Patent ID: 7267857

Claim:
A single-pass thermal laminated assembly comprising: a substantially flexible pouch formed by at least two opposing layers of substantially flexible film, the pouch having a perimeter edge with the opposing layers of film being attached to each other along at least a portion of the perimeter edge and not being attached to each other along another portion of the perimeter edge so as to form an opening between the opposing layers of film along the perimeter edge, each opposing layer having an inner surface facing the other layer so as to form an inner chamber therebetween and each opposing layer having an outer surface facing away from the other layer; a thermal activated adhesive that has not been activated substantially covering an outer surface of at least one of the layers and substantially covering an inner surface of at least one of the layers, the thermal adhesive capable of being activated upon being heated to at least a threshold activation temperature; a first substrate adapted to fit through the opening and within the inner chamber so as to be in contact with the adhesive on the inner surface; a substantially semi-rigid or rigid second substrate in contact with the adhesive on the outer surface; and, the assembly capable of being formed by positioning the pouch adjacent the second substrate and then once through a thermal laminating system applying at least the threshold activation temperature and a pressure so that the first substrate becomes laminated within the pouch and the pouch becomes laminated to the second substrate.