in  claim 29  wherein the support piece is chosen from the group consisting of cardboard and cardstock. 
     
     
       37. The continuous web as in  claim 29  wherein the flexible overwrap is heat- sealed to the support piece via the coating.   
     
     
       38. The continuous web as in any one of claims  29 - 37  wherein the flexible overwrap material is sealed to itself so as to provide two relatively- flat, transverse band surfaces defining each of the ends of each of the inserts.   
     
     
       39. The continuous web as in  claim 38  wherein one of the relatively- flat, transverse band surfaces interconnects the insert with a second such insert by one of its relatively - flat transverse band surfaces to form a connection band.   
     
     
       40. The continuous web as in  claim 39  wherein the connection band includes a weakened portion formed therein. 
     
     
       41. The continuous web as in  claim 40  wherein the weakened portion includes a perforation. 
     
     
       42. An insert adapted for use in conjunction with packaging apparatus comprising: 
         a three - dimensional object;    
       
         a substrate having a top surface, first and second ends, and first and second side edges; and  
       
         an overwrap material circumscribing the three - dimensional object and the substrate, the overwrap material being in sealing relation with the top surface of the substrate proximate to the first and second side edges to inhibit lateral movement of the three - dimensional object toward the side edges of the substrate; and    
       
         wherein a sealable coating is applied to at least a portion of the top surface of the substrate. 
       
     
     
       43. The insert as in  claim 42  wherein the coating extends the lengthwise dimension of the substrate. 
     
     
       44. The insert as in  claim 42  or  43  wherein the overwrap material is heat- sealed to the substrate.   
     
     
       45. The insert as in  claim 42  or  43  wherein the overwrap material is heat- sealed proximate the ends of the substrate to provide a relatively flat transverse band surface.   
     
     
       46. The insert as in  claim 45  wherein said relatively- flat, transverse band surface interconnects the insert with a second insert.   
     
     
       47. The insert as in  claim 46  wherein the transverse band includes a weakened portion formed therein. 
     
     
       48. The insert as in  claim 47  wherein the weakened portion includes a perforation. 
     
     
       49. The insert as in  claim 42  wherein the coating comprises an olefin- based thermo - sealable material.   
     
     
       50. The insert as in  claim 42  wherein the coating is applied to only the periphery of the substrate. 
     
     
       51. The insert as in  claim 42  wherein the coating is applied only proximate the side edges. 
     
     
       52. The insert as in  claim 42  wherein the coating is applied to substantially all of the top surface. 
     
     
       53. A continuous web of a plurality of three- dimensional inserts, each insert in the web comprising:    
         a three - dimensional object;    
       
         a substrate including a top surface, first and second ends, and first and second side edges; and  
       
         an overwrap material in surrounding relation to the three - dimensional object and to the substrate, the overwrap material being in engagement with the top surface of the substrate proximate to the first and second side edges; and    
       
         wherein the substrate has a coating applied to at least a portion of its top surface. 
       
     
     
       54. The continuous web as in  claim 53  wherein the coating is applied to only the periphery of the substrate. 
     
     
       55. The continuous web as in  claim 53  wherein the coating is applied only proximate the side edges. 
     
     
       56. The continuous web as in  claim 53  wherein the coating is applied to substantially all of the top surface. 
     
     
       57. The continuous web as in  claim 53  wherein the coating comprises a thermo- sealable olefin - based material.   
     
     
       58. The continuous web as in one of claims  53 - 57  wherein the overwrap material is heat- sealed proximate to the ends of the substrate to provide a relatively flat transverse band connecting one insert in the web with a succeeding insert in the web.   
     
     
       59. The continuous web as in  claim 58  wherein the transverse band has a weakened portion formed therein. 
     
     
       60. The continuous web as in  claim 59  wherein the weakened portion includes a perforation.