Container with sealed compartments

Abstract

A container (4) for a consumer product includes a first base layer (8) and an overlying second base layer (10). A first portion (3) of the first base layer and a first portion (5) of the second base layer (10) form a compartment region (7), the periphery (18) of which is completely sealed to form a sealed compartment (16) for containing the consumer product. A second portion (9) of the first base layer and a second portion (11) of the second base layer form an access region (13) directly adjacent to the compartment region. The access region includes an unsealed region (22) and its periphery (20) extends around the unsealed region. The first base layer is attached to the second base layer at the periphery. The unsealed region is separated from the sealed compartment by the completely sealed periphery of the compartment region. The container also includes a first weakening line (128) extending at least partially in the unsealed region only in the first base layer and a second weakening line (131) of a different shape only in the second base layer. The difference in shape between the first and second weakening lines defines a closing tab (143) in the second base layer in the unsealed region.

Description

Technical Field

[0001] This disclosure relates to a container for consumer products, the container including a sealed compartment and an access area including an unsealed area. This disclosure also relates to a method of manufacturing a packaged aerosol-generating article. Background Technology

[0002] It is known to package consumer products in containers comprising two layers of material covering each other to form a compartment in which the consumer product is positioned. In some instances, the two layers of material may be sealed to each other to form a sealed compartment in which the consumer product is positioned. To open the sealed container, it may be necessary to peel one layer of material from the other. It is desirable to manufacture containers that are easy for consumers to open. However, it is also desirable to manufacture containers that reduce the risk of accidental opening. Generally, providing a container that is difficult to open accidentally but easy to open when desired is challenging. Summary of the Invention

[0003] According to a first aspect of this disclosure, a container for consumer products is provided, the container including a first base layer and a second base layer covering the first base layer. A first portion of the first base layer and a first portion of the second base layer form a compartment region, wherein the periphery of the compartment region is completely sealed to form a sealed compartment for accommodating one or more consumer products. A second portion of the first base layer and a second portion of the second base layer form an access region directly adjacent to the compartment region. The access region includes an unsealed region, wherein the periphery of the access region extends around the unsealed region. The first base layer is attached to the second base layer at the periphery of the access region. The unsealed region is separated from the sealed compartment by the completely sealed periphery of the compartment region. The container further includes a weakening line extending at least partially within the unsealed region of the access region.

[0004] As used herein, the term "sealed" refers to a portion of a container where the first base layer is anchored to the second base layer. When referring to the perimeter of a region of the container, the term "fully sealed" means a perimeter that is 100% sealed along its length.

[0005] As used herein, the term "directly adjacent" refers to a first portion of a container being adjacent to a second portion of the container, with no intervening portion of the container positioned between the first and second portions. The access area is directly adjacent to the compartment area.

[0006] For ease of reference, the perimeter of the entry area will be referred to as the "entry area perimeter" in this article. The perimeter of the compartment area will be referred to as the "compartment area perimeter" in this article.

[0007] Advantageously, the unsealed area of ​​the access zone facilitates the user opening of the container. For example, after breaking the weakening line in the unsealed area, the user can grasp the first base layer in the unsealed area with one hand and the second base layer in the unsealed area with the other hand, and then peel the first base layer off the second base layer along at least a portion of the perimeter of the fully sealed compartment area.

[0008] Advantageously, attaching the first base layer to the second base layer around the perimeter of the entry area reduces the risk of accidental opening of the container, or prevents accidental opening. For example, attaching the first base layer to the second base layer around the perimeter of the entry area prevents the user from grasping the first and second base layers separately in unsealed areas.

[0009] Advantageously, providing a weakening line that extends at least partially within the unsealed area facilitates the user's opening of the container when desired. For example, by breaking at least one of the first and second base layers along the weakening line in the unsealed area, the user can grasp the first and second base layers respectively in the unsealed area.

[0010] The unsealed area can be separated from the sealed compartment by the fully sealed perimeter of the compartment area and the perimeter of the access area.

[0011] The weakening line may be present only in one of the first and second base layers. Advantageously, providing a weakening line in only one of the first and second base layers facilitates the container remaining a single piece when either the first or second base layer breaks along the weakening line. Advantageously, this reduces or prevents littering by minimizing the number of container pieces discarded by the user when the container has been opened and is no longer needed. For example, in an embodiment where the weakening line is present only in the first base layer, even if the first base layer breaks into two pieces when the container breaks along the weakening line, the two pieces of the first base layer can still remain attached to a single second base layer by completely sealing the perimeter of the compartment area and the perimeter of the access area.

[0012] The weakening line may be present in both the first and second substrate layers. Advantageously, providing the weakening line in both the first and second substrate layers facilitates the breaking of both the first and second substrate layers in the unsealed area. Advantageously, breaking the first and second substrate layers facilitates the user's gripping of the first and second substrate layers respectively in the unsealed area.

[0013] The weakening line can extend between the first edge and the second edge of the container.

[0014] Advantageously, the weakening line extending between the first edge and the second edge of the container facilitates the user in breaking open at least one of the first and second base layers along the weakening line. For example, starting from the first edge or the second edge of the first base layer, the user can tear or otherwise break open at least one of the first and second base layers along the weakening line.

[0015] Advantageously, when the container has been broken along the weakening line, the weakening line extending between the first edge and the second edge of the container facilitates the disassembly of a portion of the container, including a portion of the unsealed area of ​​the access region. Advantageously, disassembling the portion of the container including the unsealed area facilitates the user to grasp the first and second base layers respectively at the remaining unsealed area of ​​the access region.

[0016] The perimeter of the access area may include at least one unsealed portion, with a weakening line extending across the at least one unsealed portion. Advantageously, once the container has been broken along the weakening line, the at least one unsealed portion allows a user to grasp the first and second base layers respectively at the perimeter of the access area. Advantageously, the at least one unsealed portion may be positioned at the edge of the container. Advantageously, once the container has been broken along the weakening line, positioning the at least one unsealed portion at the edge of the container allows a user to grasp the first and second base layers respectively at the edge of the container. Advantageously, grasping the first and second base layers respectively at the edge of the container reduces the force required to separate the first and second base layers along the perimeter of the sealed compartment area when opening the container.

[0017] At least one unsealed portion may include a first unsealed portion and a second unsealed portion, wherein a first end of a weakening line extends across the first unsealed portion, and wherein a second end of a weakening line extends across the second unsealed portion. Advantageously, once the container has been broken along the weakening line, this configuration further facilitates a user's gripping of the first and second base layers, respectively, at the entry area. The first unsealed portion, the second unsealed portion, and the unsealed area of ​​the entry area may extend continuously between a first edge and a second edge of the container.

[0018] The weakening line may extend across a portion of the sealed periphery of the compartment area. Advantageously, the weakening line extending across a portion of the sealed periphery of the compartment area facilitates opening the compartment area when the user breaks the container along the weakening line. In other words, when opening the container, the weakening line extending across a portion of the periphery of the sealed compartment area facilitates the user separating the first base layer from the second base layer across at least a portion of the periphery of the sealed compartment area.

[0019] The weakening line may include a first end extending from a first portion across the sealing periphery of the compartment region and a second end extending from a second portion across the sealing periphery of the compartment region. Advantageously, the first and second ends of the weakening line extending from the first and second portions across the periphery of the sealed compartment region further facilitate opening the compartment region when the user breaks the container along the weakening line.

[0020] Preferably, the central portion of the weakening line extends across a portion of the unsealed area of ​​the entry region. Advantageously, when opening the container, the user can first break the container at the central portion of the weakening line. Advantageously, breaking the container at the central portion of the weakening line in the unsealed area allows the user to grasp the first and second base layers respectively. Advantageously, pulling the first base layer away from the second base layer at the central portion of the weakening line allows the breaking of the weakening line to simultaneously propagate from the central portion to both the first and second ends of the weakening line.

[0021] The weakening line can be linear. In other words, the weakening line can extend in a substantially straight line. Advantageously, a linear weakening line facilitates the simple manufacture of the container. Advantageously, a linear weakening line facilitates the user tearing or otherwise breaking the container along the weakening line. A linear weakening line may be particularly advantageous in embodiments where the weakening line extends between the first edge and the second edge of the container.

[0022] At least a portion of the weakening line may be curved. Advantageously, when the container breaks along the weakening line, the curved weakening line facilitates providing a desired shape to a portion of at least one of the first and second base layers.

[0023] The perimeter of the access area can be completely sealed. Advantageously, a completely sealed perimeter of the access area further reduces the risk of accidental opening of the container.

[0024] The weakening line may be a first weakening line only in the first substrate layer, and the container further includes a second weakening line only in the second substrate layer.

[0025] Preferably, the second weakening line extends at least partially within the unsealed area of ​​the entry region. Advantageously, when the container breaks along the first and second weakening lines, the second weakening line, extending at least partially within the unsealed area of ​​the entry region, further facilitates the user's gripping of the first and second base layers, respectively, in the unsealed area.

[0026] The second weakening line may at least partially cover the first weakening line. Advantageously, the second weakening line, which at least partially covers the first weakening line, allows the user to break the container along both the first and second weakening lines simultaneously.

[0027] The second weakening line may have a different shape than the first weakening line. Advantageously, when the container breaks along the first and second weakening lines, the second weakening line having a different shape than the first weakening line can cause a portion of the first base layer to have a different shape than a portion of the second base layer. Advantageously, after the container has broken along the first and second weakening lines, providing a portion of the first base layer with a different shape than the portion of the second base layer facilitates the user's gripping of the first and second base layers in the unsealed area. Advantageously, after the container has broken along the first and second weakening lines, providing a portion of the first base layer with a different shape than the portion of the second base layer can provide the container with one or more additional features or functions.

[0028] Preferably, the shape difference between the first and second weakening lines defines a closing tab in the second base layer within the unsealed region of the entry area. Advantageously, the closing tab facilitates the re-closure of the container after it has been broken along the first and second weakening lines. For example, a portion of the first base layer may be tucked beneath the closing tab formed by the second base layer to hold the first base layer in the closed position.

[0029] Preferably, a first portion of at least one of the first and second base layers includes a recess, wherein the recess at least partially defines a compartment for receiving one or more consumer products. Advantageously, the recess can increase the storage capacity of the compartment. Advantageously, the recess can facilitate the positioning of one or more consumer products within the compartment during container manufacturing. Advantageously, the recess can facilitate the retention of one or more consumer products within the compartment.

[0030] A first portion of the first substrate layer may include a recess, and the second substrate layer may be substantially planar. A first portion of the second substrate layer may include a recess, and the first substrate layer may be substantially planar.

[0031] A first portion of the first substrate layer may include a first recess, and a first portion of the second substrate layer may include a second recess covering the first recess, wherein the first and second recesses together define a compartment for receiving one or more consumer products. Preferably, the first and second recesses are of the same size. Preferably, the first and second recesses are of the same shape.

[0032] The weakening line may include at least one of perforation lines, fold lines, crease lines, and scribing lines. Preferably, the weakening line includes a perforation line. Advantageously, the perforation line can be easily formed during the manufacturing process of the first base layer, the second base layer, or the container. Advantageously, the user may be able to easily break the container along the perforation line. Advantageously, the perforation line facilitates tearing the container along the weakening line.

[0033] In embodiments where the container includes a first weakening line and a second weakening line, each of the first weakening line and the second weakening line may include at least one of a perforation line, a fold line, a crease line, and a scribing line. Preferably, each of the first weakening line and the second weakening line includes a perforation line.

[0034] Each of the first and second base layers may include a laminating material. The laminating material may include at least one paper layer and at least one polymer film layer. Advantageously, the at least one paper layer may be biodegradable. Advantageously, the at least one polymer film layer facilitates securing the first base layer to the second base layer at each of the first and second sealing regions.

[0035] Preferably, at least one paper layer forms the outer surface of each of the first and second base layers. Preferably, at least one polymer film layer forms the inner surface of each of the first and second base layers.

[0036] The laminated material may include a paper layer, a first polymer film layer covering the paper layer, a second polymer film layer covering the first polymer film layer, and a third polymer film layer covering the second polymer film layer. Advantageously, the second polymer film layer may form an impermeable barrier layer. Advantageously, the first polymer film layer may secure the paper layer to the impermeable barrier layer. Advantageously, the third polymer film layer may facilitate securing the first base layer to the second base layer at each of the perimeters of the fully sealed compartment area and the access area. Each of the first and third polymer film layers may include polyethylene. The second polymer film layer may include ethylene vinyl alcohol.

[0037] The first base layer can be secured to the second base layer in each of the periphery of the fully sealed compartment area and the periphery of the access area using at least one of adhesives and welding. The first base layer can also be secured to the second base layer in each of the periphery of the fully sealed compartment area and the periphery of the access area using thermal welding. In embodiments where each of the first and second base layers comprises a laminated material, thermal welding may be particularly advantageous; the laminated material comprises at least one paper layer and at least one polymer film layer.

[0038] According to a second aspect of this disclosure, a packaged aerosol-generating article is provided according to any embodiment described herein, comprising a container according to a first aspect of the invention. The packaged aerosol-generating article further includes an aerosol-generating article sealed within a compartment.

[0039] As used herein, the term "aerosol-generating article" refers to an article comprising an aerosol-forming matrix capable of releasing volatile compounds that can form aerosols. Such volatile compounds can be released by heating the aerosol-forming matrix. Aerosol-generating articles may be disposable.

[0040] Aerosol-generating articles can be filter cigarettes or other smoking articles, wherein the aerosol-forming matrix includes tobacco material that is burned to form smoke. Aerosol-generating articles can be articles in which tobacco material is heated rather than burned to form an aerosol. Aerosol-generating articles can be articles in which nicotine-containing aerosols are generated from tobacco material, tobacco extracts, or other nicotine sources without combustion and, in some cases, without heating (e.g., through a chemical reaction).

[0041] The aerosol generating article may be a cylinder, the cylinder comprising a shell and an aerosol forming matrix positioned within the shell. The aerosol forming matrix may be a liquid aerosol forming matrix. The liquid aerosol forming matrix may be a nicotine-containing liquid. The cylinder may be configured for connection to an aerosol generating device.

[0042] As used herein, the term "aerosol generating apparatus" refers to an apparatus that interacts with an aerosol generating article, including an aerosol forming matrix, to generate aerosols.

[0043] As described herein, at least one of the first and second base layers of a container according to a first aspect of the invention may include a recess that at least partially defines a compartment for receiving one or more consumer products. Furthermore, it is more generally known to package consumer products in containers that include recesses for receiving consumer products. When at least a portion of a container is formed from sheet material, it may be desirable to form recesses into the sheet material during the manufacture of the container. However, in some cases, it is difficult to form recesses of sufficient size to accommodate consumer products without tearing or damaging the sheet material.

[0044] According to a third aspect of this disclosure, a plunger-assisted thermoforming process is provided, comprising providing a mold and a plunger, wherein the plunger includes a plunger body and an elastomeric cap extending over at least a portion of the plunger body. The plunger-assisted thermoforming process further includes heating a substrate material web to form a heated substrate material web, and positioning the heated substrate material web between the mold and the plunger. The plunger-assisted thermoforming process further includes engaging the elastomeric cap of the plunger with the heated substrate material web, and inserting the plunger into the mold to form the heated substrate material web into a mold shape.

[0045] Advantageously, the plunger-assisted thermoforming process according to the invention can be used to form recesses in a base material when forming containers for consumer products.

[0046] Advantageously, the inventors have recognized that, compared to what is possible when using a conventional plunger that only includes the plunger body, providing an elastomeric cap extending over at least a portion of the plunger body facilitates the formation of deeper recesses without tearing or breaking the base material.

[0047] Elastomer covers can be formed from any suitable material that exhibits elastic or rubber-like properties.

[0048] The plunger body may be formed of at least one metal. The at least one metal may include a metal alloy. The plunger body may be formed of steel. The plunger body may be formed of stainless steel.

[0049] Preferably, the plunger body has a shape including one or more circular vertices and one or more circular edges. Advantageously, the circular vertices and circular edges reduce the risk of the plunger tearing or breaking through the base material. Preferably, at least a portion of the plunger body has a rounded cuboid shape.

[0050] Preferably, the step of heating the substrate web includes heating the substrate web to a temperature between about 65 degrees Celsius and about 95 degrees Celsius, more preferably between about 65 degrees Celsius and about 75 degrees Celsius.

[0051] The substrate web may include a laminated material. The laminated material may include at least one paper layer and at least one polymer film layer. Advantageously, the at least one paper layer may be biodegradable. Advantageously, the at least one polymer film layer facilitates the attachment of the substrate web to one or more additional materials in subsequent manufacturing processes. For example, the at least one polymer film layer facilitates the attachment of the substrate web to an additional polymer material using thermal welding.

[0052] Preferably, the step of bonding the plunger's elastomeric cap to the heated substrate material web includes bonding the plunger's elastomeric cap to at least one polymer film layer.

[0053] The laminated material may include a paper layer, a first polymer film layer covering the paper layer, a second polymer film layer covering the first polymer film layer, and a third polymer film layer covering the second polymer film layer. Advantageously, the second polymer film layer may form an impermeable barrier layer. Advantageously, the first polymer film layer may secure the paper layer to the impermeable barrier layer. Advantageously, the third polymer film layer may facilitate securing the first base layer to the second base layer at each of the first and second sealing regions. Each of the first and third polymer film layers may include polyethylene. The second polymer film layer may include ethylene vinyl alcohol.

[0054] According to a fourth aspect of this disclosure, a method of forming a packaged aerosol-generating article is provided according to any embodiment described herein. The method includes providing a first substrate material web and forming a first recess in the first substrate material web using a plunger-assisted thermoforming process according to a third aspect of this disclosure. The method further includes positioning the aerosol-generating article in the first recess, providing a second substrate material web, and positioning the second substrate material web over the aerosol-generating article and the first substrate material web. The method also includes securing the second substrate material web to the first substrate material web around the aerosol-generating article to form a compartment between the first and second substrate material webs, wherein the first recess at least partially defines the compartment, and wherein the aerosol-generating article is sealed within the compartment. The method further includes cutting the first and second substrate material webs to form a packaged aerosol-generating article, the packaged aerosol-generating article including the aerosol-generating article and a container, the container including a first substrate layer, a second substrate layer, and a compartment.

[0055] According to any embodiment described herein, the method may further include forming a second recess in a second base material web using a plunger-assisted thermoforming process according to a third aspect of this disclosure. Preferably, the step of positioning the second base material web over the aerosol-generating article and the first base material web includes positioning the second recess over the aerosol-generating article, wherein the first recess and the second recess together define a compartment.

[0056] Aerosol-generating articles may include any of the optional or preferred features described herein with reference to the second aspect of this disclosure.

[0057] According to a fifth aspect of this disclosure, a method of forming a packaged aerosol-generating article is provided, the method comprising providing a first substrate material web and positioning the aerosol-generating article on the first substrate material web. The method further comprises providing a second substrate material web and positioning the second substrate material web above the aerosol-generating article and the first substrate material web. The method further comprises securing a first portion of the first substrate material web to a first portion of the second substrate material web to form a compartment region, wherein the periphery of the compartment region is completely sealed to form a sealed compartment, and wherein the aerosol-generating article is contained within the sealed compartment. The method further comprises securing a second portion of the first substrate material web to a second portion of the second substrate material web to form an entry region directly adjacent to the compartment region, wherein the entry region includes an unsealed region, wherein the periphery of the entry region extends around the unsealed region, wherein a first substrate layer is attached to a second substrate layer at the periphery of the entry region, and wherein the unsealed region is separated from the sealed compartment by the completely sealed periphery of the compartment region. The method further comprises forming a weakening line in at least one of the first substrate material web and the second substrate material web, wherein the weakening line extends at least partially within the unsealed region of the entry region. The method further includes cutting a first substrate web and a second substrate web to form a packaged aerosol generating article, the packaged aerosol generating article including an aerosol generating article and a container, the container including a first substrate layer, a second substrate layer, a compartment region, an entry region and a weakening line.

[0058] Advantageously, the unsealed area of ​​the access zone facilitates the user opening the container. For example, the user can grasp the first base layer with one hand in the unsealed area and the second base layer with the other hand in the unsealed area, and then peel the first base layer off the second base layer along at least a portion of the perimeter of the fully sealed compartment area.

[0059] Advantageously, attaching the first base layer to the second base layer around the perimeter of the entry area reduces the risk of accidental opening of the container, or prevents accidental opening. For example, attaching the first base layer to the second base layer around the perimeter of the entry area prevents the user from grasping the first and second base layers separately in unsealed areas.

[0060] Advantageously, providing a weakening line that extends at least partially within the unsealed area facilitates the user's opening of the container when desired. For example, by breaking at least one of the first and second base layers along the weakening line in the unsealed area, the user can grasp the first and second base layers respectively in the unsealed area.

[0061] According to any of the embodiments described herein, an aerosol-generating article of a package formed according to the method of the fifth aspect of this disclosure may be an aerosol-generating article of a package according to the second aspect of this disclosure.

[0062] The unsealed area can be separated from the sealed compartment by the fully sealed perimeter of the compartment area and the perimeter of the access area.

[0063] The step of forming the weakening line may include forming the weakening line in only one of the first substrate material web and the second substrate material web. Advantageously, providing the weakening line in only one of the first and second substrate layers facilitates the container remaining a single piece when either the first or second substrate layer breaks along the weakening line. Advantageously, this reduces or prevents littering by minimizing the number of container pieces discarded by the user when the container has been opened and is no longer needed. For example, in an embodiment where the weakening line is only in the first substrate layer, even if the first substrate layer breaks into two pieces when the container breaks along the weakening line, the two pieces of the first substrate layer can still remain attached to a single second substrate layer by completely sealing the perimeter of the compartment area and the perimeter of the access area.

[0064] The step of forming the weakening line may include forming the weakening line in both the first substrate web and the second substrate web. Advantageously, providing the weakening line in both the first substrate layer and the second substrate layer facilitates the breaking of both the first substrate layer and the second substrate layer in the unsealed area. Advantageously, breaking the first substrate layer and the second substrate layer facilitates the user to grasp the first substrate layer and the second substrate layer respectively in the unsealed area.

[0065] The weakening line can extend between the first edge and the second edge of the container.

[0066] Advantageously, the weakening line extending between the first edge and the second edge of the container facilitates the user in breaking open at least one of the first and second base layers along the weakening line. For example, starting from the first edge or the second edge of the first base layer, the user can tear or otherwise break open at least one of the first and second base layers along the weakening line.

[0067] Advantageously, when the container has been broken along the weakening line, the weakening line extending between the first edge and the second edge of the container facilitates the disassembly of a portion of the container, including a portion of the unsealed area. Advantageously, disassembling the portion of the container including the unsealed area allows the user to grasp the first and second base layers respectively at the remainder of the unsealed area.

[0068] The perimeter of the access area may include at least one unsealed portion, with a weakening line extending across the at least one unsealed portion. Advantageously, once the container has been broken along the weakening line, the at least one unsealed portion allows a user to grasp the first and second base layers respectively at the perimeter of the access area. Advantageously, the at least one unsealed portion may be positioned at the edge of the container. Advantageously, once the container has been broken along the weakening line, positioning the at least one unsealed portion at the edge of the container allows a user to grasp the first and second base layers respectively at the edge of the container. Advantageously, grasping the first and second base layers respectively at the edge of the container reduces the force required to separate the first and second base layers along the perimeter of the sealed compartment area when opening the container.

[0069] At least one unsealed portion may include a first unsealed portion and a second unsealed portion, wherein a first end of a weakening line extends across the first unsealed portion, and wherein a second end of a weakening line extends across the second unsealed portion. Advantageously, once the container has been broken along the weakening line, this configuration further facilitates a user's gripping of the first and second base layers, respectively, at the entry area. The first unsealed portion, the second unsealed portion, and the unsealed area of ​​the entry area may extend continuously between a first edge and a second edge of the container.

[0070] The weakening line may extend across a portion of the sealed periphery of the compartment area. Advantageously, the weakening line extending across a portion of the sealed periphery of the compartment area facilitates opening the compartment area when the user breaks the container along the weakening line. In other words, when opening the container, the weakening line extending across a portion of the periphery of the sealed compartment area facilitates the user separating the first base layer from the second base layer across at least a portion of the periphery of the sealed compartment area.

[0071] The weakening line may include a first end extending from a first portion across the sealing periphery of the compartment region and a second end extending from a second portion across the sealing periphery of the compartment region. Advantageously, the first and second ends of the weakening line extending from the first and second portions across the periphery of the sealed compartment region further facilitate opening the compartment region when the user breaks the container along the weakening line.

[0072] Preferably, the central portion of the weakening line extends across a portion of the unsealed area of ​​the entry region. Advantageously, when opening the container, the user can first break the container at the central portion of the weakening line. Advantageously, breaking the container at the central portion of the weakening line in the unsealed area allows the user to grasp the first and second base layers respectively. Advantageously, pulling the first base layer away from the second base layer at the central portion of the weakening line allows the breaking of the weakening line to simultaneously propagate from the central portion to both the first and second ends of the weakening line.

[0073] The weakening line can be linear. In other words, the weakening line can extend in a substantially straight line. Advantageously, a linear weakening line facilitates the simple manufacture of the container. Advantageously, a linear weakening line facilitates the user tearing or otherwise breaking the container along the weakening line. A linear weakening line may be particularly advantageous in embodiments where the weakening line extends between the first edge and the second edge of the container.

[0074] At least a portion of the weakening line may be curved. Advantageously, when the container breaks along the weakening line, the curved weakening line facilitates providing a desired shape to a portion of at least one of the first and second base layers.

[0075] The perimeter of the access area can be completely sealed. Advantageously, a completely sealed perimeter of the access area further reduces the risk of accidental opening of the container.

[0076] The weakening line may be a first weakening line only in the first substrate material web, and the method further includes the step of forming a second weakening line only in the second substrate material web.

[0077] Preferably, the second weakening line extends at least partially within the unsealed area of ​​the entry region. Advantageously, when the container breaks along the first and second weakening lines, the second weakening line, extending at least partially within the unsealed area of ​​the entry region, further facilitates the user's gripping of the first and second base layers, respectively, in the unsealed area.

[0078] The second weakening line may at least partially cover the first weakening line. Advantageously, the second weakening line, which at least partially covers the first weakening line, allows the user to break the container along both the first and second weakening lines simultaneously.

[0079] The second weakening line may have a different shape than the first weakening line. Advantageously, when the container breaks along the first and second weakening lines, the second weakening line having a different shape than the first weakening line can cause a portion of the first base layer to have a different shape than a portion of the second base layer. Advantageously, after the container has broken along the first and second weakening lines, providing a portion of the first base layer with a different shape than the portion of the second base layer facilitates the user's gripping of the first and second base layers in the unsealed area. Advantageously, after the container has broken along the first and second weakening lines, providing a portion of the first base layer with a different shape than the portion of the second base layer can provide the container with one or more additional features or functions.

[0080] Preferably, the shape difference between the first and second weakening lines defines a closing tab in the second base layer within the unsealed region of the entry area. Advantageously, the closing tab facilitates the re-closure of the container after it has been broken along the first and second weakening lines. For example, a portion of the first base layer may be tucked beneath the closing tab formed by the second base layer to hold the first base layer in the closed position.

[0081] The method may include the step of forming a recess in at least one of a first portion of a first base material web and a second base material web, wherein the recess at least partially defines a compartment for receiving one or more consumer products. Advantageously, the recess may increase the storage capacity of the compartment. Advantageously, the recess may facilitate the positioning of one or more consumer products within the compartment during container manufacturing. Advantageously, the recess may facilitate the retention of one or more consumer products within the compartment.

[0082] A first portion of the first substrate material web may include a recess, and the second substrate material web may be substantially planar. A first portion of the second substrate material web may include a recess, and the first substrate material web may be substantially planar.

[0083] The step of forming the recess includes forming a first recess in a first portion of a first substrate material web and forming a second recess in a first portion of a second substrate material web, wherein the step of positioning the second substrate material web above the aerosol generating article and the first substrate material web includes positioning the second recess above the aerosol generating article, and wherein the first recess and the second recess together define a compartment.

[0084] The step of forming a recess may include using a plunger-assisted thermoforming process to form the recess. In embodiments where the step of forming a recess includes forming a first recess and forming a second recess, each of the first recess and the second recess may be formed using a plunger-assisted thermoforming process.

[0085] According to any of the embodiments described herein, the plunger-assisted thermoforming process may be the plunger-assisted thermoforming process according to the third aspect of this disclosure.

[0086] The plunger-assisted thermoforming process may include the step of forming a recess with a mold and a plunger, wherein the plunger includes a plunger body and an elastomeric cap extending over at least a portion of the plunger body.

[0087] Elastomer covers can be formed from any suitable material that exhibits elastic or rubber-like properties.

[0088] The plunger body may be formed of at least one metal. The at least one metal may include a metal alloy. The plunger body may be formed of steel. The plunger body may be formed of stainless steel.

[0089] Preferably, the plunger body has a shape including one or more circular vertices and one or more circular edges. Advantageously, the circular vertices and circular edges reduce the risk of the plunger tearing or breaking through the base material. Preferably, at least a portion of the plunger body has a rounded cuboid shape.

[0090] Preferably, the plunger-assisted thermoforming process includes the step of heating at least one of a first base material web and a second base material web to a temperature between about 65 degrees Celsius and about 95 degrees Celsius, preferably between about 65 degrees Celsius and about 75 degrees Celsius.

[0091] The step of forming a weakening line may include forming at least one of a perforation line, a fold line, a crease line, and a scribing line. Preferably, the step of forming a weakening line includes forming a perforation line. Advantageously, the perforation line can be easily formed during the manufacturing process. Advantageously, the user may be able to easily tear the container along the perforation line. Advantageously, the perforation line facilitates tearing the container along the weakening line.

[0092] In embodiments where the container includes a first weakening line and a second weakening line, each of the first weakening line and the second weakening line may include at least one of a perforation line, a fold line, a crease line, and a scribing line. Preferably, each of the first weakening line and the second weakening line includes a perforation line.

[0093] Each of the first substrate web and the second substrate web may include a laminated material. In embodiments where each of the first substrate web and the second substrate web includes a laminated material, each of the first substrate layer and the second substrate layer includes a laminated material.

[0094] The laminated material may include at least one paper layer and at least one polymer film layer. Advantageously, the at least one paper layer may be biodegradable. Advantageously, the at least one polymer film layer facilitates the attachment of the first substrate web to the second substrate web at each of the perimeters of the fully sealed compartment area and the access area.

[0095] Preferably, at least one paper layer forms the outer surface of each of the first and second base layers. Preferably, at least one polymer film layer forms the inner surface of each of the first and second base layers.

[0096] The laminated material may include a paper layer, a first polymer film layer covering the paper layer, a second polymer film layer covering the first polymer film layer, and a third polymer film layer covering the second polymer film layer. Advantageously, the second polymer film layer may form an impermeable barrier layer. Advantageously, the first polymer film layer may secure the paper layer to the impermeable barrier layer. Advantageously, the third polymer film layer may facilitate securing a first substrate web to a second substrate web at each of the perimeters of the fully sealed compartment area and the access area. Each of the first and third polymer film layers may include polyethylene. The second polymer film layer may include ethylene vinyl alcohol.

[0097] The step of securing a first substrate web to a second substrate web at each of the perimeters of the fully sealed compartment area and the access area may include securing the second substrate web to the first substrate web using at least one of an adhesive and a weld. The first substrate web may be secured to the second substrate web at each of the perimeters of the fully sealed compartment area and the access area using thermal welding. In embodiments where each of the first and second substrate webs comprises a laminate, thermal welding may be particularly advantageous; the laminate comprises at least one paper layer and at least one polymer film layer.

[0098] Aerosol-generating articles can be filter cigarettes or other smoking articles, wherein the aerosol-forming matrix includes tobacco material that is burned to form smoke. Aerosol-generating articles can be articles in which tobacco material is heated rather than burned to form an aerosol. Aerosol-generating articles can be articles in which nicotine-containing aerosols are generated from tobacco material, tobacco extracts, or other nicotine sources without combustion and, in some cases, without heating (e.g., through a chemical reaction).

[0099] The aerosol generating article may be a cylinder, the cylinder including a shell and an aerosol forming matrix positioned within the shell. The aerosol forming matrix may be a liquid aerosol forming matrix. The liquid aerosol forming matrix may be a nicotine-containing liquid. The cylinder may be configured for connection to an aerosol generating apparatus. The cylinder may include a heater arranged to heat the aerosol forming matrix. The heater may be an electric heater. The electric heater may be arranged to receive a power supply from the aerosol generating apparatus when the cylinder is connected to the aerosol generating apparatus.

[0100] The invention is defined in the claims. However, a non-exhaustive list of non-limiting examples is provided below. Any one or more features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0101] Example Ex1: A container for consumer products, the container comprising:

[0102] First basal layer;

[0103] A second base layer covering the first base layer;

[0104] The first portion of the first base layer and the first portion of the second base layer form a compartment region, wherein the periphery of the compartment region is completely sealed to form a sealed compartment for accommodating one or more consumer products;

[0105] The second portion of the first base layer and the second portion of the second base layer form an entry area directly adjacent to the compartment region, wherein the entry area includes an unsealed area, wherein the periphery of the entry area extends around the unsealed area, wherein the first base layer is attached to the second base layer at the periphery of the entry area, and wherein the unsealed area is separated from the sealed compartment by a fully sealed periphery of the compartment region; and

[0106] The container further includes a weakening line extending at least partially within the unsealed area of ​​the entry region.

[0107] Example Ex2: According to the container of Example Ex1, wherein the unsealed area is separated from the sealed compartment by the fully sealed periphery of the compartment area and the periphery of the entry area.

[0108] Example Ex3: A container based on Example Ex1 or Ex2, wherein the weakening line is only in one of the first base layer and the second base layer.

[0109] Example Ex4: A container based on Example Ex1 or Ex2, wherein the weakening line is in both the first substrate layer and the second substrate layer.

[0110] Example Ex5: A container according to any of the preceding examples, wherein the weakening line extends between the first edge of the container and the second edge of the container.

[0111] Example Ex6: According to any of the preceding examples, the periphery of the access area includes at least one unsealed portion, and the weakening line extends across the at least one unsealed portion.

[0112] Example Ex7: According to the container of Example Ex6, wherein the at least one unsealed portion includes a first unsealed portion and a second unsealed portion, wherein a first end of the weakening line extends across the first unsealed portion, and wherein a second end of the weakening line extends across the second unsealed portion.

[0113] Example Ex8: According to any of the preceding examples, the weakening line extends across a portion of the sealed periphery of the compartment area.

[0114] Example Ex9: According to the container of Example Ex8, the weakening line includes a first end extending from a first portion across the sealing periphery of the compartment region and a second end extending from a second portion across the sealing periphery of the compartment region.

[0115] Example Ex10: A container based on any of the preceding examples, wherein the weakening line is linear.

[0116] Example Ex11: A container according to any one of Examples Ex1 to Ex9, wherein at least a portion of the weakening line is curved.

[0117] Example Ex12: The container according to any of the preceding examples, wherein the periphery of the access area is completely sealed.

[0118] Example Ex13: A container according to any of the preceding examples, wherein the weakening line is a first weakening line only in the first base layer, and the container further includes a second weakening line only in the second base layer.

[0119] Example Ex14: According to the container of Example Ex13, the second weakening line extends at least partially within the unsealed area of ​​the entry region.

[0120] Example Ex15: A container according to Example Ex13 or Ex14, wherein the second weakening line at least partially covers the first weakening line.

[0121] Example Ex16: The container according to Example Ex13, Ex14 or Ex15, wherein the second weakening line has a different shape than the first weakening line.

[0122] Example Ex17: According to the container of Example Ex16, the shape difference between the first weakening line and the second weakening line is defined as a closing tab in the second base layer in the unsealed area of ​​the entry region.

[0123] Example Ex18: According to any of the preceding examples, a first portion of at least one of the first base layer and the second base layer includes a recess, and the recess at least partially defines a compartment for accommodating one or more consumer products.

[0124] Example Ex19: According to the container of Example Ex18, a first portion of the first base layer includes a first recess, a first portion of the second base layer includes a second recess covering the first recess, and the first recess and the second recess together define the compartment for accommodating one or more consumer products.

[0125] Example Ex20: A container according to any of the preceding examples, wherein each of the first base layer and the second base layer comprises a laminated material, and wherein the laminated material comprises at least one paper layer and at least one polymer film layer.

[0126] Example Ex21: A packaged aerosol-generating article, comprising:

[0127] Based on the container of any of the foregoing instances; and

[0128] Aerosol-generated articles sealed within the compartment.

[0129] Example Ex22: A plunger-assisted thermoforming process, comprising:

[0130] A mold and a plunger are provided, wherein the plunger includes a plunger body and an elastomeric cap extending over at least a portion of the plunger body;

[0131] Heating the substrate web to form a heated substrate web;

[0132] Position the heated substrate material web between the mold and the plunger;

[0133] The elastomeric cap of the plunger is joined to the heated substrate material web;

[0134] The plunger is inserted into the mold to form the heated substrate material web into the shape of the mold.

[0135] Example Ex23: A plunger-assisted thermoforming process according to Example Ex22, wherein the elastomer cap is formed of a material exhibiting elastic or rubbery properties.

[0136] Example Ex24: A plunger-assisted thermoforming process according to Example Ex22 or Ex23, wherein the plunger body is formed of at least one metal.

[0137] Example Ex25: A plunger-assisted thermoforming process according to Examples Ex22, Ex23 or Ex24, wherein the step of heating the substrate material web includes heating the substrate material web to a temperature between 65 degrees Celsius and 95 degrees Celsius.

[0138] Example Ex26: A plunger-assisted thermoforming process according to any one of Examples Ex22 to Ex25, wherein the substrate web comprises a laminated material comprising at least one paper layer and at least one polymer film layer.

[0139] Example Ex27: A method for forming a packaged aerosol article, the method comprising:

[0140] Provide the first substrate material web;

[0141] A first recess is formed in the first substrate material web using a plunger-assisted thermoforming process according to any one of Examples Ex22 to Ex26;

[0142] The aerosol-generated product is positioned in the first recess;

[0143] Provide a second substrate material web;

[0144] Position the second substrate material web above the aerosol-generating product and the first substrate material web;

[0145] A second substrate web is fixed to a first substrate web around the aerosol-generating article to form a compartment between the first substrate web and the second substrate web, wherein the first recess at least partially defines the compartment, and wherein the aerosol-generating article is sealed within the compartment; and

[0146] Cutting the first substrate material web and the second substrate material web to form a packaged aerosol generating article, the packaged aerosol generating article including the aerosol generating article and a container, the container including a first substrate layer, a second substrate layer and a compartment.

[0147] Example Ex28: The method according to Example Ex27 further includes forming a second recess in a second base material web using a plunger-assisted thermoforming process according to any one of Examples Ex22 to Ex26, wherein the step of positioning the second base material web above the aerosol-generating article and the first base material web includes positioning the second recess above the aerosol-generating article, and wherein the first recess and the second recess together define the compartment.

[0148] Example Ex29: A method for forming a packaged aerosol article, the method comprising:

[0149] Provide the first substrate material web;

[0150] Position the aerosol-generated article on the web of the first substrate material;

[0151] Provide a second substrate material web;

[0152] Position the second substrate material web above the aerosol-generating product and the first substrate material web;

[0153] A first portion of the first substrate material web is fixed to a first portion of the second substrate material web to form a compartment region, wherein the periphery of the compartment region is completely sealed to form a sealed compartment, and wherein the aerosol-generating article is contained within the sealed compartment.

[0154] A second portion of the first base material web is fixed to a second portion of the second base material web to form an access area directly adjacent to the compartment region, wherein the access area includes an unsealed area, wherein the periphery of the access area extends around the unsealed area, wherein the first base layer is attached to the second base layer at the periphery of the access area, and wherein the unsealed area is separated from the sealed compartment by a fully sealed periphery of the compartment region.

[0155] A weakening line is formed in at least one of the first substrate material web and the second substrate material web, wherein the weakening line extends at least partially within the unsealed area of ​​the entry region; and

[0156] Cutting the first substrate material web and the second substrate material web to form a packaged aerosol generating article, the packaged aerosol generating article including the aerosol generating article and a container, the container including a first substrate layer, a second substrate layer, the compartment region, the entry region and the weakening line.

[0157] Example Ex30: According to the method of Example Ex29, the unsealed area is separated from the sealed compartment by the fully sealed periphery of the compartment area and the periphery of the access area.

[0158] Example Ex31: According to the method of Example Ex29, the step of forming the weakening line includes forming the weakening line in only one of the first substrate material web and the second substrate material web.

[0159] Example Ex32: According to the method of Example Ex29 or Ex30, the step of forming the weakening line includes forming the weakening line in both the first substrate web and the second substrate web.

[0160] Example Ex33: The method according to any one of Examples Ex29 to Ex32, wherein the weakening line extends between the first edge of the container and the second edge of the container.

[0161] Example Ex34: According to the method of any one of Examples Ex29 to Ex33, the periphery of the access area includes at least one unsealed portion, and the weakening line extends across the at least one unsealed portion.

[0162] Example Ex35: According to the method of Example Ex34, the at least one unsealed portion includes a first unsealed portion and a second unsealed portion, wherein a first end of the weakening line extends across the first unsealed portion, and wherein a second end of the weakening line extends across the second unsealed portion.

[0163] Example Ex36: According to the method of any one of Examples Ex29 to Ex35, wherein the weakening line extends across a portion of the sealing periphery of the compartment region.

[0164] Example Ex37: According to the method of Example Ex36, the weakening line includes a first end extending across a first portion of the sealing periphery of the compartment region and a second end extending across a second portion of the sealing periphery of the compartment region.

[0165] Example Ex38: The method of any one of Examples Ex29 to Ex37, wherein the weakening line is linear.

[0166] Example Ex39: According to the method of any one of Examples Ex29 to Ex37, at least a portion of the weakening line is curved.

[0167] Example Ex40: The method according to any one of Examples Ex29 to Ex39, wherein the periphery of the access area is completely sealed.

[0168] Example Ex41: The method according to any one of Examples Ex28 to Ex38, wherein the weakening line is a first weakening line only in the first substrate material web, the method further comprising the step of forming a second weakening line only in the second substrate material web.

[0169] Example Ex42: According to the method of Example Ex41, the second weakening line extends at least partially within the unsealed area of ​​the entry region.

[0170] Example Ex43: According to the method of Example Ex41 or Ex42, wherein the second weakening line at least partially covers the first weakening line.

[0171] Example Ex44: According to the method of Example Ex41, Ex42 or Ex43, wherein the second weakening line has a different shape from the first weakening line.

[0172] Example Ex45: According to the method of Example Ex44, the shape difference between the first weakening line and the second weakening line is defined as a closing tab in the second base layer in the unsealed region of the entry region.

[0173] Example Ex46: The method according to any one of Examples Ex29 to Ex45 further includes the step of forming a recess in at least one of a first portion of the first substrate material web and a first portion of the second substrate material web, wherein the recess at least partially defines a compartment for accommodating one or more consumer products.

[0174] Example Ex47: According to the method of Example Ex46, the step of forming the recess includes forming a first recess in a first portion of the first substrate material web and forming a second recess in a first portion of the second substrate material web, wherein the step of positioning the second substrate material web above the aerosol generating article and the first substrate material web includes positioning the second recess above the aerosol generating article, and wherein the first recess and the second recess together define a compartment.

[0175] Example Ex48: According to the method of Example Ex46 or Ex47, the step of forming the recess includes forming the recess using a plunger-assisted thermoforming process.

[0176] Example Ex49: The method according to Example Ex48, wherein the plunger-assisted thermoforming process is a plunger-assisted thermoforming process according to any one of Examples Ex22 to 25.

[0177] Example Ex50: The method according to any one of Examples Ex29 to Ex49, wherein each of the first substrate web and the second substrate web comprises a laminate, and wherein the laminate comprises at least one paper layer and at least one polymer film layer. Attached Figure Description

[0178] Several embodiments will now be further described with reference to the accompanying drawings, in which:

[0179] Figure 1 A top view of an aerosol-generating article of a package according to a first embodiment of the present disclosure is shown;

[0180] Figures 2 to 4 The section cut along line 1-1 is shown. Figure 1 A cross-sectional view of the aerosol-generating product of the packaging;

[0181] Figure 5 A top view of an aerosol-generating article of a package according to a second embodiment of the present disclosure is shown;

[0182] Figure 6 It shows Figure 5 Bottom view of the aerosol-generating product of the packaging;

[0183] Figure 7 The section cut along line 5-5 is shown. Figure 5 and 6 A cross-sectional view of the aerosol-generating product of the packaging;

[0184] Figures 8 to 10 It shows the shape of the line wrapped in 7-7 loops. Figure 7 An enlarged view of a portion of the aerosol-generating product from the packaging;

[0185] Figures 11 to 13 A plunger auxiliary device for thermoforming recesses in a web of base material is shown;

[0186] Figure 14 The steps of a plunger-assisted thermoforming process according to embodiments of the present disclosure are illustrated; and

[0187] Figure 15 The steps of a method for forming a packaged aerosol-generated article according to an embodiment of the present disclosure are shown. Detailed Implementation

[0188] Figures 1 to 4 An aerosol generating article 2 packaged according to a first embodiment of the present disclosure is shown. The packaged aerosol generating article 2 includes a container 4 and an aerosol generating article 6 received within the container 4. The container 4 includes a first base layer 8 and a second base layer 10 covering the first base layer 8. Each of the first base layer 8 and the second base layer 10 is formed of a laminate material including a paper layer forming the outer surface of the base layer and a polymer film layer forming the inner surface of the base layer.

[0189] A first portion 3 of the first base layer 8 and a first portion 5 of the second base layer 10 form a compartment region 7, wherein the periphery 18 of the compartment region 7 is completely sealed by continuous thermal welding to form a sealed compartment 16 in which an aerosol-generating article 6 is positioned. The first portion 3 of the first base layer 8 includes a first recess 12, and the first portion 5 of the second base layer 10 includes a second recess 14, wherein the first recess 12 and the second recess 14 together define the compartment 16.

[0190] The second portion 9 of the first base layer 8 and the second portion 11 of the second base layer 10 form an entry region 13 directly adjacent to the compartment region 7, wherein the entry region 13 includes an unsealed region 22, and wherein a periphery 20 of the entry region 13 extends around the unsealed region 22. The first base layer 8 is attached to the second base layer 10 along a portion of the entry region periphery 20. The entry region periphery 20 includes two unsealed portions 15 on opposite sides of the unsealed region 22, where the first base layer 8 is not attached to the second base layer 10. The unsealed region 22 is separated from the sealed compartment 16 by the fully sealed periphery 18 of the compartment region 7.

[0191] A weakening line 28, including a perforation line, is disposed in the first base layer 8 and the second base layer 10, and the weakening line 28 extends between the first edge 24 and the second edge 26 of the container 4.

[0192] Although the first base layer 8 is not fixed to the second base layer 10 at the unsealed area 22, the fact that the first base layer 8 is attached to the second base layer 10 along the length of the perimeter 20 of the entry area makes it difficult to separate the first base layer 8 from the second base layer 10. Therefore, the attachment of the first base layer 8 to the second base layer 10 along the length of the perimeter 20 of the entry area reduces the risk of accidental opening of the container 4.

[0193] Opening container 4 to remove aerosol-generated product 6 from container 4 is a two-step process.

[0194] First, the user tears, breaks, or tears open the container 4 along the entire length of the weakening line 28 to disassemble a portion of the container 4, said portion including a portion entering the perimeter 20 of the area. The result of this step is... Figure 3 As shown in the image.

[0195] Next, the user grasps the first base layer 8 and the second base layer 10 respectively at the unsealed area 22, and pulls the first base layer 8 and the second base layer 10 away from each other to separate the first base layer 8 and the second base layer 10 at the perimeter 18 of the sealed compartment area. This step is... Figure 4 As shown in the figure. Once the first base layer 8 has been separated from the second base layer 10 across at least a portion of the perimeter 18 of the sealed compartment area, the aerosol-generating article 6 can be removed from the compartment 16.

[0196] Figures 5 to 10 An aerosol-generating article 102 packaged according to a second embodiment of the present disclosure is shown. The packaged aerosol-generating article 102 is similar to the referenced article. Figures 1 to 4 The aerosol-generating article 2 of the package is described, and the same reference numerals are used to indicate the same parts.

[0197] The packaged aerosol generating article 102 includes a container 4 and an aerosol generating article 6 received within the container 4. The container 4 includes a first base layer 8 and a second base layer 10 covering the first base layer 8. Each of the first base layer 8 and the second base layer 10 is formed of a laminate material comprising a paper layer forming the outer surface of the base layer and a polymer film layer forming the inner surface of the base layer.

[0198] A first portion 3 of the first base layer 8 and a first portion 5 of the second base layer 10 form a compartment region 7, wherein the periphery 18 of the compartment region 7 is completely sealed by continuous thermal welding to form a sealed compartment 16 in which an aerosol-generating article 6 is positioned. The first portion 3 of the first base layer 8 includes a first recess 12, and the first portion 5 of the second base layer 10 includes a second recess 14, wherein the first recess 12 and the second recess 14 together define the compartment 16.

[0199] The second portion 9 of the first base layer 8 and the second portion 11 of the second base layer 10 form an entry region 13 directly adjacent to the compartment region 7, wherein the entry region 13 includes an unsealed region 22, and wherein a periphery 20 of the entry region 13 extends around the unsealed region 22 and is completely sealed. The unsealed region 22 is separated from the sealed compartment 16 by the completely sealed periphery 18 of the compartment region 7.

[0200] A first weakening line 128 is disposed in the first base layer 10 and includes a perforated line 129 extending across a portion of the unsealed region 22. The first weakening line 128 also includes a first cut line 135 extending across the periphery 18 of the sealed compartment region between a first end of the perforated line 129 and a first edge 24 of the container 4. The first weakening line 128 also includes a second cut line 137 extending across the periphery 18 of the sealed compartment region between a second end of the perforated line 129 and a second edge 26 of the container 4.

[0201] A second weakening line 131, including a perforated line, is disposed in the second base layer 10 and extends across a portion of the unsealed region 22. The second weakening line 131 has a different shape from the first weakening line 128, such that the second weakening line 131 only partially covers the first weakening line 128. Specifically, the end portions of the second weakening line 131 cover the corresponding end portions of the perforated lines 129 of the first weakening line 128. However, the central portion of the second weakening line 131 is shaped to define a tab 143. The function of the tab 143 is described in more detail below.

[0202] Although the first base layer 8 is not secured to the second base layer 10 at the unsealed area 22, the fully sealed entry area perimeter 20 makes it difficult to separate the first base layer 8 from the second base layer 10. Therefore, the fully sealed entry area perimeter 20 reduces the risk of accidental opening of the container 4.

[0203] Opening container 4 to remove aerosol-generated product 6 from container 4 is a two-step process.

[0204] First, the user bends container 4 to break the first base layer 8 along the first weakening line 128 and the second base layer 10 along the second weakening line 131. The result of this step is... Figure 8 As shown in the image.

[0205] Next, the user grasps the first base layer 8 and the second base layer 10 respectively at the unsealed area 22 and pulls the first base layer 8 and the second base layer 10 away from each other to separate the first base layer 8 from the second base layer 10 at the perimeter 18 of the sealed compartment area. The first cut line 135 and the second cut line 137 in the first base layer 8 facilitate the separation of the first base layer 8 from the second base layer 10 at the perimeter 18 of the sealed compartment area. This step... Figure 9 As shown in the figure. Once the first base layer 8 has been separated from the second base layer 10 across at least a portion of the perimeter 18 of the sealed compartment area, the aerosol-generating article 6 can be removed from the compartment 16.

[0206] Figure 10 The function of the tab 143 formed by the second base layer 10 when it breaks along the second weakening line 131 is illustrated. The tab 143 facilitates the re-closure of the container 4 by allowing the user to position a portion of the first base layer 8 at the unsealed area 22 below the tab 143. For example, when the aerosol-generating article 6 has been used, the user can reinsert the aerosol-generating article 6 into the compartment 16 and re-close the container 4 by positioning a portion of the first base layer 8 at the unsealed area 22 below the tab 143. The used aerosol-generating article 6 can then be carried in the container 4 until the user can dispose of the used aerosol-generating article 6 and the container 4 together.

[0207] Figures 11 to 13 A plunger auxiliary device 200 for thermoforming recesses in a web of base material is shown. (Refer to...) Figures 1 to 10 The plunger auxiliary device 200 can be used to thermoform the first recess 12 and the second recess 14 of the first base layer 8 and the second base layer 10.

[0208] The plunger auxiliary device 200 includes a plunger 202, which includes a plunger body 204 formed of stainless steel and an elastomeric cap 206 extending over a portion of the plunger body 204. The plunger body 204 has a rounded cuboid shape.

[0209] The plunger auxiliary device 200 also includes a mold 208 made of stainless steel and positioned relative to the plunger 202. Each of the plunger 202 and the mold 208 is arranged to move linearly along the forming direction 210.

[0210] exist Figure 11 In the first configuration shown, the plunger 202 and the mold 208 are spaced apart from each other, and the base material web 212 is positioned between the plunger 202 and the mold 208. The base material web is arranged to move linearly along a machine direction 214 orthogonal to the forming direction 210.

[0211] To form a recess 216 in the base material web 212, the plunger 202 and the mold 208 are advanced toward each other along the forming direction 210. The elastomeric cap 206 of the plunger 202 engages the base material web 212 and deforms the base material web 212 into the mold 208. Then, the plunger 202 and the mold 208 are withdrawn from the base material web 212 along the forming direction 210 to leave the formed recess 216 in the base material web 212.

[0212] Figure 14 The steps of a plunger-assisted thermoforming process 300 according to an embodiment of the present disclosure are shown. (Refer to...) Figures 11 to 13 The plunger auxiliary device 200 is described Figure 14 The process is described, but a skilled technician will recognize that it can be performed using any equipment that includes molds and plungers (including the plunger body and the elastomer cap).

[0213] The plunger-assisted thermoforming process 300 includes providing a mold 208 302 and a plunger 202, the plunger including a plunger body 204 and an elastomeric cap 206 extending over a portion of the plunger body 204.

[0214] The plunger-assisted thermoforming process 300 also includes heating 304 the substrate material web 212. The heating step can be performed by passing the substrate material web 212 across at least one of a heating roller and a heating plate, by impacting the surface of the substrate material web with heated air or heated gas, by passing the substrate material web through an oven, and combinations thereof.

[0215] The plunger-assisted thermoforming process 300 also includes positioning 306 of a heated base material web 212 between the mold 208 and the plunger 202. For example, the heated base material web 212 can be positioned between the mold 208 and the plunger 202 by advancing the heated base material web 212 along the machine direction 214.

[0216] The plunger-assisted thermoforming process 300 also includes engaging the elastomeric cap 206 of the plunger 202 with the heated substrate material web 212 308, and inserting the plunger 202 into the mold 208 310 to form the heated substrate material web 212 into the shape of the mold 208.

[0217] The plunger-assisted thermoforming process 300 may further include withdrawing the mold 208 and the plunger 202 from the heated substrate material web 212, and advancing the heated substrate material web 212 to position different portions of the heated substrate material web 212 between the mold 208 and the plunger 202. Steps 308, 310, and 312 may be repeated cyclically to form a series of recesses 216 in the heated substrate material web 212.

[0218] Figure 15The steps of a method 400 for forming a packaged aerosol-generating article according to an embodiment of the present disclosure are shown. The packaged aerosol-generating article formed according to method 400 can be used as a reference. Figures 1 to 4 The aerosol-generating product described in the packaging 2, refer to Figures 5 to 10 The aerosol-generating article 102 described herein, or aerosol-generating articles in different packaging.

[0219] Method 400 includes providing a first substrate material web 402 and forming a first recess 404 in the first substrate material web. The step of forming the first recess 404 in the first substrate material web can be performed using a plunger-assisted thermoforming process. A plunger-assisted thermoforming process can be referenced... Figure 14 The described plunger-assisted thermoforming process 300.

[0220] Method 400 further includes providing a second base material web 406 and forming a second recess 408 in the second base material web. The step of forming the second recess 408 in the second base material web can be performed using a plunger-assisted thermoforming process. A plunger-assisted thermoforming process can be referenced... Figure 14 The described plunger-assisted thermoforming process 300.

[0221] Method 400 further includes the step of positioning the aerosol-generating article 410 in a first recess of the first substrate material web.

[0222] Method 400 further includes positioning a second substrate material web 412 above the aerosol-generating article and the first substrate material web, such that the aerosol-generating article is covered by a second recess of the second substrate material web.

[0223] The method 400 further includes fixing a first portion 414 of a first substrate material web to a first portion of a second substrate material web to form a compartment region, wherein the periphery of the compartment region is completely sealed to form a sealed compartment, and wherein the aerosol-generating article is contained within the sealed compartment. The sealed compartment includes a first recess and a second recess. Preferably, the step of fixing the second substrate material web 414 to the first substrate material web is performed using thermal welding.

[0224] The method 400 further includes fixing a second portion 416 of the first substrate material web to a second portion of the second substrate material web to form an entry region directly adjacent to the compartment region, wherein the entry region includes an unsealed region, wherein the periphery of the entry region extends around the unsealed region, wherein the first substrate layer is attached to the second substrate layer at the periphery of the entry region, and wherein the unsealed region is separated from the sealed compartment by a fully sealed periphery of the compartment region. Preferably, the step of fixing the second substrate material web 416 to the first substrate material web is performed using thermal welding.

[0225] It should be recognized that the step of fixing the second substrate web 416 to the first substrate web to form the access area can be performed before the step of fixing the second substrate web 414 to the first substrate web to form the compartment area.

[0226] It should be recognized that the step of fixing the second substrate web 416 to the first substrate web to form the entry area can be performed simultaneously with the step of fixing the second substrate web 414 to the first substrate web to form the compartment area.

[0227] The method 400 further includes forming a weakening line 418 in at least one of a first substrate material web and a second substrate material web, wherein the weakening line extends at least partially within an unsealed region of the access area.

[0228] It should be recognized that the step of forming the 418 weakening line can be performed before any of the aforementioned steps.

[0229] The step of forming the 418 weakening line may include forming a first weakening line in a first substrate material web and forming a second weakening line in a second substrate material web. In embodiments where the step of forming the 418 weakening line is performed prior to step 412, method 400 may include separate steps of forming the first weakening line in the first substrate material web and forming the second weakening line in the second substrate material web.

[0230] Method 400 further includes cutting 420 of a first substrate material web and a second substrate material web to form a packaged aerosol-generating article. The packaged aerosol-generating article includes an aerosol-generating article and a container, said container including a first substrate layer, a second substrate layer, a compartment region, an entry region, and a weakening line.

[0231] For the purposes of this specification and the appended claims, unless otherwise stated, all figures representing quantities, quantities, percentages, etc., shall be understood to be modified by the term "about" in all cases. Furthermore, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges that may be specifically listed or not listed herein. Thus, in this context, the number A is understood to be A ± 10% A. In this context, the number A can be considered to include a value within the general standard error for the measurement of the attribute modified by the number A. In some cases used in the appended claims, the number A may deviate from the percentages listed above, provided that the amount of deviation from A does not materially affect the essential and novel features of the claimed invention. Furthermore, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges that may be specifically listed or not listed herein.

Claims

1. A container for consumer products, the container comprising: First basal layer; A second base layer covering the first base layer; The first portion of the first base layer and the first portion of the second base layer form a compartment region, wherein the periphery of the compartment region is completely sealed to form a sealed compartment for accommodating one or more consumer products; The second portion of the first base layer and the second portion of the second base layer form an entry area directly adjacent to the compartment region, wherein the entry area includes an unsealed area, wherein the periphery of the entry area extends around the unsealed area, wherein the first base layer is attached to the second base layer at the periphery of the entry area, and wherein the unsealed area is separated from the sealed compartment by the fully sealed periphery of the compartment region; and The container further includes a weakening line extending at least partially within the unsealed region of the entry area, wherein the weakening line is a first weakening line only in the first base layer, and the container further includes a second weakening line only in the second base layer, wherein the second weakening line has a different shape from the first weakening line, wherein the shape difference between the first and second weakening lines defines a closing tab in the second base layer within the unsealed region of the entry area, and wherein the shape difference between the first and second weakening lines allows a portion of the first base layer to be tucked under the closing tab to hold the first base layer in a closed position.

2. The container of claim 1, wherein the weakening line extends between the first edge of the container and the second edge of the container.

3. The container of claim 1 or 2, wherein the periphery of the access area includes at least one unsealed portion, and wherein the weakening line extends across the at least one unsealed portion.

4. The container of claim 3, wherein the at least one unsealed portion comprises a first unsealed portion and a second unsealed portion, wherein a first end of the weakening line extends across the first unsealed portion, and wherein a second end of the weakening line extends across the second unsealed portion.

5. The container according to claim 1 or 2, wherein the weakening line is linear.

6. The container according to claim 1 or 2, wherein at least a portion of the weakening line is curved.

7. The container according to claim 1 or 2, wherein the second weakening line at least partially covers the first weakening line.

8. The container of claim 1 or 2, wherein a first portion of at least one of the first base layer and the second base layer includes a recess, and wherein the recess at least partially defines the sealed compartment for receiving one or more consumer products.

9. The container according to claim 1 or 2, wherein each of the first base layer and the second base layer comprises a laminated material, and wherein the laminated material comprises at least one paper layer and at least one polymer film layer.

10. A packaged aerosol-generating article, comprising: The container according to any one of claims 1 to 9; as well as Aerosol-generated articles sealed within the sealed compartment.

11. A method for forming a packaged aerosol article, the method comprising: Provide the first substrate material web; Position the aerosol-generated article on the web of the first substrate material; Provide a second substrate material web; Position the second substrate material web above the aerosol-generating product and the first substrate material web; A first portion of the first substrate material web is fixed to a first portion of the second substrate material web to form a compartment region, wherein the periphery of the compartment region is completely sealed to form a sealed compartment, and wherein the aerosol-generating article is contained within the sealed compartment. A second portion of the first base material web is secured to a second portion of the second base material web to form an entry area directly adjacent to the compartment region, wherein the entry area includes an unsealed area, wherein the periphery of the entry area extends around the unsealed area, wherein the first base material web is attached to the second base material web at the periphery of the entry area, and wherein the unsealed area is separated from the sealed compartment by the fully sealed periphery of the compartment region. A weakening line is formed extending at least partially within the unsealed area of ​​the entry region, wherein the weakening line is a first weakening line only in the first substrate material web, and a second weakening line is further formed only in the second substrate material web, wherein the second weakening line has a different shape from the first weakening line, wherein the shape difference between the first weakening line and the second weakening line defines a closing tab in the second substrate material web in the unsealed area of ​​the entry region, and wherein the shape difference between the first weakening line and the second weakening line allows a portion of the first substrate material web to be tucked under the closing tab to hold the first substrate material web in a closed position; as well as Cutting the first substrate material web and the second substrate material web to form a packaged aerosol generating article, the packaged aerosol generating article including the aerosol generating article and a container, the container including the first substrate material web, the second substrate material web, the compartment area, the entry area and the weakening line.

12. The method of claim 11, wherein each of the first substrate web and the second substrate web comprises a laminate, and wherein the laminate comprises at least one paper layer and at least one polymer film layer.

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